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Owner's Manual Link 10 Xantrex Link 10 Battery Monitor i4.25[...]

2 Xantr ex Link 10 Battery Monitor © November 2002 Xantrex International. All rights reserved. Xantrex is a registered trademark of Xantrex International. © 2002 Xantrex International. All rights reserved. Disclaimer UNLESS SPECIFICALL Y AGREED T O IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX”) (a ) MAKES NO W ARRANTY AS T O THE ACCURACY , S[...]

3 T able of Contents Quick Reference Guide ..................................................................................................5–6 Introduction ................................................................... ......................................................7 Battery Basics ...................................................[...]

4 T op Rear V iew of Meter -DC Meter Negative (BLACK) [1] Shunt Sense Lead Load Side (GREEN) [2] Shunt Sense Lead Battery Side (ORANGE) [3] Battery V olt Sense (0–50 V DC 1 ) (BLUE) [4] +DC Meter Power (9.5–40 V DC) (RED) [5] Optional T emperature Sensor Input [6] Optional Low Battery Alarm [7] Optional T emperature Sensor Ground [8] SYSTEM POS[...]

5 Quick Reference Quick Reference Quick Reference Quick Reference Quick Reference Full 80–99%+ 60–79%+ 40–59%+ 20–39%+ 0–19%+ EMPTY FULL The Light Bar The light bar shows state-of-char ge at a glance. Here's what the lights mean: When you press the button, you SEL ect a numeric display . In normal operation, each press illuminates a [...]

6 V olts is electricity’ s poten- tial to do work . V oltage helps assess approximate state-of-charge and to check for proper charging. A 12 V battery is consid- ered 100% discharged when it drops below 10.5 V . Amps is the present flow of current in or out of your battery . For example, a re- frigerator may draw 6.2 amps of current. This is disp[...]

7 Intr oduction Congratulations! The Xantrex Link 10 is the most advanced (Patents Pending) DC power measurement instrument available. It shows you: Battery State-of-Charge on a multicolor light bar . System voltage accurate to 1/20th of a volt ( <20 VDC). System current accurate to 1/10th of an amp ( <40 amps). Amp hours removed from, or put[...]

8 Why monitor a battery? Batteries can be ruined by excessive discharge. They may also be dam- aged by under-charging. A battery (or bank of batteries) may be storing less energy than you think. The Link 10 provides all the key data you, or your technician, need to make decisions about battery use and charging. How does the Link 10 w o r k ? The Li[...]

9 Basic installation of the Link 10 on a 12 or 24 volt system involves only five wires. Because the Link 10 will work on systems up to 500 volts, special high voltage installation techniques are discussed beginning on page 44. Y ou need to read this section if you're working on an electric vehicle or system where more than 50 volts is encounte[...]

10 Mounting Our Patent Pending "Ratchet Ring" makes mounting easy and fast. TIP: When installing from the front of a panel or dashboard slide the Ratchet Ring onto cable with correct orientation and then connnect the wires. Push Ratchet Ring o n until firmly in contact with panel. The gasket around the ring o f the Link 10 should pro- vid[...]

11 Removing Removing the Link 10 i s the reverse of mounting with a TWIST as shown in the following diagrams. T wist 1/8th turn to unlock teeth. Then pull lock ring straight back as shown below . Pull both sides of the lock ring equally Patented P A TENT PENDING[...]

12 W iring Overview This drawing is for 12 V & 24 V systems. For higher voltages see Prescaler use on page 44. DC+ T wisted pair cable Fuses T erminal Strip Connections See Detail page 14 Mounting Page 10 Removing page 1 1 INST ALLA TION TIP: Use appropriate strain relief to avoid damage to the connector and terminal strip on the rear of the Li[...]

13 Shunt & Battery W ir es The shunt is the current sensor for the Link 10. Its 500 A, 50 mV rating means that when 500 amps flows through it there is 50 mV generated across it. The millivolt signal is translated into an amps display in the Link 10 . For example: a 50 A load would generate 5 mV across the shunt and would be displayed as 50 amps[...]

