Owner’s Guide XPLORE 120A 12V Battery Charger Model XPLORE 120/12 Battery Charger 819-0120-12
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Information About Your System As soon as you open your product, record the following information and be sure to keep your proof of purchase. Serial Number ____________________________ Product Number ____________________________ Purchased From ____________________________ Purchase Date ____________________________ To view, download, or print the latest revision, visit the website shown under Contact Information.
Purpose The purpose of this Owner’s Guide is to provide explanations and procedures for installing, operating, configuring, maintaining, and troubleshooting a XPLORE 120A 12V Battery Charger for Recreational or Commercial Marine installations. Scope The guide provides safety and operating guidelines as well as information on installing, configuring, and maintaining the charger. It also provides information about troubleshooting the unit. It does not provide details about particular brands of batteries.
PPE RCBO SAE V VAC, VV, VDC, VZ W Personal Protective Equipment Residual Current Circuit Breaker with Overcurrent Protection (Type B) Society of Automotive Engineers Voltage Volts AC Volts DC Product rating and safety labels Read these instructions carefully and look at the equipment to become familiar with the device before installing, operating, configuring, maintaining, and troubleshooting it.
CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE NOTICE is used to address practices not related to physical injury. Figure 1 Product rating label (sample) NOTE: Actual label may vary. Figure 2 Product safety label (sample) NOTE: Actual label may vary.
IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS 1. SAVE THESE INSTRUCTIONS—This manual contains important safety and operating instructions for the battery charger. 2. Do not expose charger to rain or snow. 3. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fire, electric shock, or injury to persons. Note: For Lithium-Ion batteries, a qualified battery management system (BMS) must ALWAYS be used. 4.
10. PERSONAL PRECAUTIONS a. Consider having someone close enough by to come to your aid when you work near a lead-acid battery. b. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes. c. Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery. d. If battery acid contacts skin or clothing, wash immediately with soap and water.
of battery charger. Charge battery initially at lowest charge rate, if possible. 12. CHARGER LOCATION a. Locate charger as far away from battery as dc cables permit. b. Never place charger directly above battery being charged; gases from battery will corrode and damage charger. c. Never allow battery acid to drip on charger when reading electrolyte specific gravity or filling battery. d. Do not operate charger in a closed-in area or restrict ventilation in any way. e. Do not set a battery on top of charger.
Regulatory 15. FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VESSEL. A SPARK NEAR THE BATTERY MAY CAUSE BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR BATTERY: a. Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has a larger diameter than NEGATIVE (NEG, N, –) post. b. Attach at least a 24-inch-long (60 cm) 6-gauge (AWG) insulated battery cable to NEGATIVE (NEG, N, -) battery post. c. Connect POSITIVE (RED) charger connection to POSITIVE (POS, P, +) post of battery. d.
EMC/EMI Information to the User EMC/EMI Information to the User End of Life Disposal This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to EMC directive and part 15 of the FCC / CAN ICES-003 Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a residential/commercial environment.
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CONTENTS Important Safety Instructions Regulatory EMC/EMI Information to the User End of Life Disposal Introduction XPLORE 120A 12V Battery Charger Product Features Features Front Panel Terminals and Ports Onboard Status LED Panel Accessories Basic Installation Preparing For Installation Tools and Materials vii x xi xi 1 2 2 5 6 7 8 9 11 12 15 Location 15 Wiring Requirements 18 Configuring Charge Current for Battery Size 21 975-1038-01-01 Installing the XPLORE 120A 12V Battery Charger Install
Troubleshooting Maintaining the Charger Troubleshooting Specifications Physical Specifications Environmental Specifications AC Input Specifications DC Output Specifications Protection Features Accessory Regulatory Approvals North America Regulatory Approvals IEC/EN xiv 47 48 49 53 54 54 55 55 56 56 56 57 XPLORE 120/12 Battery Charger Owner's Guide
1 INTRODUCTION The XPLORE 120A 12V Battery Charger is designed with dual chemistry, multiple battery bank charging features suitable for Recreational or Commercial Marine installations. Please read this section to familiarize yourself with the main performance and protection features of the XPLORE Charger.
XPLORE 120A 12V Battery Charger XPLORE 120A 12V Battery Charger The XPLORE Charger ships with the following items: A. one XPLORE Charger unit B. one Xantrex BLE Module (PN: 808-0889) package C. an Owner's Guide and extra labels Product Features The XPLORE 120A 12V Battery Charger provides the following standard features: n n n n n n A B C n n n NOTE: Keep the carton and packing material in case you need to return the XPLORE Charger for servicing.
