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Xantrex TM500A User's Manual

1. Press and release the SELECT and RESET button together Press the RESET button until the desired voltage level is displayed Press the SELECT button to accept this value Press the SELECT button to return to the metering mode Step 1 dSF Step 2 bLO Step 4 value Figure 4 5 Low Voltage Indicator 2001 Xantrex Technology Inc 31 P N 973 0012 01 02 Rev A 05 01 4 0 OPERATION Reminders and Indicators continued CHARGED Indicator The CHARGED indicator figg can be programmed to flash every four seconds when specified charging criteria are met This can be voltage only voltage and current or voltage and time When the programmed conditions are met for a minimum of 30 seconds the CHARGED indicator flashes The CHARGED indicator stops flashing and remains ON solid when the charged conditions are no longer met i e the current flow is negative battery discharging continuously for one minute The Amp Hour Meter also resets to zero at this time To reset the CHARGED LED 1 Press the RESET button while the Q9 or O LED is ON Reset when any of these are ON Trace Maco Meter CHARGED Press RESET to reset the Indicator LED CHARGED Indicator Figure 4 6 Resetting the CHARGED Indicator 32 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 Symptom LED in INVERTER ON OFF switch does not light Voltage displayed on meters is not correct Battery State of Charge di
2. 2 0 INSTALLATION 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 I s NOTE The shunt must be of the proper type 50 mV 500 amps and have the necessary threaded screw holes to accommodate the shunt board Remove the existing two machine screws if installed and hardware from the side of the shunt Install the shunt circuit board and supplied hardware exactly as shown in Figure 2 8 I s NOTE Use only the hardware supplied in the kit Spade Lug Brass Screw for extended length installations J 2 Washer Metal Standoff Figure 2 8 Shunt Circuit Board and Hardware 2001 Xantrex Technology Inc 10 P N 973 0012 01 02 Rev A05 01 2 0 INSTALLATION 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 RJ11 jack on the shunt board This cable can be extended up to 100 feet 30 meters Replace the fuse in the fuse holder Replace the fuse holder cap by pushing and rotating it clockwise To J1 To battery s connector on positive back of terminal In line Fuse meter Figure 2 9 In line Fuse
3. ie TM500A Battery Status Monitor Installation amp Operator s Guide About Xantrex Xantrex Technology 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 connected and stand alone systems Xantrex products include inverters battery chargers programmable power supplies and variable speed drives that convert supply control clean and distribute electrical power Trademarks Trace is a trademark of Xantrex Technology Inc Xantrex is a registered trademark of Xantrex Technology Inc Notice of Copyright Xantrex TM500A Battery Status Monitor May 2001 Xantrex Technology All rights reserved Disclaimers While every precaution has been taken to ensure the accuracy of the contents of this guide Xantrex Technology Inc assumes no responsibility for errors or omissions Note as well that specifications and product functional ity may change without notice Since the use of this manual and the conditions or methods of installa tion operation use and maintenance of the unit are beyond the control of Xantrex Technology Inc the company does not assume responsibility and expressly disclaims liability for loss damage or expense arising out of or any way connected with such installation operation use or maintenanc
4. Setting the Charge Efficiency Factor 14 Amp Hours o 415 Setting the Amp Hours ERES CHARGED Indicator Setup ig as 14 Trigger on Voltage Only 317 Trigger on Voltage and Amperage 5419 Trigger on Voltage and Time 2 21 Charger Considerations 23 Relay Chargers 229 Taper Chargers 229 Threesstage Ghatg6rs ect 23 Low Voltage Indicator v 24 Configuring the Low Voltage Alarm 24 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 Table of Contents continued 4 0 OPERATION Indicators and Controls BUHONS sci Select BUMO Messias rte eo Reset BUtOF e ict eee err reet tx cae Deo re erae Rd ela Us INVERTER ON OFF Button Basic Meters mee coe Available Meters state of charge boc EET AX AMBPS csiiesseni bei qup e psc ra rd EM SERRE Ah AMP HOURS Power Saving Mode Data Monitors Reminders and Indicators Amp hour Reminder Low Voltage Indicator CHARGED lIfidiCatOr 22 citt eer teet three mto cb redeas 5 0 TROUBLESHOOTING eene 33 6 0 SERVICE INFORMATION errem 34 7 0 SPECIFICATIONS iii 35 8 0 WARRANTY 36 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 IMPORTANT SAFETY INSTRUCTIONS This manual
5. accuracy in 5 increments FULL gt 92 5 Current Draw Power Saving Mode All other modes Amp Hours Battery Capacity Data Monitoring Functions dSF Days Since Full cAH Cumulative Ah Removed bHI Battery High Volts bLO Battery Low Volts LED Display LED Indicators Dimensions Weight Mounting Surface Flush Specifications 25 C 18 mA maximum 32 mA maximum 0 00 to 167 000 amp hours 10 to 2550 amp hours 0 01 655 days 0 999 000 in nonvolatile memory to 35 1 VDC resettable 12 24 VDC to 70 2 VDC w optional 48 VDC adaptor 8 0 volts resettable 12 24 VDC 16 0 volts resettable w 48 VDC adaptor 3 digit 7 segment red LED with 5 additional indicators State of Charge SOC Battery Efficiency Battery Voltage Amps Amp Hours Removed Battery Capacity Recharge Reminder adjustable Low Battery Voltage adjustable 3 7 8 H x 5 3 8 W x 1 1 4 D 14 cm H x 9 5 cm W x 3 2 cm D approximately 3 Ib 1 36 kg using molded plastic adaptor using plastic mounting bracket Specifications subject to change without notice 92001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 35 8 0 WARRANTY Limited Warranty Xantrex Technology 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 purchasers or