14 Meter W iring Detail Make the necessary wire connections to the Link 10 as shown in the following diagram: CAUTION Use correct sized screwdriver for terminal screws. T ighten firmly but do not over-tighten to avoid damage Color code shown for Xantrex 4 twisted pair cable. P/Ns below: P/N 84-2014-00 -25' P/N 84-2015-00 -50' 1) For V olt[...]

15 Most failures and problems are due to wiring errors. Please double check the wiring. (Color code shown is for Xantrex wire P/Ns on page 14.) # 1 - DC Power (Black Wire) . Start at terminal #1 of the Link 10 and follow it to the big bolt on the Load side of the shunt. Do not connect this wire to the small screw terminal with the Green shunt sense[...]

16 Once you have completed ALL instructions on page 15, insert the voltage sense wire fuse, then the meter power fuse. (BLUE wire fuse first, RED wire fuse last!) The fuse should be in a fuse holder and should be con- nected in a smooth motion. A "ragged" power-up may cause a meter lockup. Both the bar graph and digital display should com[...]

17 Synchr onizing the Link 10 Synchr onize the Link 10 t o a Full Battery After installing the Link 10, charge the battery until the far right Green LED begins flashing, which indicates the Charged Parameters have been met. Amp hours will have started at 0 and counted up as a positive num- ber . As you begin discharging the battery , the LED will s[...]

18 Although the Link 10 is a very sophisticated device, obtaining basic battery information from it is simple. W ith the unit turned on and the ( V olts) LED on, let's learn how to display the four most important DC system parameters. When you touch the button, you are SEL ecting the display you wish. Each time you touch SEL in normal operatio[...]

19 Reading the Bar Graph Under the LED bar graph are the words RESET RESET RESET RESET RESET, DA DA DA DA DA T T T T T A A A A A, L L L L L OCK OCK OCK OCK OCK, and FUNC FUNC FUNC FUNC FUNC . These words are ignored during normal operation. They are used to indicate programming and advanced function modes which are explained beginning on page 28. S[...]

20 Pressing and holding the SET button for three seconds enters the Setup and Advanced Functions mode. The word SEL SEL SEL SEL SEL apppears in the display , prompting you to press the SEL button to choose what function you want to SEL ect. Pressing SEL chooses a variable or function . The SETUP mode always begins at the (V olts) function. Each pre[...]

21 The first time you use the Link 10, it assumes you have 200 amp-hour lead acid batteries. If your battery capacity is different you must change the declared battery capacity . Follow these instructions to declare a new capacity: 1) Press and hold the SET button for three seconds to enter SETUP (and Advanced Functions) menu. SEL SEL SEL SEL SEL a[...]

22 The Char ged Parameters The Link 10 depends on the Charged Parameters to stay in sync with the battery state-of-charge, to automatically reset to zero, and to automatically calculate the CEF . The default settings are for 12 V lead acid (liquid or gelled) batteries. They have been carefully chosen to work on most systems, including constant volt[...]

23 Char ged Parameters & CEF If you change the Charged Parameters please use the following rules: 1 ) The Charged V oltage Parameter MUST BE A T LEAST 0.1V BELOW the voltage at which the charging system finishes charg ing. Example: If your charging system finishes the battery at 13.8 volts, a Charged V oltage Parameter of 14.0 volts will not wo[...]

24 Setting Up Five dif ferent displays are available in the T ime function. Y ou may select present consumption level, a 4-minute average, a 16-minute, or a 32-minute average, or display the percent of rate compensated capacity remaining. Which method is best for you depends on your installation. Most installa tions will find four-minute averaging [...]

25 The Link 10 may support an optional two wire temperature sensor . The temperature sensor is activated by turning Advanced Function F16 ON. W ith F16 ON, F03 shows battery temperature in degrees Celsius. When activated, F03 will continue to display temperature after exiting the Setup mode until one of the two front panel buttons, SET or SEL , is [...]

