Xantrex Technology TM500A manual

Installation & Operator ’ s Guide TM500A Battery S t atus Monitor ™[...]

© 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 About Xantrex Xantrex T echnology Inc., is a world-leading supplier of advanced power electronics and controls with products from 50 watt portables to 1 megawatt utility-scale systems for wind, solar , batteries, fuel cells, microturbines, and backup power applications in both grid-c[...]

© 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 i T able of Content s 1.0 INTRODUCTION ............................................................... 1 The TM500A .......................................................................................... 1 Unpacking and Inspection ..................................................[...]

© 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 ii T able of Content s (continued) 4.0 OPERA TION ................................................................... 2 5 Indicators and Controls ....................................................................... 2 5 Buttons ......................................................[...]

© 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 IMPORT ANT SAFETY INSTRUCTIONS This manual contains important safety instructions that should be followed during the installation and maintenance of this product. T o reduce the risk of electrical shock, and to ensure the safe installation and operation of this product, the following[...]

© 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 BA TTER Y SAFETY INFORMA TION • Always wear eye protection, such as safety glasses, when working with batteries. • Remove all loose jewelry before working with batteries. • Never work alone. Have someone assist you with the installation or be close enough to come to your aid wh[...]

1 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 The TM500A The TM500A features six data monitoring functions and three indicators including: • S tate of charge/amp-hour content (full or percent of capacity) • S tate of charge/voltage (real-time volt age level, historical high and low system voltage) • Amps (real-time amps,[...]

2 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Unpacking and Inspection Upon receiving the TM500A, check that the following items are included. TM500A (12/24 V olt) • TM500A (meter panel, adaptor and mounting bracket) • Manual • 50-foot communications cable • Deltec™ 500 amp/50 mV shunt • 12/24 volt shunt-printed ci[...]

3 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Required T ools • Phillips screw driver • 3/32" and 3/16" drill bits • Hole saw If the TM500A will also function as a remote control (INVERTER ON/OFF), an additional cable must be ordered. Available lengths are: 10 feet–TC/10 25 feet–TC/25 50 feet–TC/50 100 fe[...]

4 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Surface Mounting • Using the mounting bracket as a template, mark the positions for the screw holes and an area where the cable(s) will feed through. • Drill out the four screws holes (if required) and wire access opening. Use a 3/16" bit if the supplied plastic anchors ar[...]

5 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Figure 2-2 Surface Mounting the TM500A Using the Adaptor Wire Access Hole T race Meter Bracket Trace Meter Adaptor T race Meter Figure 2-3 Communication and Remote Cable Connections J2 TO INVERTER ONL Y J1 TO SHUNT ONL Y SP ADE LUG 2.0 INST ALLA TION[...]

6 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Flush Mounting T o flush mount the TM500A , an opening must be cut in the backing material to allow room for the circuit board, wires and connectors. Allow at least one inch depth behind the circuit board for the connectors and wires. • Use the bracket as a template and mark the [...]

7 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Figure 2-4 Flush Mounting the TM500A Area T o Be Cut-Out T race Meter Bracket Trace Meter Figure 2-5 Communication and Remote Cable Connections J2 TO INVERTER ONL Y J1 TO SHUNT ONL Y SP ADE LUG 2.0 INST ALLA TION[...]

8 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Extended Length Installations If the TM500A is mounted in excess of 100 feet from the inverter , an additional wire (with a spade lugs on both ends) must be connected between the TM500A and shunt spade lugs. This wire acts as a ground reference and ensures the meter will read accur[...]

9 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Deltec™ Shunt W ARNING: BEFORE WIRING THE SHUNT TO THE BA TTERIES, SWITCH THE DC DISCONNECT TO OFF AND/OR REMOVE THE DC FUSE. Mounting/Wiring the Shunt The shunt connects between the inverter and batteries in the negative (–) line (Figure 2-10). • Mount the shunt on or near t[...]

10 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Mounting Circuit Board to an Existing Shunt Model TM500A - NS is supplied without a shunt and is intended to be wired to an existing shunt. The kit includes two brass 8-32 x 5/8 inch machine screws, two lock-washers and two metal standoffs. NOTE: The shunt must be of the proper ty[...]