6. DC FUSE DISCONNECT BATTERY INVERTER INVERTER RC4 RC8 REMOTE JACK SHUNT IN LINE FUSE SHUNT WIRE GROUND WIRE IF RUN IS OVER INVERTER ON OFF 100 FEET A REMOTE CABLE TC10 TC25 TC50 TC100 TRACE NOT SUPPLIED METER Back View J4 J2 i SHUNT JACK REMOTE JACK 3507 008 F01 Figure 2 10 Circuit Diagram 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 11 3 0 CONFIGURATION 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 Q Charge Efficiency 94 96 v Voltage full charge 14 4 volts DC Q Amperage DC 35 amps o Amp Hours 200 Hours Low Voltage Indicator 11 2 volts DC Recharge Reminder OFF Restoring the Factory Defaults The factory defaults can be restored to their original settings if desired The default values will return to those listed above and are for a 12 VDC system To restore the factory defaults 1 Set the TM500A into the power saving mode by repeatedly pressing the SELECT button until the LED display goes blank 2 Press and hold the RESET button The display will indicate ALL flashing in the display Continue to hold the RESET button until the LED display remains blank The factory defaults are now restored Step 2 ALL then blank Trace AL
7. Rev A05 01 3 0 CONFIGURATION Setting Parameters continued Set Battery Amp Hour Rating Trace Trace Meter Ah LED Indicates Amp Hour Function is Selected Figure 3 4 Setting the Amp Hours 16 2001 Xantrex Technology Inc PIN 973 0012 01 02 Rev A05 01 3 0 CONFIGURATION Setting Parameters continued CHARGED Indicator Setup gj 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 current parameters are met Trigger the LED when voltage and time parameters are met Trigger on Voltage Only When the TM500A is setup to trigger on voltage only the CHARGED LED illuminates when the voltage reaches the level programmed into the TM500A NOTE This mode must be setup first before setting the Voltage and Current or Voltage and Time modes Step A Setting the Fully Charged Voltage Level 1A Press the SELECT button until the Voltage LED O is illuminated 2A Press the SELECT and RESET buttons simulataniously until the LED display flashes 3A Press the RESET button to change the displayed voltage to the desired fully charged voltage level For a 12 VDC system set this voltage between 14 3 14 9 volts for lead acid batteries For a 24 VDC system set this voltage between 28 6 29 6 volts for lead acid batteries For a 48 VDC system set
8. capacity V VOLTS When this indicator is illuminated the LED display shows the real time voltage from 08 0 to 35 volts for 12 to 24 volt systems 0 1 volt accuracy or 16 0 to 69 9 volts for 48 volt systems 0 2 volt accuracy A AMPS When this indicator is illuminated the LED display shows the real time charge or load current in amps The range is from 0 1 to 999 amps with a refresh rate of one second The accuracy is 1 5 26 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 4 0 OPERATION 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 reading by 1000 i e 111 111 000 This meter automatically resets to zero approximately one minute after the CHARGED LED remains ON solid stops flashing Amperage Indicator Battery Voltage Indicator __ Load or Charge State of Amp Hours Charge Indicator Receiving or Used Indicator Figure 4 3 Mode Indicator LEDs Power Saving Mode The TM500A can be put into a low power power saving mode by repeat edly pressing the SELECT button until the display goes blank In this mode none of the LED indicators illuminate The power consumption of the unit is reduced from 32 mA maximum to approximatel
9. or implied arising by law course of dealing course of performance usage of trade or otherwise including but not limited to implied warranties of merchantability and fitness for a particular purpose are limited in duration for a period of two 2 years from the original date of purchase Some states or countries do not allow limitations on the term of an implied warranty or the exclusion or limitation of incidental or consequential damage which means the limitations and exclusions of this warranty may not apply to you Even though this warranty gives you specific legal rights you may also have other rights which vary from state to state XAN T REX Smart Choice For Power 5916 195th Street N E Arlington WA 98223 Phone 360 435 8826 Fax 360 435 2229 visit our website at www xantrex com 36 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A05 01 Xantrex Technology Inc 5916 195th Northeast Arlington WA 98223 U S A t 360 435 8826 f 360 435 3945 www xantrex com 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 Printed in U S A XAMIAEX Smart Choice For Power
10. over 100 feet SPADE LUG Figure 2 6 Extended Length Ground Wire 2001 Xantrex Technology Inc 8 P N 973 0012 01 02 Rev A 05 01 2 0 INSTALLATION Deltec Shunt WARNING BEFORE WIRING THE SHUNT TO THE BATTERIES 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 e Mount the shunt on or near the battery enclosure close to the negative battery terminal Use appropriate screws to secure the shunt to the battery enclosure Disconnect the NEGATIVE cable that connects between the inverter and battery from the battery s negative terminal e Connect the free end of the negative cable to the shunt s terminal labeled INVERTER Ensure all connections are tight Connect a short length of cable same gauge between the battery s negative terminal and the shunt s terminal labeled BAT MINUS Ensure all connections are tight e Connect the cables and hardware to the shunt as shown in Figure 2 7 i s NOTE The cable connection must be flat against the shunt block with nothing between it for a good connection Shunt Hex Bolt 9 16 inch head Split Lock Washer Large Washer Cable Lug Shunt To Battery s Negative Terminal To Inverter s Negative Terminal lt a Figure 2 7 Shunt Connections 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A05 01 9