26 Peukert's Exponent is a number which describes how battery capacity shrinks as the rate of discharge is increased. The Link 10 uses a number between 1.00 and 1.50 to describe how fast a particular battery will "shrink" when a heavy load is connected. A more complete technical discussion of the Peukert Exponent, and typical value t[...]

27 Alarms T wo T ypes of Alarms The Link 10 i s equipped with both a visual Power Loss Alarm and a visual Low Battery Alarm. It is important that you understand the difference between these functions. Power Loss Alarm: Shows when power being supplied to the Link 10 has dropped to an unsafe level. Certain display features are turned off as meter pow[...]

28 In addition to reporting primary system values, the Link 10 is capable of many other front panel functions and will also display important historical battery data. The words below the bar graph display indicate which of these functions you are accessing. T o use these functions you must read and understand the following section of this manual. R[...]

29 Historical Data RES E T D A T A L OCK FU N C Key Battery Data Displayed DA T A Key historical battery information is available through this functi on . Each time the SEL button is pressed while in the DA T A mode the next piece of data is displayed. T o see DA T A, s elect DA T A as previously described. CEF ( Displayed as E99 ): The Charging Ef[...]

30 Advanced Functions Advanced Functions FUNC Allows setup of Advanced Functions. T o access the FUNC mode, SEL ect the FUNC mode as previously de- scribed. The letters F0i F0i F0i F0i F0i will appear in the display and the FUNC LED will be lit, indicating you are in the FUNC mode. Continue pressing the SEL button until the function you wish to set[...]

31 F03 DISPLA Y OR SET BA TTER Y TEMPERA TURE If there is no external temp sensor and F16 is OFF (factory default), this function sets ambient battery temperature used to caluculate rate corr ected battery capacity which drives the LED bar graph and the T ime remaining display . Feature not available on units with serial numbers prior to 05000. DEF[...]

32 Advanced Functions F06 MANUALL Y SET CEF (Not Recommended) Allows manual setup of CEF . Displayed as two digits. Default display A90 indicates automatic CEF recalculation feature active. Returning to A90 from a user CEF turns the automatic CEF feature back on. A user-set CEF will appear as a UXX in the DA T A mode. See page 29. DEF AUL T : A90 R[...]

33 Advanced Functions CAUTION: If you set the discharge floor high, such as 50%, and continue to discharge well beyond this point, you will notice that the bar graph does not "fill up" until you have charged the battery above the discharge floor . In other words, if you set the dischar ge floor at 50% and discharge 75%, you must recharge [...]

34 F16 TEMPERA TURE SENSOR ON/OFF This function turns the optional external temperature sensor on or off. This feature is only operable when a temperature sensor has been connected between Pin 6 and Pin 8 of the Link 10. T o fully understand this feature, please refer to F03 on page 31. Not available prior to Serial Number 005000. DEF AUL T : OFF R[...]

35 Low Battery Alarm Units with serial numbers greater than 005000 allow access to an enhanced Low Battery Alarm feature. T o activate this feature, change Function F14 to ON . When F14 is ON, the Link 10 displays a visual alarm when the monitored bat tery meets either of two conditions: 1) A settable rated compensated (Peukert) amp-hour depth of d[...]

36 Alarm Functions F10 LOW BA TTER Y ALARM OFF (RECHARGE) SET POINT Once the Low Battery Alarm is activated, recharging the battery to this point turns the alarm OFF . This recharged point must always be at least 10% higher than Low Battery Line closure point. DEF AUL T : 70% RANGE: 0%–70% STEP: 5% F1 1 LOW BA TTER Y ALARM ON SET POINT Sets when [...]

37 NOTE: The Low Battery Alarm ON and OFF points operate on rate compensated (Peukert) amp hours consumed. Once the alarm is activated, the battery must be charged until Alarm OFF Set Point is reached to turn the alarm off. F12 LOW V OL T AGE ALARM THRESHOLD F12 sets the voltage below which the Low Battery Alarm is activated. But the voltage must r[...]