11 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Connecting the Shunt Board • Remove the fuse from the in-line fuse holder by rotating the fuse holder cap counterclockwise. • Connect the ring terminal from the fuse holder to the battery’s positive terminal. • Connect the shunt communications cable into the RJ1 1 jack on [...]

12 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Setup The TM500A is configured at the factory for monitoring a 12 VDC system. These settings can be changed to meet specific system parameters. The default settings are: % Charge Efficiency 94 % V V oltage (full-charge) 14.4 volts DC A Amperage DC 35 amps Ah Amp Hours 200 Hours Lo[...]

© 2001 Xantrex T echnology Inc. 13 P/N 973-0012-01-02 Rev . A 05/01 Setting Parameters Individual system parameters can be set by the following procedure: 1. Press the SELECT button until the mode selection indicator to be set is illuminated. 2. Press the SELECT and RESET buttons simulat aniously . Release both buttons when the LED display flashes[...]

14 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Setting Parameters (continued) Charge Efficiency % Since batteries are not 100 percent efficient, more energy is required to charge them than can be extracted. Some of this energy is lost in the form of heat and gassing. An efficiency factor of 94 to 98% is typical for lead-acid b[...]

© 2001 Xantrex T echnology Inc. 15 P/N 973-0012-01-02 Rev . A 05/01 Setting Parameters (continued) Amp Hours Ah The amp-hour setting should be set to a value equal or lower than the actual amp-hour capacity of the system’s battery bank. Using a number that is lower than the actual amp-hour capacity allows the % Battery S tate-of- Charge meter to[...]

16 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Figure 3-4 Setting the Amp Hours Setting Parameters (continued) 4 280. Set Battery Amp-Hour Rating 2 3 1 Ah LED Indicates Amp-Hour Function is Selected 3.0 CONFIGURA TION[...]

© 2001 Xantrex T echnology Inc. 17 P/N 973-0012-01-02 Rev . A 05/01 Setting Parameters (continued) CHARGED Indicator Setup The CHARGED indicator LED can be programmed to light when the batteries are fully charged based on several different parameters: • Trigger the LED when voltage only parameters are met • Trigger the LED when voltage and cur[...]

18 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Setting Parameters (continued) CHARGED Indicator Setup (continued) The fully-charged voltage parameters are now set. T o allow the voltage only setting to trigger the fully-charged LED, the amperage setting must be switched OFF . Step B Switching OFF the Amperage Detection 1B. Pre[...]

© 2001 Xantrex T echnology Inc. 19 P/N 973-0012-01-02 Rev . A 05/01 Setting Parameters (continued) CHARGED Indicator Setup (continued) T rigger on Voltage and Amperage When this mode is selected, the CHARGED indicator LED illuminates when the volt age reaches the programmed level (Step A) and the amperage decreases to the value set in S tep B. As [...]

20 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Step B Setting the Amperage Trigger Level 1B. Press the SELECT button until the Amperage LED ( A ) is illuminated. 2B. Press the SELECT and RESET buttons simulataniously until the LED display flashes. 3B. Press the RESET button until the display indicates the desired amperage. 4B.[...]

© 2001 Xantrex T echnology Inc. 21 P/N 973-0012-01-02 Rev . A 05/01 Setting Parameters (continued) CHARGED Indicator Setup (continued) T rigger on V oltage and Time When this mode is selected, the CHARGED indicator LED illuminates when the volt age reaches the programmed level (Step A) and the amperage remains positive for the specified time (S te[...]

22 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Setting Parameters (continued) CHARGED Indicator Setup (continued) Step B Setting the Time Duration 1B. Press the SELECT button until the Amperage LED ( A ) is illuminated. 2B. Press the SELECT and RESET buttons simulataniously until the LED display flashes. 3B. Press the RESET bu[...]

© 2001 Xantrex T echnology Inc. 23 P/N 973-0012-01-02 Rev . A 05/01 Setting Parameters (continued) CHARGED Indicator Setup (continued) Charger Considerations There are several different types of chargers (relay , taper or three- stage) which can affect the settings and prevent the CHARGE LED from illuminating. Relay Chargers Relay type chargers ra[...]

24 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Setting Parameters (continued) Low-V oltage Indicator V The TM500A should be set to trigger on a user specified low DC voltage level. When the battery voltage falls below this level, the VOL T AGE indicator ( V ) flashes approximately once every four seconds. This meter is useful [...]