11. owners of the product during the warranty period Xantrex does not warrant its products from any and all defects arising out of material or workmanship not provided by Xantrex or its Authorized Service Centers e when the product is installed or exposed to an unsuitable environment as evidenced by generalized corrosion or biological infestation resulting from abnormal use of the product alteration or use in violation of the instructions in components parts or products expressly warranted by another manufacturer Xantrex agrees to supply all parts and labor to repair or replace defects covered by this warranty with parts or products of original or improved design at the company s option Xantrex also reserves the right to improve the design of its products without obligation to modify or upgrade those previously manufactured Defective products must be returned to Xantrex or its Authorized Service Center in the original packaging or equivalent The cost of transportation and insurance on items returned for service is the responsibility of the customer Return transporta tion UPS Ground or equivalent as well as insurance on all repaired items is paid by Xantrex All remedies and the measure of damages are limited to the above Xantrex shall in no event be liable for consequential incidental contingent or special damages even if Xantrex has been advised of the possibility of such damages Any and all other warranties expressed
12. shunt or is manually reset bLO Low Battery Voltage This meter displays the lowest battery voltage detected Use this meter to determine if the batteries are being over discharged This meter resets to the current battery voltage value when the RESET button is pressed and must be manually reconfigured after the DC power is cycled or when first installed 28 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 4 0 OPERATION Indicators and Controls continued To access the Data Monitor Function Press and hold the SELECT button until dSF appears in the LED display The display alternates between the data monitor function and its data Press the RESET button to display the value for the selected function e Continue pressing the SELECT button to scroll through all the available displays and their data When the bLO data has been accessed another press of the SELECT button returns to the basic meters function To reset the data monitor values to zero or the present value press and hold the RESET button for approximately 5 seconds the data monitor value flashes three times and then updates 2001 Xantrex Technology Inc 29 P N 973 0012 01 02 Rev A 05 01 4 0 OPERATION 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 followin
13. I s NOTE The CHARGED indicator remains ON solid even when the batteries are discharging until reset Set Amps to OFF Amperage LED Illuminates to Indicate the Amperage Function is Selected Figure 3 6 Turn Amps OFF for VOLTAGE ONLY Detection 18 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A05 01 3 0 CONFIGURATION Setting Parameters continued CHARGED Indicator Setup gj continued Trigger on Voltage and Amperage When this mode is selected the CHARGED indicator LED illuminates when the voltage reaches the programmed level Step A and the amperage decreases to the value set in Step B As batteries charge their voltage slowly increases and the charging current decreases Setting these parameters allows the CHARGED indicator LED to illuminate when specified conditions are met However if a suffi ciently high amperage is being drawn from DC loads during charging the meter detects this current and it prevents the TM500A from illuminating the CHARGED indicator LED To set the meter to illuminate the CHARGED LED the amperage trigger level must be increased to account for the additional DC loads ls NOTE The batteries may not be fully charged if DC loads are in the system and the current level is increased To determine the appropriate fully charged amperage for the system divide the battery bank amp hour capacity by 20 For example if the battery bank s amp hour rating equals 880 amp hours divide th
14. L Figure 3 1 Resetting to Factory Defaults 12 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A05 01 3 0 CONFIGURATION 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 simulataniously Release both buttons when the LED display flashes 3 Press and release the RESET button to scroll through the selections or values slowly or hold the RESET button to scroll rapidly 4 When the desired value is shown in the LED display press the SELECT button to accept it Select Value Mode Indicators Figure 3 2 Setting Parameters 2001 Xantrex Technology Inc 13 P N 973 0012 01 02 Rev A05 01 3 0 CONFIGURATION 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 batteries Consult the battery manufacturer s specifications for other battery types Set this value to 96 for new batteries and 94 or lower for batteries already in service The default setting is 94 Changing this setting affects the State of Charge meter The setting range is from 60 to 100 Setting the Charge Efficiency Factor If the charge efficien