XPLORE 120A 12V Battery Charger The XPLORE Charger provides the following protection features: n n n n n n n n battery reverse polarity protection via user-replaceable output fuse(s) AC input out-of-range derating and shutdown ambient over-temperature derating and shutdown battery over-charging protection electronic current limiting provides protection against short circuit conditions on the charger’s output ignition-protected rating, enabling installation in engine spaces short circuit protection for the
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2 FEATURES This section identifies the default settings and the hardware features of the XPLORE 120A 12V Battery Charger.
Front Panel Front Panel Item Figure 3 Front Panel A E B C D Description A Mounting flanges are used to permanently install the product. B Onboard status LED panel (see Onboard Status LED Panel on page 8 for more information) for monitoring charging status for the three banks. C Wiring compartment cover protects the DC and AC terminals, as well as accessory ports. Remove and replace when installing cables.
Terminals and Ports Terminals and Ports Item This section describes the inside parts of the XPLORE Charger including the terminals and ports.
Onboard Status LED Panel Onboard Status LED Panel This section describes the parts of the onboard status LED panel of the XPLORE Charger. See Reading Onboard Display LEDs on page 1 for more information. Item Status LEDs n Figure 5 Onboard Status LED Panel Battery Type LEDs and Select button Item Bank LEDs Description n n n 8 - displays the status of BAT1 (group 1). Solid green indicates battery is connected and detected. Off means battery is not present. - displays the status of BAT2 (group 1).
Accessories Accessories This section lists all available accessories for the XPLORE 120A 12V Battery Charger. To order, contact Xantrex or your authorized dealer. Battery Temp Sensor (BTS) with (7.
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3 BASIC INSTALLATION Please read this section for safety information and installation instructions regarding your XPLORE Charger.
Preparing For Installation Preparing For Installation DANGER ELECTRICAL SHOCK AND FIRE HAZARD Installation must be done by qualified personnel to ensure compliance with all applicable installation and electrical codes and regulations. Instructions for installing the XPLORE 120A 12V Battery Charger are provided here for use by qualified personnel only. Failure to follow these instructions will result in death or serious injury.
Preparing For Installation NOTE: The XPLORE Charger is designed to be permanently mounted. Figure 6 shows a full installation with six batteries and an AC (mains) source connection. It also shows the AC and DC wiring and protection devices required for a safe installation. Means of over-current protection and disconnection must be incorporated into the fixed wiring, in accordance with the electrical code that governs each installation.
Preparing For Installation Figure 6 Battery Connections A AC (mains) source protected by correct size G and type of branch rated circuit breaker*. Connection to vessel chassis * single pole breaker for North America * double-pole breaker for Europe C B D E A F B AC (mains) source terminals [G/PE, L, N) protected by fuses H Battery cable (neg(-)) .
Preparing For Installation Tools and Materials Location To mount and connect the XPLORE Charger you need the following tools: n Phillips #2 (3.5mm or equivalent) torque screwdriver for removing and re-securing the AC and DC wiring compartment cover n power drill n drill bit set for pilot holes for mounting screws (if using #10 (M4) mounting screws, use 1/16 in. (1.
Preparing For Installation Condition Requirement Ventilated DANGER ELECTRICAL SHOCK HAZARD A n B B n A NOTES: In moist environments, there is a likelihood that condensation will be present and may drip on to the charger. Use the appropriate mounting orientations as shown in Figure 7 . Ventilation openings located at the top and bottom of the base mounting plate on the charger must not be obstructed. Ensure adequate ventilation is provided to prevent overheating.
Preparing For Installation Figure 7 Mounting Orientations (deck versus wall) IP-rated n n n Vertical Wall Mount (Wiring panel facing down) - this meets IP32 requirements and is drip-proof. Deck Mount - this orientation is not recommended for IPrated orientation. Horizontal Wall Mount - this orientation is not recommended for IP-rated orientation.
Preparing For Installation Wiring Requirements DANGER ELECTRICAL SHOCK AND FIRE HAZARD Do not operate the battery charger with damaged or substandard wiring. Make sure that all wiring is in good condition and is not undersized. See notes below. Failure to follow these instructions will result in death or serious injury. NOTES: Wiring and fuse sizes are governed by electrical codes and standards.
Preparing For Installation Over-current Protection Disconnect Electrical codes require the DC circuit from each battery to the charger to be equipped with a disconnect and an over-current protection device, usually within 7 inches (17.8 cm) of each battery. The devices are usually DC-rated circuit breakers, fused disconnects, or a separate fuse and disconnect for each circuit.