38 Special versions of the Link 10 are available, for additional charge, which include a solid state Alarm Switch to ground via rear panel terminal strip Pin #7. This option is used in a variety of settings such as lift pump lock out on fork lifts, two wire generator start/stop, audible low battery alarms, and charge controllers. The additional cir[...]

39 Peukert's Equation Peukert's Equation describes the effect of different discharge rates on b a t tery capacity . As the dischar ge rate increases, the available battery capacity decreases. The table and examples on the following page illustrate this effect and how to use the table to estimate the exponent " n ". The tables on[...]

40 Peukert's Equation PERCENT AGE OF A V AILABLE CAP ACITY FROM A 100 Ah BA TTER Y A T DIFFERENT DISCHARGE RA TES USING DIFFERENT PEUKER T'S EXPONENTS DISCHARGE RA TE IN AMPS n 5 10 16.7 25 50 75 100 150 200 250 300 400 500 1 100 100 100 100 100 100 100 100 100 100 100 100 100 1.1 100 93 88 85 79 76 74 71 69 67 66 64 63 1.2 100 87 78 72 6[...]

41 T ypical V alues for Peukert's Exponent "n" This table contains values for the exponent "n" for various batteries and manufacturer s. They are calculated from the 20-hour rating and the R e serve Minutes @ 25 A as supplied by the manufacturer . They should be considered only a guide for selecting "n." Pr evaile[...]

42 Surr ette and Rolls Batteries Model V olts Res. Min. 20-Hr . rating "n" EHG-208 6 345 208 1.42 EIG-225 6 350 225 1.54* EIG-262 6 395 262 1.72* 24/90 12 165 90 1.16 27/12M 12 190 1 12 1.23 30H/108 12 230 108 1.08 HT/4D 12 3 48 1 70 1.15 HT/8D 12 4 50 2 21 1.20 *Use Max allowed "n" of 1.50 Peukert's Exponent log t 2 - log [...]

43 T r oubleshooting Pr oblem Suggestion No lights or display Check Power Connections Reset meter (page 28) No keyboard response Check Lock is not invoked Reset meter (page 28) T ime Remaining Not Check Battery Capacity (page 21) Accurate Check T emperature Coefficient (page 32) Check Peukert Exponent (page 26) Digital Display Dim Clean front panel[...]

44 Options & V ersions User-installable OPTIONS available include: Prescalers: Extend the voltage range covered by the Link 10 to either 0–100 V (Xantrex P/N 84-6000-0) or 0–500 V (Xantrex P/N 84-6000-05). T emperature Sensor: Reports battery temperature in Degrees Celsius (Xantrex P/N 84-2024-00) All other options must be installed at the [...]

45 + + - - High V oltage Pr escaler CAUTION! 1. Installation of the Prescaler Option involves work with poten- tially fatal voltages. NEVER work alone—have at least one person present who can render assistance and CPR in the event of an accident. If you have any doubt about your qualifications to work on a high-voltage system, DON'T DO IT! 2[...]

46 Electric V ehicles (EVs) The Link 10 is the ideal energy meter for EV instrumentation. It not only provides v olts, a mps, amp hours and time r emaining, it adds two impor tant bonuses: kilowatt hours and optional serial computer output. If you design or work with electric vehicles or battery-powered equipment of any type, you should realize tha[...]

47 + - - - + + EV Installations The negative of the Link 10's power supply must be common to the nega- tive of the battery (motive pack) which you are measuring. This may pose difficulty if your electric vehicle uses an "unbonded" or "floating" (no connection to the chassis) motive pack and a "bonded" (connected t[...]

48 + - - - + + Lift T ruck Installations Installation of the Link 10 in lift trucks, which have the motive pack bonded to the chassis and also have a 12 V accessory battery bonded to the chas sis, may use the diagram below for proper wiring of the appropriate Prescaler . The 0–100 V Prescaler is used where system voltage does not exceed 100 V at [...]