15. VERTER ON OFF button remotely controls the inverter s ON OFF function via the RC4 or RC8 remote control jack This button duplicates the function of the inverter s power switch The LED duplicates the indications of the RC8 remote control Refer to the RC4 RC8 documentation supplied with the cable for LED indications and modes available depends on inverter Remote control cables are available in 10 25 50 and 100 foot lengths This button LED does not function if a remote control cable is not connected or if the inverter does not support an RC4 or RC8 remote control 2001 Xantrex Technology Inc 25 P N 973 0012 01 02 Rev A 05 01 4 0 OPERATION Indicators and Controls continued Basic Meters To 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 Value for selected mode appears in Polarity Indicator the display Press SELECT until the desired function LED illuminates Figure 4 2 Meter Selection and LED Indicators Available Meters state of charge When this indicator is illuminated the LED display shows the battery s state of charge based upon the amp hour reading divided by the amp hour capacity of the batteries or battery bank The values displayed are LO when battery is below 27 596 30 to 9096 numerical value in 596 increments FULL when the battery s state of charge is over 92 596
16. When these parameters are met the CHARGED indicator LED flashes approximately every four seconds Whenever the current goes negative discharging the timer will reset to zero The CHARGED indicator LED must be manually reset to turn it OFF 22 Set Time Duration Amperage LED Illuminates to Indicate the Amperage Function is Selected Figure 3 10 Trigger on Voltage and Time 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A05 01 3 0 CONFIGURATION Setting Parameters continued CHARGED Indicator Setup figli 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 raise the battery to a set voltage level then shut OFF using only voltage as their parameter Set the TM500A to the voltage only mode and set the voltage slightly below the charger turnoff setting Taper Chargers Taper type chargers raise the battery to a specified voltage and shut OFF when the amperage decreases to a specified level When using taper type chargers pulse width modulated set the voltage and taper amperage parameters slightly below that of the charger If the taper charger is a type that charges up to a certain level and then waits for a period of time to determine if the batteries are charged then set the TM500A to a voltage slightly below the charger s settings Se
17. able from the shunt to the J4 TO SHUNT ONLY jack Figure 2 5 If the TM500A is to function as an ON OFF remote control for the inverter connect the remote control cable not supplied to the J2 INVERTER ONLY jack This connector only functions if the inverter contains a REMOTE jack that allows operation with an RC4 or RC8 remote control CAUTION Do not reverse these cables or the TM500A circuit board will be permanently damaged This is not covered under warranty Install the meter onto the bracket by pressing it tightly into place 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 2 0 INSTALLATION Area To Be Cut Out Trace Meter oae Bracket Trace Meter Figure 2 4 Flush Mounting the TM500A J2 TO INVERTER ONLY Figure 2 5 Communication and Remote Cable Connections 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 7 2 0 INSTALLATION 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 accurately Use the following gauge wire for the distance the TM500A is mounted from the inverter Maximum Distance Wire Gauge 250 feet 16 AWG 400 feet 14 AWG 630 feet 12 AWG 1000 feet 10 AWG J2 TO INVERTER ONLY Interconnect for distances
18. accept The selectable amperage values are from 1 to 99 amps The TM500A is now setup to trigger the CHARGED indicator LED fagli when the voltage level equals or exceeds the value programmed in Step A and the amperage level falls below the value programmed in Step B When these parameters are met the CHARGED indicator LED flashes approximately every four seconds Whenever the current goes negative discharge the timer resets to zero The CHARGED indicator must be manually reset to turn it OFF 20 Set Amperage Amperage LED Illuminates to Indicate the Amperage Function is Figure 3 8 Trigger on Voltage and Amperage 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A05 01 3 0 CONFIGURATION Setting Parameters continued CHARGED Indicator Setup jg continued Trigger on Voltage and Time When this mode is selected the CHARGED indicator LED illuminates when the voltage reaches the programmed level Step A and the amperage remains positive for the specified time Step B Step A Setting the Fully Charged Voltage Level 1A Press the SELECT button until the Voltage LED O is illuminated 2A Press the SELECT and RESET buttons simulataniously until the LED display flashes 3A Press the RESET button to change the displayed voltage to the desired fully charged voltage level For a 12 VDC system set this voltage between 14 3 14 9 volts for lead acid batteries For a 24 VDC system set this voltage betwe