Preparing For Installation For example: n n In US NEC, you may use a 14 AWG wire with a 15 A breaker for up to 12 A continuous current (or 12 AWG for a 20 A breaker for up to 16 A continuous current) Note that every jurisdiction will have different requirements as will each application, so research the regulations for your local jurisdiction to determine which wire size and type is correct based on the maximum AC input current marked on the chargers and given in AC Input Specifications on page 55.
Preparing For Installation Configuring Charge Current for Battery Size The XPLORE Charger is designed to work with a minimum battery bank size. Each bank should meet the minimum Ah rating shown in Table 3. These minimum values are based on twice the charger’s rated maximum charging current. The XPLORE Charger features an adjustable charger current between 5 to 120A (see Changing the Charge Current on page 1).
Installing the XPLORE 120A 12V Battery Charger Installing the XPLORE 120A 12V Battery Charger Be sure to read the safety guidelines and pay attention to all cautions and warnings throughout the installation procedure. The installer is responsible for ensuring compliance with the installation codes for your particular application. See CAUTION statement under Preparing For Installation on page 12. DANGER ELECTRICAL SHOCK HAZARD Disconnect all sources of AC mains and DC power before proceeding.
Installation Sequence Step 1: Mounting the Battery Charger To make charger installation quick and easy, perform the installation tasks in the following sequence: n Step 1: Mounting the Battery Charger n Step 2: Connecting the DC Equipment Ground/Earth on page 24 n Step 3: Installing DC Wiring on page 26 n Step 4: Installing AC (Mains) Wiring on page 29 n Step 5: Powering Up on page 32 Mount the XPLORE Charger using all four mounting keyholes of the mounting brackets. See Mounting flanges on page 24.
4. Hang the XPLORE Charger on the two anchors making sure the flanges are flush to the wall and the screw heads are positioned on the narrow side of the key holes. 5. Permanently secure the XPLORE Charger to the wall by fastening the two top anchors as well driving two additional anchors through the two round holes on the flanges.
The XPLORE Charger has a ground/earth lug on the side of the unit as shown in Figure 10 . Follow the guidelines in DC Grounding (Earthing) Locations to connect the charger’s chassis to the ground. Figure 10 DC equipment ground/earth connection DC Grounding (Earthing) Locations NOTE: For simplicity, all references to ground is also a reference to earth.
Step 3: Installing DC Wiring The procedure for installing the DC wiring applies to a single battery, as well as multiple batteries or battery banks. WARNING ACCIDENTAL SHORT OR SPARK HAZARD Leave the DC disconnects or breakers in the Off position or DC fuses removed from their fuse holders until installation is complete. Failure to follow these instructions can result in death, serious injury, or equipment damage. 1. Remove the wiring compartment cover. 1.
5. Install the provided cable glands prior to routing the cables. Figure 11 Installing cable glands A A Cable gland NPT ½ B B Cable gland NPT ¾ NOTE: Make sure the positive terminals of the XPLORE Charger will be connected to the correct terminal of the DC circuit breaker or a DC fused disconnect and from there to the positive terminal of the battery. Make sure the negative terminal of the XPLORE Charger will be connected to the battery negative terminal (or DC negative bus).
6. Connect the negative cable from the negative terminal on the battery to the negative DC terminal on the XPLORE Charger. See Terminal stacking below for proper connection. 7. Tighten the flare nut to 20 lb-in.(2.3 N-m) torque and test by tugging that the wire is secure. Do not over-tighten as this may result in damage to the XPLORE Charger.
11. Connect the free end of each positive cable assembly (that is, from the DC terminal of the DC circuit breaker or the DC fused disconnect from the previous step on page 26) to the correct positive terminal of the battery, using sufficient torque as recommended by your battery manufacturer. 12. Connect the free end of the negative cable to the correct negative terminal of the battery, using sufficient torque as recommended by your battery manufacturer.
To connect AC supply wires: 1. Plan the route that the AC supply wiring will follow from the source (usually an AC distribution panel) to the XPLORE Charger. 2. Measure and cut the required length of three-conductor (G/PE, L, N) cable allowing some extra length for connections and providing some slack [6 in. (150 mm) suggested]. 3. Unscrew the wiring compartment cover, if not already from the previous step, and feed cables through the appropriate cable glands (as applicable). 4. Carefully remove 3 in.
