Xantrex Technology Computer Monitor TM500A User Manual

™

TM500A

Battery Status Monitor

Installation &

Operator’s Guide

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Table of Contents

1.0 INTRODUCTION ...............................................................1

The TM500A .......................................................................................... 1

Unpacking and Inspection ..................................................................... 2

TM500A (12/24 Volt) ............................................................................. 2

TM500A - NS (12/24 Volt) ..................................................................... 2

TM48 (48 Volt) ....................................................................................... 2

2.0 INSTALLATION ................................................................3

Required Tools....................................................................................... 3

Pre-Installation ....................................................................................... 3

Mounting ................................................................................................ 3

Surface Mounting .............................................................................. 4

Flush Mounting .................................................................................. 6

Extended Length Installations ........................................................... 8

Deltec™ Shunt ...................................................................................... 9

Mounting/Wiring the Shunt ................................................................ 9

Mounting Circuit Board to an Existing Shunt .................................. 10

Connecting the Shunt Board ........................................................... 11

3.0 CONFIGURATION........................................................... 12

Setup ................................................................................................... 12

Restoring the Factory Defaults ........................................................... 12

Setting Parameters .............................................................................. 13

Charge Efficiency

.......................................................................... 14

Setting the Charge Efficiency Factor ............................................. 14

Amp Hours

.................................................................................... 15

Setting the Amp Hours .................................................................... 15

CHARGED Indicator Setup ............................................................ 17

Trigger on Voltage Only ..................................................................... 17

Trigger on Voltage and Amperage .................................................. 19

Trigger on Voltage and Time ........................................................... 21

Charger Considerations .................................................................. 23

Relay Chargers ........................................................................... 23

Taper Chargers ........................................................................... 23

Three-stage Chargers ................................................................ 23

Low-Voltage Indicator

................................................................... 24

Configuring the Low-Voltage Alarm ............................................... 24

P/N 973-0012-01-02 Rev.A05/01

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Table of Contents

(continued)

4.0 OPERATION ...................................................................25

Indicators and Controls ....................................................................... 25

Buttons ................................................................................................ 25

Select Button ................................................................................... 25

Reset Button.................................................................................... 25

INVERTER ON/OFF Button .............................................................. 25

Basic Meters ....................................................................................... 26

Available Meters ............................................................................. 26

% (state-of charge) .................................................................... 26

V (Volts) ...................................................................................... 26

A (AMPS)..................................................................................... 26

Ah (AMP HOURS) ....................................................................... 27

Power Saving Mode........................................................................ 27

Data Monitors ...................................................................................... 28

Reminders and Indicators ................................................................... 30

Amp-hour Reminder ........................................................................ 30

Low-Voltage Indicator..................................................................... 31

CHARGED Indicator ......................................................................... 32

5.0 TROUBLESHOOTING ....................................................33

6.0 SERVICE INFORMATION ............................................... 34

7.0 SPECIFICATIONS ..........................................................35

8.0 WARRANTY.................................................................... 36

P/N 973-0012-01-02 Rev.A05/01

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IMPORTANT SAFETY INSTRUCTIONS

This manual 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.

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’extrême prudence lors de la réalisation de

ces tâches.

CAUTION - This procedure is critical to the safe installation or

operation of the unit. Follow these instructions closely.

ATTENTION - Cette procédure est essentielle à l’installation ou

l’utilisation de l’unité en toute sécurité. Suivre ces instructions de

près.

NOTE - This statement is important. Follow instructions closely.

NOTE - Cette déclaration est importante. Suivre les instructions de

près.

•

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.

To 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.

P/N 973-0012-01-02 Rev.A05/01

iii

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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 running cold water for

at least 15 minutes and get immediate medical attention.

SAVE THESE INSTRUCTIONS

P/N 973-0012-01-02 Rev.A05/01

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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).

14.2

Figure 1-1

The TM500A

P/N 973-0012-01-02 Rev.A05/01

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1.0 INTRODUCTION

Unpacking and Inspection

Upon receiving the TM500A, check that the following items are included.