19. contains important safety instructions that should be followed during the installation and maintenance of this product To reduce the risk of electrical shock and to ensure the safe installation and operation of this product the following safety symbols have been placed throughout this manual to indicate dangerous conditions and important safety instructions N WARNING A dangerous voltage or condition exists in this area Use extreme caution when performing these tasks AVERTISSEMENT Une tension ou condition dangereuse existe dans cette zone Faire preuve d extr me prudence lors de la r alisation de ces t ches CAUTION This procedure is critical to the safe installation or operation of the unit Follow these instructions closely ATTENTION Cette proc dure est essentielle l installation ou l utilisation de l unit en toute s curit Suivre ces instructions de pr s I s NOTE This statement is important Follow instructions closely NOTE Cette d claration est importante Suivre les instructions de pr s All electrical work must be done in accordance with local national and or international electrical codes Before installing or using this device read all instructions and cautionary markings located in or on the TM500A the manual the batteries the inverter the PV array etc Do not expose this unit to rain snow or liquids of any type This product is designed only for indoor mounting T
20. cy factor is not known and lead acid batteries are used in the system set the charge efficiency factor to 94 After the batteries have been discharged and then fully recharged the amp hour reading should be approximately 000 If this reading is negative when the CHARGED LED jig flashes increase the efficiency factor If the numbers are substantially going above zero before the CHARGED LED flashes decrease the efficiency factor The setting is correct when the CHARGED LED flashes and the reading is slightly positive 1 Press the SELECT button until the BATTERY LEVEL LED Q is illuminated 2 Pressthe SELECT and RESET buttons simulataniously until the LED display flashes 3 Press the RESET button to change the displayed efficiency factor 4 Press the SELECT button to accept the value Set Battery Efficiency Factor in Display LED Indicates Efficiency Function Figure 3 3 Setting Charger Efficiency 14 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A05 01 3 0 CONFIGURATION Setting Parameters continued Amp Hours o 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 State of Charge meter to provide a more conservative indication for the use of the batteries to avoid excessively discharging them Also note the temperature at which the battery capaci
21. d RESET button simultaneously IST NOTE Pressing the RESET button alone while bLO is displayed will reset the meter to the current battery voltage 4 Press the RESET button until the desired voltage level is displayed 5 Press the SELECT button to accept this value 6 Press the SELECT button to return to the metering mode Step 1 dSF Step 2 bLO Step 4 value Figure 3 11 Low Voltage Indicator 24 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A05 01 4 0 OPERATION 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 displays alphanumeric messages with a resolution to 0 00 A negative value indicator is positioned to the left of the display 3 digit Negative 7 Display Mode Indicators Inverter Mode LED Select on Button Inverter ON OFF Button CHARGED Reset Button Indicator Figure 4 1 Front Panel Controls and Indicators Buttons SELECT Button The SELECT button is used to switch the TM500A between the different meters and modes One of the LEDs located above the buttons illuminate indicating the active function RESET Button The RESET button is used to change the metering parameters and to reset the CHARGED indicator INVERTER ON OFF Button The IN
22. e Due to continual improvement through product updates photographs and or illustrations used in this manual may not exactly match your unit Xantrex Technology Inc reserves the right to update this product without notice or releasing an updated manual when fit form or function are not affected Date and Revision May 2001 Revision A Part Number 973 0012 01 02 Contact Information Web www xantrex com Email tracewarranty traceengineering com Phone 360 435 8826 Fax 360 474 0616 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 Table of Contents 1 0 INTRODUCTION 1 The TM500Ais iarcaniinsi E E alia ee 1 Unpacking and Inspection uoc coercere iere ce reete en voee 2 TM500A 12 24 Volt TM500A INS 12 24 Volt tenter lia 2 HUEEEC img 2 2 0 INSTALLATION Required T00lS53 eh terat regir rete c eren e eite cete rado Pre Installation MOUNtINg arrarani ant denied Surface MOUNN s cicer lea alias 4 Flush Mounting Extended length Installations rario enere 8 Deltec7M Shurtan eret irri eher e en i Teig Mounting Wiring the Shunt Mounting Circuit Board to an Existing Shunt 10 Connecting the Shunt BOANO sereins aisiari 11 3 0 CONFIGURATION enne eee xxn ene nss Ia E Restoring the Factory Defaults Se Setting Parameters t tree ae AN ecu uo ees Charge Efficiency Q RR e ai 14
23. e Section 3 Configuration Setting Parameters Charged Indicator Setup The CHARGED indicator must be manually reset to turn it OFF 973 0012 D 001A 33 6 0 SERVICE INFORMATION Xantrex Technology 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 or fax this page with the following information to 360 474 0616 Or contact the Xantrex Warranty Department at Tracewarranty traceengineering com Please provide Model Number Serial Number Purchase Date Problem Include a telephone number where you can be reached during business hours and a complete return shipping address P O Box numbers are not acceptable Name Address City State Province Zip Postal Code Country Phone ___ FAX ___ E mail Address XAN T REX Smart Choice For Power visit our website at www xantrex com or e mail us at xantrex com 34 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A05 01 Specifications 7 0 SPECIFICATIONS Function Range Accuracy Battery Volts 8 0 35 volts 0 1 volt 16 0 70 volts 0 2 volt Battery Amps 0 1 999 amps 1 5 Battery Amps Resolution 0 1 to 99 9 amps 100 to 999 amps Battery Level Low lt 27 5 30 90 least significant digit 2 5