Figure 15 AC supply wiring 9. Secure cables in place using tie-wraps or cable straps according to electrical codes. 10. Tighten the cable glands, if applicable. 11. Replace the wiring compartment cover. WARNING ELECTRICAL SHOCK HAZARD n Replace the wiring compartment cover before turning on power to this equipment. n Use a torque screwdriver to tighten both the captive nut panel screws to 5 in-lb (0.56 N-m) torque to ensure a required tool access to the wiring compartment.
Step 5: Powering Up Make one last check that all connections are correct and secure. The XPLORE Charger may now be powered up. 1. Close the DC disconnect switch or breaker. 2. Switch the AC (mains) power on at the source breaker. It is normal to see a seven to ten second delay while the charger powers up. NOTE: Battery qualification may not be correctly performed if AC power is switched on first.
4 BATTERY OPERATION Please read this section for safety information and operational instructions regarding your XPLORE Charger.
Three-Stage Charging Figure 17 Typical Multiple Battery Installation with one of the banks of a different chemistry LFP Flooded Three-Stage Charging The three-stage charging mode employs the following sequence: Bulk, Absorption, and Float. During the Bulk stage the batteries are accepting a constant maximum current. In the Absorption stage, the battery voltage is held constant and the current declines.
Two-Stage Charging Two-Stage Charging Float Only Charging The two-stage charging mode employs the following sequence: Bulk and Absorption. It runs similar to the three-stage sequence except that there is no float stage; after the absorption stage the charger stops providing current to the battery and the charger output drops to 9 VZ. In this manner, DC loads draw power supplied by batteries and the charger enters a “rest or standby stage.
Charging Voltage Setpoints Charging Voltage Setpoints Battery Qualification The XPLORE Charger charging process is designed to make the battery or battery banks reach the following voltage setpoints. The XPLORE Charger will perform a battery qualification on each application of AC (or DC > 9 V), to determine if battery banks are present and healthy. To force a battery detection sequence, 1. Turn off AC (mains) and DC power sources. 2.
5 CONFIGURATION This section includes descriptions on how to change charger settings of the XPLORE 120A 12V Battery Charger using the Xantrex BLE Module (PN: 808-0889). If you do not connect the BLE Module, you can only configure the battery type for each battery bank using the Onboard Status LED Panel on page 8.
Configuring the Battery Charger Configuring the Battery Charger Once the charger is connected to AC (mains), it is live and it may be configured. The indicator LEDs on the onboard status display will illuminate for a second (power on test) before reporting charging and battery status information. You can configure the battery type for Group 1 or Group 2 using the Onboard Status LED Panel on page 8.
6 OPERATION This section includes descriptions of the different modes and settings of the XPLORE 120A 12V Battery Charger.
Transitioning Power States Transitioning Power States Turn ON the XPLORE Charger: n Connect the batteries to the charger then connect AC power at the source. The charger runs through a preset charging cycle. There is only ONE way to safely turn the XPLORE Charger off (Disable): 1. Disconnect AC (mains) power at the source. 2. Disconnect all DC batteries. DANGER ELECTRICAL SHOCK HAZARD n n Do not disassemble the battery charger.
Transitioning Power States Charging Batteries Before you start to charge batteries read the Important Safety Instructions on page vii and follow all safety precautions when working with batteries.
Transitioning Power States Equalizing Flooded Batteries IMPORTANT: Connect the Xantrex BLE Module (PN: 808-0889) in order to use this function. NOTICE RISK OF BATTERY DAMAGE The XPLORE Charger will only equalize flooded lead-acid batteries. It does not enter equalization when other battery types are selected since they will be damaged by this process. Use the correct settings for your battery types. Failure to follow these instructions can result in equipment damage.
Transitioning Power States Performing An Equalization NOTICE RISK OF EQUIPMENT DAMAGE n n Turn off or disconnect all DC loads on the battery during equalization. Do not equalize if the level of equalization voltage (see note below) does not comply with the battery manufacturer’s recommendation. Failure to follow these instructions can result in equipment damage.
Transitioning Power States 5. Carefully check the specific gravity of each cell and repeat the equalization cycle until they all meet the battery manufacturer’s specifications for specific gravity or until the specific gravity stabilizes relative to each other for an hour. 6. The charger automatically exits equalization to float/no float mode or rest mode after one cycle. To manually exit equalization mode early, repeat Step 3. 7. Check the battery electrolyte level.