49 (optional) Serial Port, RS-232 The Link 10 may be equipped to transmit serial communications data to a personal computer or a data logging device. When equipped with the o p tional RS-232 port, the Link 10 will trans mit a data mes sage once a second. The structure of this data is as follows: Data Rate: 9600 Data Bits: 8 Stop Bits: 1 Parity Bits[...]

50 High V oltage Notes IF YOU USE MOTIVE BA TTERIES TO POWER THE LINK 10: If the HV battery is "tapped" to provide meter power , it is recommended that a 24 V tap, not a 12 V tap, be used. The reason for this is that under heavy acceleration under low battery conditions, voltage may fall to levels low enough to cause the meter display to [...]

51 EC Declaration of Conformity CE Manufacturer: XANTREX TECHNOLOGY , INC. Address: Xantrex T echnology , Inc. 8999 Nelson W ay Burnaby , BC Canada V5A 4B5 Herewith declares that the Xantrex Link 10 is in conformity with the provision of the EEC Directive EMC 89/336/EEC and amend- ments 92/31/EEC, 93/68/EEC. The following harmonized standards have [...]

52 What does this warranty cover? This Limited Warranty is provided by Xantrex Technology, Inc. (“Xantrex”) and covers defects in workmanship and materials in your Xantrex Link 10 Battery Monitor. This warranty lasts for a Warranty Period of 12 months from the date of purchase at point of sale to you, the original end user customer. This Limite[...]

53 IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL, DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, LOSSES, COSTS OR EXPENSES HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND, ANY LOSS OR DAMAGE TO PROPERTY, ANY PERSONAL INJURY, ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MI[...]

54[...]

55 RS-232 W arning When using an RS-232-equipped version of the Link 10 in an electric vehicle which has a floating motive battery negative, remember that Pin #5 of the DB-9 connector coming out of the back of the Link 10 is con- nected to the motive battery negative. This normally causes no problem when used with laptop computers. However , if you[...]

56 Softwar e History Softwar e Enhancement Rev . E 1.5 The Link 10 now includes the following additional functions: F02 - ENHANCED SLEEP MODES DEF AUL T : ON Range: ON, OFF , AUTOMA TIC When the Sleep Mode is ON, the Link 10's numeric display turns off after 10 minutes in order to reduce power consumption. Pressing either SET or SEL buttons re[...]

57 Softwar e Addendum Softwar e Enhancement This version of the Link 10 includes special software. F18 - SMALL BA TTER Y SENSING DEF AUL T : OFF Range: OFF , ON When this function is OFF , the meter operates as described elsewhere in this manual. When this function is ON, the amp-hour capacity range allows capacities as low as 2 amp-hours to be dec[...]

58 Index Advanced Functions, 30–34 Battery Basics, 8 CE Declaration of Conformity , 5 1 Char ge Ef ficiency Factor , 23 Charged Parameters, 22–23 High V oltage Notes, 50 Historical Data, 29 Installation (General), 9–15 Introduction, 7 Low Battery Alarm, 27, 35–38 Low V oltage, 27 Meter W iring Detail, 14 Mounting, 10 Operation (Basic), 18?[...]

59 Specifications V oltage : For 12 V–24 V systems. Optional Prescalers extend voltage range. Standard Model: T wo Auto-ranges: 0 to 19.95 V (0.05 V resolution) 20.0 to 50.0 V (0.1 V resolution) Optional Prescalers: 0–100 V , 0–500 V (Used with standard model) Amperage: Low Range: + 0–40.0 amps (0.1 amp resolution) High Range: + 500 amps (1[...]

Xantrex T echnology Inc. T oll free 1 800 670 0707 Direct 1 604 422 2777 Fax 1 604 420 2145 CustomerService@xantrex.com www .xantrex.com 445-0195-01-01 Rev . 1 Printed in the U .S .A.[...]