24. en 28 6 29 6 volts for lead acid batteries For a 48 VDC system set this voltage between 57 2 59 2 volts for lead acid batteries Refer to the battery manufacturer s recommendation for other types of batteries 4A Press the SELECT button to accept the new value The selection range is between 10 to 64 9 VDC 5A Proceed to Step B Set Voltage Level Voltage LED Illuminates to Indicate the Voltage Function is Selected Figure 3 9 Setting the CHARGED Indicator Voltage Level 2001 Xantrex Technology Inc 21 P N 973 0012 01 02 Rev A 05 01 3 0 CONFIGURATION Setting Parameters continued CHARGED Indicator Setup figli continued Step B 1B 2B 3B 4B Setting the Time Duration Press the SELECT button until the Amperage LED O is illuminated Press the SELECT and RESET buttons simulataniously until the LED display flashes Press the RESET button until the display reaches the hour settings These selections are available following the amperage settings Select the desired time in hours or tenths of hours the voltage must remain at this level to trigger the CHARGED LED Press SELECT button to accept The selectable amperage values are from 0 2H to 2 0H 12 minutes to 2 hours The TM500A is now setup to trigger the CHARGED indicator LED jj when the voltage level equals or exceeds the value programmed in Step A and the current remains positive for the time duration programmed in Step B
25. g Provide at least one inch clearance behind the meter circuit board for the cabling when flush mounting The TM500A ships in three sections TM500A Adaptor for surface mounting Mounting Bracket Trace Meter Adaptor Mounting Panel Figure 2 1 TM500A and Mounting Components 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 3 2 0 INSTALLATION 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 are used If placing the screws directly into the backing material use a 3 32 bit The wire access hole should be at least 1 2 diameter to allow the connector to pass through Mount the bracket using the screws and anchors if necessary supplied See Figure 2 2 Do not overtighten the screws Install the adaptor onto the bracket by pressing it tightly into place Connect the communications cable from the shunt to the J1 TO SHUNT ONLY jack on the TM500A See Figure 2 3 If the TM500A is to function as an ON OFF remote control for the inverter connect the remote control cable not supplied to the J2 INVERTER ONLY jack This connector only functions if the inverter contains a REMOTE jack that allows operation with an RC4 or RC8 remote control N CAUTION Do not rever
26. g recharge as a reminder that it is time to charge the batteries The range is from 1 to 99 days or it can be turned off When the number of days programmed into this counter is exceeded the Amp Hour LED flashes The specified value remains in memory until power is removed from the TM500A Recharging the batteries synchronizes the State of Charge and Amp hours meters To configure this function 1 Press and hold the SELECT button until the dSF message is displayed in the LED display then release the button 2 Press and release the SELECT and RESET buttons together 3 Press the RESET button repeatedly until the desired value appears in the display 4 Press the SELECT button to accept the value The range is from 1 to 99 days or OFF Step 1 dSF Step 3 value Figure 4 4 Meter Selection and LED Indicators 30 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 4 0 OPERATION Reminders and Indicators continued Low Voltage Indicator A voltage between 10 and 35 volts 10 and 64 9 volts for 48 volt systems can be specified to activate the low voltage alarm When the battery voltage falls below this level the voltage indicator O flashes approximately once every four seconds To configure this alarm 1 o a a WwW Press and hold the SELECT button until the dSF message is displayed then release Press and release the SELECT button until the bLO message is displayed in the LED display
27. is value by 20 for an amperage setting of 44 amps Step A Setting the Fully Charged Voltage Level 1A Press the SELECT button until the Voltage LED O is illuminated 2A Press the SELECT and RESET buttons simulataniously until the LED display flashes 3A Press the RESET button to change the displayed voltage to the desired fully charged voltage level For a 12 VDC system set this voltage between 14 3 14 9 volts for lead acid batteries For a 24 VDC system set this voltage between 28 6 29 6 volts for lead acid batteries Fora 48 VDC system set this voltage between 57 2 59 2 volts for lead acid batteries Refer to the battery manufacturer s recommendation for other types of batteries 4A Press the SELECT button to accept the new value The selection range is between 10 to 64 9 VDC 2001 Xantrex Technology Inc 19 P N 973 0012 01 02 Rev A05 01 3 0 CONFIGURATION Setting Parameters continued CHARGED Indicator Setup gl continued Step B 1B 2B 3B 4B Set Voltage Level Voltage LED Illuminates to Indicate the Voltage Function is Selected Figure 3 7 Setting the CHARGED Indicator Voltage Level Setting the Amperage Trigger Level Press the SELECT button until the Amperage LED O is illuminated Press the SELECT and RESET buttons simulataniously until the LED display flashes Press the RESET button until the display indicates the desired amperage Press SELECT button to