TM500A (12/24 Volt)

•

TM500A (meter panel, adaptor and mounting bracket)

Manual

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)

•

TM500A (meter panel, adaptor and mounting bracket)

Manual

50-foot communications cable

Shunt-printed circuit board with in-line 2-amp fuse

TM48 (48 Volt)

•

48-volt shunt-printed circuit board with in-line 2-amp fuse

P/N 973-0012-01-02 Rev.A05/01

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2.0 INSTALLATION

Required Tools

•

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

50 feet–TC/50

25 feet–TC/25

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).

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 opening. 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

Panel

Adaptor

Mounting

Figure 2-1

TM500A and Mounting Components

P/N 973-0012-01-02 Rev.A05/01

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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.

CAUTION: Do not reverse these cables or the TM500A

circuit board will be permanently damaged.

•

Install the meter onto the adaptor by pressing it tightly into place.

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2.0 INSTALLATION

Wire

Access

Hole

Trace Meter

Bracket

Trace Meter

Adaptor

Figure 2-2

Surface Mounting the TM500A Using the Adaptor

J2 TO

INVERTER

ONLY

J1 TO

SHUNT

ONLY

SPADE LUG

Figure 2-3

Communication and Remote Cable Connections

P/N 973-0012-01-02 Rev.A05/01

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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.

•

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 cable (from the shunt) to the “J1 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.

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2.0 INSTALLATION

Area To Be Cut-Out

Trace Meter

Bracket

Trace Meter

Figure 2-4

Flush Mounting the TM500A

J2 TO

INVERTER

ONLY

J1 TO

SHUNT

ONLY

SPADE LUG

Figure 2-5

Communication and Remote Cable Connections

P/N 973-0012-01-02 Rev.A05/01

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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

400 feet

630 feet

1000 feet

#16 AWG

#14 AWG

#12 AWG

#10 AWG

J2 TO

INVERTER

ONLY

J1 TO

SHUNT

ONLY

SPADE LUG

Interconnect for distances over

100 feet

SPADE LUG

Figure 2-6

Extended Length Ground Wire

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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).

•

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.

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.

•

Connect the cables and hardware to the shunt as shown in Figure 2-7.

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

To Battery’s

Shunt

To Inverter’s

Negative Terminal

Figure 2-7

Shunt Connections

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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.

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.

NOTE: Use only the hardware supplied in the kit.

Spade Lug

(for extended length installations)

Brass Screw

Brass Lock

Washer

Metal Standoff

Figure 2-8

Shunt Circuit Board and Hardware

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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

positive

connector on

back of

terminal

meter

In-line Fuse

Figure 2-9

In-line Fuse

DC FUSE

DISCONNECT

SHUNT

BATTERY

INVERTER

RC4/RC8

REMOTE

JACK

SHUNT IN-LINE FUSE

SHUNT WIRE

GROUND WIRE

(IF RUN IS OVER

100 FEET)

INVERTER ON/OFF

REMOTE CABLE

TC10, TC25, TC50, TC100

(NOT SUPPLIED)

TRACE

METER

(Back View)

SHUNT JACK

REMOTE JACK

3507-00B-F01

Figure 2-10

Circuit Diagram

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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:

Charge Efficiency

Voltage (full-charge)

Amperage DC

94 %

14.4 volts DC

35 amps

Amp Hours

Low-Voltage Indicator

Recharge Reminder

200 Hours

11.2 volts DC

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

A L L

Figure 3-1

Resetting to Factory Defaults

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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

14.4

Mode Indicators

Figure 3-2

Setting Parameters

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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 efficiency 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 (

) 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 ( ) is

illuminated.

2. Press the 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

9 4

Figure 3-3

Setting Charger Efficiency

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3.0 CONFIGURATION

Setting Parameters (continued)

Amp Hours

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 capacity 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.

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).

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3.0 CONFIGURATION

Setting Parameters (continued)

Set Battery Amp-Hour

Rating

Ah LED Indicates

Amp-Hour Function is

Selected

280.