Using A Generator As Source Power Using A Generator As Source Power The XPLORE Charger can be run from a regular AC (mains) power source or from an alternate AC power source such as a generator. Refer to Specifications on page 53 for AC input current draw to determine the size of generator you need. Many generators provide output voltage that is modified sine wave or modified square wave rather than the true sine wave that the power utility provides.
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7 TROUBLESHOOTING This section will help you narrow down the source of any problem you encounter.
Maintaining the Charger Maintaining the Charger DANGER ELECTRICAL SHOCK HAZARD Do not disassemble the battery charger. See note below. Failure to follow these instructions will result in death or serious injury. NOTE: The XPLORE 120A 12V Battery Charger does not have any user-serviceable parts. Do not disassemble the XPLORE Charger except where noted for wiring and cabling. See your warranty for instructions on obtaining service.
Troubleshooting Troubleshooting In the event that you have a problem with your XPLORE Charger, the following tables will help you to identify the problem and offer possible solutions to the problem. For more help not covered in this section, please contact http://www.xantrex.com/powerproducts-support/. Symptom Indicator LEDs do not illuminate when charger is connected to an AC power source. Possible Cause Solution No power at AC (mains) source.
Troubleshooting Symptom Alert indicator LED illuminates. Symptom XPLORE Charger completes a charging cycle, but the battery voltage seems too low. WARNING EXPLOSION HAZARD n n Battery has a shorted cell. Never charge a frozen battery. Never charge a Lithium Ion type battery with an ambient of 0 °C (32 °F) or colder. Failure to follow these instructions can result in death, serious injury, or equipment damage.
Troubleshooting Symptom The XPLORE Charger appears to be taking too long to charge battery. Ready indicator LED does not illuminate after 24 hours of charging. Symptom The XPLORE Charger appears to have quickly charged the battery. Ready indicator LED illuminates sooner than expected. Possible Cause Possible Cause Battery capacity is too high for the XPLORE Charger model. Solution Use a higher capacity charger.
Troubleshooting Symptom The XPLORE Charger will not perform equalization. Possible Cause Solution Battery is the wrong type, or Determine if the battery type is set set to the wrong type to to Flooded (FLD). Only this battery equalize. type can be equalized. Not all batteries are fully charged. The charger will wait for all batteries to be in float stage of three-stage charging or rest stage of two-stage charging before attempting to equalize (the ready indicator LED will illuminate).
8 SPECIFICATIONS This section summarizes the hardware and electrical specifications of the XPLORE 120A 12V Battery Charger.
Physical Specifications Physical Specifications BLE Module Unit dimensions L XPLORE Charger 0.97 in. (24.8 mm) AC input connections 3-position WAGO terminal block accepts a three color-coded 8AWG (10mm2) wires (G/PE, L, N) W H 1.98 in. (50.3 mm) Battery output connections 7-position DC stud terminals @ color coded max 4AWG (16mm2) (6 positives and 1 common negative) Cable length 25 ft (7.6 m) Connector type RJ-12 Unit weight 16.3 lbs (7.
AC Input Specifications AC Input Specifications DC Output Specifications AC input voltage range Nominal: XPLORE Charger 110 | 120 | 230 | 240 VV Full: 100 – 270 VV Automatic derating to 60% output: 80 – 100 VV Max. AC input current Power factor at rated load Frequency 19.6 A ≥0.
Protection Features Absorption voltage @ 77 °F (25 °C) Flooded GEL AGM LFP 14.0 ±0.1 14.2 ±0.1 14.4 ±0.1 14.6 ±0.1 Accessory To order, contact Xantrex or your authorized dealer. Regulatory Approvals North America Float voltage @ 77 °F (25 °C) Flooded GEL AGM LFP 13.5 ±0.1 13.8 ±0.1 13.4 ±0.1 13.5 ±0.1 Equalize mode current 10A Equalize mode—maximum output voltage 16 ±0.1 VZ Off-state current draw <2 mA Z Voltage regulation Uncompensated load voltage regulation < 0.
Regulatory Approvals IEC/EN Regulatory Approvals IEC/EN Safety CE marked for the Low Voltage Directive 2014/35/EU, (complying with EN60335-1 and EN IEC 60335-2-29 Battery Chargers). EMC CE marked for the EMC Directive 2014/30/EU, EN IEC 55014-1, EN IEC 55014-2, EN IEC 61000-3-2, and EN IEC 61000-3-3). Environmental CE marked for Restriction of certain Hazardous Substances (RoHS) Directive 2011/65/EU and amending Directive (EU)/2015/863 (complying with EN IEC 63000 and EN IEC 62321 (all parts)).
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