28. nning cold water for at least 15 minutes and get immediate medical attention SAVE THESE INSTRUCTIONS 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 1 0 INTRODUCTION The TM500A The TM500A features six data monitoring functions and three indicators including State of charge amp hour content full or percent of capacity State of charge voltage real time voltage level historical high and low system voltage Amps real time amps total charging amps total load amps Amp hours removed Days since fully charged Cumulative amp hours Recharge indicator Low voltage indicator Full charge indicator The unit is configurable for specific system or application functions such as setting the CHARGED indication parameters battery capacity charging efficiency low battery warning conditions and a recharge reminder The TM500A can monitor any battery supply from approximately 8 to 65 volts track energy consumption and estimate remaining battery life In addition to its status monitoring features the unit can act as a remote control switching the inverter OFF or ON only on inverters incorporating an RC4 RC8 compatible remote control jack The TM500A operates on 12 24 or 48 volt battery systems 48 volt systems require an optional shunt board Figure 1 1 The TM500A 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A05 01 1 0 INTRODUCTION Unpacking and Inspection Upon
29. o reduce the chance of short circuits when installing or working with the inverter the batteries or the PV array use insulated tools Remove all jewelry such as rings bracelets necklaces etc while installing this system This will greatly reduce the chance of accidental exposure to live circuits The inverter contains more than one live circuit batteries PV array and AC Power may be present at more than one source This product contains no user serviceable parts Do not attempt to repair this unit 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 n BATTERY SAFETY INFORMATION 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 when working with batteries NEVER smoke in the vicinity of a battery or generator Always connect the batteries first then connect the cables to the inverter via a DC disconnect switched OFF This will greatly reduce the chance of spark in the vicinity of the batteries Use insulated tools when working with batteries When connecting batteries always verify proper voltage and polarity Do not short circuit battery cables Fire or explosion can occur In the event of exposure to battery electrolyte wash the area with soap and water If acid enters the eyes flood them with ru
30. receiving the TM500A check that the following items are included TM500A 12 24 Volt TMS500A meter panel adaptor and mounting bracket Manual e 50 foot communications cable Deltec 500 amp 50 mV shunt 12 24 volt shunt printed circuit board with in line 2 amp fuse TM500A NS 12 24 Volt TMS500A meter panel adaptor and mounting bracket Manual 50 foot communications cable Shunt printed circuit board with in line 2 amp fuse TM48 48 Volt e 48 volt shunt printed circuit board with in line 2 amp fuse 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 2 0 INSTALLATION Required Tools Phillips screw driver e 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 feet TC 100 Pre Installation Before installing the TM500A read all instructions and cautionary markings located in this manual The unit should be mounted in a clean dry protected environment Determine the wire route to the batteries and inverter if the remote INVERTER ON OFF function is desired I s NOTE Check for existing electrical plumbing or other potential areas of accidental damage prior to making cuts in structural surfaces Mounting The unit can be surface mounted using the adaptor supplied or flush mounted into a rectangular openin
31. se these cables or the TM500A circuit board will be permanently damaged Install the meter onto the adaptor by pressing it tightly into place 2001 Xantrex Technology Inc 4 P N 973 0012 01 02 Rev A 05 01 2 0 INSTALLATION Trace Meter 8 S Bracket v vers Trace Meter Trace Meter Adaptor Figure 2 2 Surface Mounting the TM500A Using the Adaptor J2 TO INVERTER ONLY Figure 2 3 Communication and Remote Cable Connections 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A 05 01 5 2 0 INSTALLATION Flush Mounting To 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 positions for the screw holes Mark the open area to be cut out for the circuit board NOTE Carefully cut out the circuit board area from the backing material i e wallboard Cut inside the lines so there is enough area left to securely hold the screws A Drill out the four screw s holes if required and wire access opening Use a 3 16 bit if the supplied plastic anchors are used If placing the screws directly into the backing material use a 3 32 bit Mount the bracket using the screws and anchors if necessary supplied See Figure 2 4 Do not overtighten the screws Connect the communications c
32. splays FULL when voltage is low bLO displays a voltage of 00 0 CHARGED LED continues to flash even though the current flow is negative battery discharging continuously for one minute 2001 Xantrex Technology Inc P N 973 0012 01 02 Rev A05 01 5 0 TROUBLESHOOTING Possible Cause J2 plug not plugged into TM500A or the inverter Inverter does not have a compatable Jack The TM500A voltage is configured above 35 0 volts for a 12 or 24 volt system The TM500A voltage is configured below 35 0 volts for a 48 volt system Amp hour setting is too low The bLO meter was not configured during set up or after being disconnected from the shunt VOLTAGE ONLY configuration for the Charged Indicator Setup may be set too low Solution Plug cable into TM500A and Inverter s RC4 RC8 remote control jack The inverter remote control only operates on models equipped with an RC4 RC8 remote control input Reconfigure the TM500A for the correct system voltage see Section 3 Configuration Charged Indicator Set up Reconfigure the amp hours to the correct setting Battery bank size see Section 3 Configuration Setting Parameters Amp Hours Reconfigure the Low Voltage Indicator bLO for the correct low battery voltage see Section 3 Configuration Setting Parameters Low Voltage Indicator Reconfigure the CHARGED voltage to an appropriate value i e 12 6 V fora 12 volt system se