Figure 3-4

Setting the Amp Hours

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3.0 CONFIGURATION

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 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 ( ) 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 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.

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).

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3.0 CONFIGURATION

Setting Parameters (continued)

CHARGED Indicator Setup (continued)

Set Voltage Level

14.4

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 ( ) is illuminated.

2B. Press the 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 (

)

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.

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

OFF

Function is Selected

Figure 3-6

Turn Amps OFF for VOLTAGE ONLY Detection

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3.0 CONFIGURATION

Setting Parameters (continued)

CHARGED Indicator Setup

(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.

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 this 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 ( ) 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 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.

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3.0 CONFIGURATION

Setting Parameters (continued)

CHARGED Indicator Setup

(continued)

Set Voltage Level

14.4

Voltage LED

Illuminates to Indicate

the Voltage Function

is Selected

Figure 3-7

Setting the CHARGED Indicator Voltage Level

Step B Setting the Amperage Trigger Level

1B. Press the SELECT button until the Amperage LED ( ) 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. Press SELECT button to accept.

The selectable amperage values are from 1 to 99 amps.

The TM500A is now setup to trigger the CHARGED indicator LED (

)

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.

Set Amperage

Amperage LED

Illuminates to Indicate the

Amperage Function is

44A

Figure 3-8

Trigger on Voltage and Amperage

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3.0 CONFIGURATION

Setting Parameters (continued)

CHARGED Indicator Setup

Trigger on Voltage and Time

(continued)

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 ( ) 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 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

14.4

Voltage LED Illuminates

to Indicate the Voltage

Function is Selected

Figure 3-9

Setting the CHARGED Indicator Voltage Level

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3.0 CONFIGURATION

Setting Parameters (continued)

CHARGED Indicator Setup

(continued)

Step B Setting the Time Duration

1B. Press the SELECT button until the Amperage LED ( ) is illuminated.

2B. Press the SELECT and RESET buttons simulataniously until the LED

display flashes.

3B. 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.

4B. 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 (

)

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.

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.

Set Time Duration

1. H

Amperage LED

Illuminates to

Indicate the

Amperage

Function is

Selected

Figure 3-10

Trigger on Voltage and Time

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3.0 CONFIGURATION

Setting Parameters (continued)

CHARGED Indicator Setup

Charger Considerations

(continued)

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. Set 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.

P/N 973-0012-01-02 Rev.A05/01

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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.

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 and RESET button simultaneously.

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

dSF

Figure 3-11

Low-Voltage Indicator

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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

Display

Negative

Mode

Indicators

Inverter Mode LED

(on Button)

Select

Inverter

ON/OFF

Button

CHARGED

Indicator

Reset Button

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 INVERTER 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.

P/N 973-0012-01-02 Rev. A 05/01

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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

the display

Polarity Indicator

12.4

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 27.5%)

30 to 90% numerical value (in 5% increments)

FULL when the battery’s state-of-charge is over 92.5% 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%.

P/N 973-0012-01-02 Rev. A 05/01

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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)

Amp Hours

(Receiving or

Used) Indicator

% State-of-

Charge Indicator

Full

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 approximately 18 mA. Pressing the

SELECT button again exits the power-saving mode.

P/N 973-0012-01-02 Rev. A 05/01

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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 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.

P/N 973-0012-01-02 Rev. A 05/01

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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.

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).

P/N 973-0012-01-02 Rev. A 05/01

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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

following 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

dSF

Figure 4-4

Meter Selection and LED Indicators

P/N 973-0012-01-02 Rev. A 05/01

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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 ( ) flashes approximately once

every four seconds.

To configure this 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 and RESET button together.

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

dSF

Figure 4-5

Low Voltage Indicator

P/N 973-0012-01-02 Rev. A 05/01

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4.0 OPERATION

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 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

, or

LED is ON.