© 2001 Xantrex T echnology Inc. 25 P/N 973-0012-01-02 Rev . A 05/01 Indicators and Controls The TM500A contains the following controls and indicators. • Large three-digit LED display • Four red mode indicators • One green CHARGED indicator • One green INVERTER ON/OFF indicator • Three pressure sensitive push-buttons The three-digit LED d[...]

26 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Indicators and Controls (continued) Basic Meters T o display one of the four meters; • Press the SELECT button until the desired indicator illuminates. • The LED display indicates the values for the selected function. A vailable Meters % (st ate-of charge) When this indicator [...]

© 2001 Xantrex T echnology Inc. 27 P/N 973-0012-01-02 Rev . A 05/01 Indicators and Controls (continued) Ah (AMP HOURS) When this indicator is illuminated, the LED display shows the total amp hours used since the last time the amp-hour meter was reset. The range is from ±0.00 to ±167,000 amp hours. When the decimal point flashes, multiply the rea[...]

28 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Indicators and Controls (continued) Dat a Monitors There are several additional data displays available, accessed by pressing and holding the SELECT button until “dSF” appears in the display . Pressing and releasing the SELECT button alternates between it s value, then scrolls[...]

© 2001 Xantrex T echnology Inc. 29 P/N 973-0012-01-02 Rev . A 05/01 Indicators and Controls (continued) T o access the Dat a Monitor Function: • Press and hold the SELECT button until dSF appears in the LED display . The display alternates between the data monitor function and it s data. • Press the RESET button to display the value for the se[...]

30 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Reminders and Indicators The TM500A features a programmable recharge reminder as well as low- voltage and charged indicators. Amp-Hour Reminder The Amp-Hour LED can be configured to flash at a specified interval following recharge as a reminder that it is time to charge the batter[...]

© 2001 Xantrex T echnology Inc. 31 P/N 973-0012-01-02 Rev . A 05/01 Reminders and Indicators (continued) Low-V oltage Indicator A voltage between 10 and 35 volts (10 and 64.9 volt s for 48-volt systems) can be specified to activate the low-voltage alarm. When the battery voltage falls below this level, the voltage indicator ( V ) flashes approxima[...]

32 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Reminders and Indicators (continued) CHARGED Indicator The CHARGED indicator ( ) can be programmed to flash every four seconds when specified charging criteria are met. This can be voltage only , voltage and current , or volt age and time . When the programmed conditions are met f[...]

© 2001 Xantrex T echnology Inc. 33 P/N 973-0012-01-02 Rev . A 05/01 m o t p m y S e s u a C e l b i s s o P n o i t u l o S F F O / N O R E T R E V N I n i D E L . t h g i l t o n s e o d h c t i w s o t n i d e g g u l p t o n g u l p 2 J . r e t r e v n i e h t r o A 0 0 5 M T a e v a h t o n s e o d r e t r e v n I . k c a J e l b a t a p m o c[...]

34 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Xantrex T echnology Inc., takes great pride in its products and makes every effort to ensure your unit fully meets your independent powering needs. If your product needs repair , contact our Customer Service department at: (360) 435-8826 to obtain an RMA# and shipping information;[...]

©2001 Xantrex T echnology Inc. 35 P/N 973-0012-01-02 Rev . A 05/01 Specifications Function Range Accuracy Battery V olts 8.0–35 volts ± 0.1 volt 16.0–70 volts ± 0.2 volt Battery Amps 0.1–999 amps ± 1.5% (+ least significant digit) Battery Amp s Resolution 0.1 to 99.9 amps ± 0.1 amp 100 to 999 amps ± 1.0 amp Battery Level % Low (< 27.[...]

36 © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01 Limited Warranty Xantrex T echnology Inc., warrants its power products against defects in materials and workmanship for a period of two (2) years from the date of purchase, established by proof of purchase or formal warranty registration, and extends this warranty to all purchaser[...]

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Xantrex T echnology Inc. 5916 195th Northeast Arlington, WA 98223 U.S.A. t: 360/435.8826 f: 360/435.3945 ww w .xantrex.com Printed in U.S.A. © 2001 Xantrex T echnology Inc. P/N 973-0012-01-02 Rev . A 05/01[...]