33. t the time a little shorter than the charger s time period Three stage Chargers Three stage chargers raise the battery to a specified voltage level and then maintain the batteries at a Float voltage and trickle current Adjust the TM500A s voltage parameters slightly below the charger s float voltage setting Set the amperage slightly below the charger s float amperage setting 2001 Xantrex Technology Inc 23 P N 973 0012 01 02 Rev A05 01 3 0 CONFIGURATION Setting Parameters continued Low Voltage Indicator The TM500A should be set to trigger on a user specified low DC voltage level When the battery voltage falls below this level the VOLTAGE indicator flashes approximately once every four seconds This meter is useful to determine if the batteries are being over discharged Refer to the battery manufacturer s specifications for the proper low voltage level A voltage between 10 and 35 volts 10 and 64 9 volts for 48 volt systems can be specified to activate the low voltage alarm ls NOTE Disconnecting the TM500A from the shunt DC voltage will cause this setting to be reset to 0 00 It must be re configured again for the proper system low voltage level Configuring the Low Voltage Alarm 1 Press and hold the SELECT button until the dSF message is displayed then release 2 Press and release the SELECT button until the bLO message is displayed in the LED display 3 Press and release the SELECT an
34. this voltage between 57 2 59 2 volts for lead acid batteries Refer to the battery manufacturer s recommendation for other types of batteries 4A Press the SELECT button to accept the new value The selection range is between 10 to 64 9 VDC 5A Proceed to Step B IST NOTE In 32 48 VDC systems whenever a voltage above 35 0 volts is selected the display multiplies the actual voltage by 2 for the TM48 48 V shunt adapter 2001 Xantrex Technology Inc 17 P N 973 0012 01 02 Rev A05 01 3 0 CONFIGURATION Setting Parameters continued CHARGED Indicator Setup ii continued Set Voltage Level Voltage LED Illuminates to Indicate the Voltage Function is Selected Figure 3 5 Setting the CHARGED Indicator Voltage Level The fully charged voltage parameters are now set To 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 Press the SELECT button until the Amperage LED y is illuminated 2B Pressthe SELECT and RESET buttons simulataniously until the LED display flashes 3B Press the RESET button until the display indicates OFF 4B Press SELECT button to accept The TM500A is now setup to trigger the CHARGED indicator LED igi when the voltage level equals or exceeds the value programmed in Step A When this voltage parameter is met the CHARGED indicator LED flashes approximately every four seconds
35. ty is rated The amp hour capacity of the batteries decreases at temperatures lower than the rated value The amp hour rating is usually printed on the battery s label If the System contains batteries in parallel then the amp hour rating of the parallel batteries is added together i e two 120 amp hour rated batteries in parallel equals 240 amp hours The amp hour capacity of a bank does not increase for series wired batteries and is equal to the lowest rated battery in the series string If the amp hour capacity is not listed on the battery consult the battery manufacturer or dealer for assistance Setting the Amp Hours 1 Press the SELECT button until the AMP HOURS LED is illuminated 2 Press the SELECT and RESET buttons simulataniously until the LED display flashes 3 Press the RESET button to change the displayed amp hours to a value slightly lower than the system s total battery amp hour capacity 4 Press the SELECT button to accept the new value The selection range is between 10 010 to 2 550 2 55 Ah I s NOTE When the flashing display indicates between 010 to 990 decimal point after the right most digit read the display directly When the flashing display indicates between 1 00 to 2 55 decimal point two places to the left multiply the reading by 1000 i e a flashing 160 equals 160 amp hours a flashing 1 60 in the display equals 1 600 amp hours 2001 Xantrex Technology Inc 15 P N 973 0012 01 02
36. y 18 mA Pressing the SELECT button again exits the power saving mode 2001 Xantrex Technology Inc 27 P N 973 0012 01 02 Rev A 05 01 4 0 OPERATION Indicators and Controls continued Data 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 its value then scrolls to the next menu item The available data monitor functions are dSF Days Since Full This meter shows the number of days since the batteries were fully charged The range on this meter is from 0 00 to 655 days The value resets to zero when the battery is recharged CHARGE LED flashes or is manually reset cAH Cumulative Amp Hours This meter measures the cumulative amp hours used from the batteries This function can be used as a battery life indicator The range is from 00 0 to 999 000 Multiply the displayed value by 1000 when the decimal point flashes The cumulative value remains in memory even if the TM500A is disconnected This meter can be manually reset to zero bHI High Battery Voltage This meter displays the highest battery voltage detected Use this meter to determine if an overvoltage condition occurred or that the charging sources are charging to the voltage setting of the charger The meter resets to the current battery voltage value when it is disconnected and reconnected to the DC

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