Reset when any of

these are ON

Press RESET to reset the

CHARGED Indicator

CHARGED

Indicator LED

Figure 4-6

Resetting the CHARGED Indicator

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5.0 TROUBLESHOOTING

Symptom

Possible Cause

Solution

LED in INVERTER ON/OFF J2 plug not plugged into

Plug cable into TM500A and

Inverter's RC4/RC8 remote

control jack.

switch does not light.

TM500A or the inverter.

Inverter does not have a

compatable Jack.

The inverter remote control

only operates on models

equipped with an RC4/RC8

remote control input.

Voltage displayed on

meters is not correct.

The TM500A voltage is

configured above 35.0 volts the correct system voltage

Reconfigure the TM500A for

for a 12- or 24-volt system.

(see Section 3,

Configuration, Charged

Indicator Set-up).

The TM500A voltage is

configured below 35.0 volts

for a 48-volt system.

Battery State-of-Charge

displays "FULL" when

voltage is low.

Amp-hour setting is too low. Reconfigure the amp hours to

the correct setting - Battery

bank size (see Section 3,

Configuration, Setting

Parameters, Amp Hours).

bLO displays a voltage of

00.0.

The bLO meter was not

configured during set-up, or Indicator (bLO) for the correct

Reconfigure the Low-Voltage

after being disconnected

from the shunt.

low-battery voltage (see

Section 3, Configuration,

Setting Parameters, Low-

Voltage Indicator).

CHARGED LED continues

to flash even though the

current flow is negative

(battery discharging)

VOLTAGE ONLY

Reconfigure the CHARGED

voltage to an appropriate

value (i.e., 12.6 V for a

12-volt system ), (see Section

3, Configuration, Setting

Parameters, Charged

configuration for the

Charged Indicator Setup

may be set too low.

continuously for one minute.

Indicator Setup).

The CHARGED indicator

must be manually reset to turn

it OFF.

973-0012-D-001A

P/N 973-0012-01-02 Rev.A05/01

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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 [email protected].

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:___________________________________

visit our website at: www.xantrex.com

or e-mail us at: xantrex.com

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7.0 SPECIFICATIONS

Specifications

Function

Range

Accuracy

Battery Volts

8.0–35 volts

16.0–70 volts

± 0.1 volt

± 0.2 volt

Battery Amps

0.1–999 amps

± 1.5%

(+ least significant digit)

Battery Amps Resolution

0.1 to 99.9 amps

100 to 999 amps

± 0.1 amp

± 1.0 amp

Battery Level %

Low (< 27.5%)

30–90%

~ 2.5% accuracy

in 5% increments

FULL (> 92.5%)

Current Draw

Power Saving Mode

All other modes

18 mA maximum

32 mA maximum

Amp Hours

Battery Capacity

-0.00 to ±167,000 amp hours

10 to 2550 amp hours

Data Monitoring Functions

dSF–Days Since Full

0.01–655 days

cAH–Cumulative Ah Removed

bHI–Battery High Volts

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)

bLO–Battery Low Volts

LED Display

3-digit, 7-segment red LED

with 5 additional indicators

LED Indicators

State of Charge(SOC)/Battery Efficiency

Battery Voltage

Amps

Amp Hours Removed/Battery Capacity

Recharge Reminder (adjustable)

Low Battery Voltage (adjustable)

Dimensions

Weight

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 lb (1.36 kg)

Mounting

Surface

using molded plastic adaptor

using plastic mounting bracket

Flush

Specifications @ 25 °C.

Specifications subject to change without notice.

P/N 973-0012-01-02 Rev.A05/01

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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 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;

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 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.

5916 - 195th Street N.E., Arlington, WA 98223 Phone: (360) 435-8826 Fax: (360) 435-2229

visit our website at: www.xantrex.com

P/N 973-0012-01-02 Rev.A05/01

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Xantrex Technology Inc.

5916 195th Northeast

Arlington, WA 98223

U.S.A.

P/N 973-0012-01-02 Rev. A 05/01

t: 360/435.8826

f: 360/435.3945

www.xantrex.com

Printed in U.S.A.

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