Xantrex Digital Alternator Regulator Xar Owner Manual(90 2006 00)
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IINTRODUCTIONThank you for choosing your Xantrex Alternator Regulator XARtor This regulator has been designed to maximize the charging efficiency of your DCThe XAR is designed to provide superior charge control for most common batteryDeepCycle Lead Acid AGM Gel and Optima battery types are alsoThe XAR can monitor and compensate for alternator overtemperature conditionswhen combined with optional alternator temperature sensor XARTSATheXAR also has the ability to monitor and compensate for under or overtemperature conditions at one battery when equipped with optional battery temperatureIIINSTALLATIONMount the regulator in a dry wellventilated place Avoid installation in areasof excess heat andor vibration Avoid locations where regulator orIf not preconnected at the factory attach the inline fourplex plug toFigure 1Figure 6ignition Attach theBROWN wire to a switched 12VDC source The ignition switch orconnection points Atoggle switch may be added to this circuit to shuttery bankss positive output The RED wirecharged When using an isolatorthe RED sense wire MUSTconput alternator the RED wire mustlarger battery bank XAR Digital Alternator RegulatorInstallation and Operation ManualCAUTIONIIntroductionIIInstallationIIIOperationIVProgramming forBattery TypeVAdvanced ProgrammingVISystem Voltage AdjustmentVIISystem Time AdjustmentVIIIAmp ManagerIXEqualization VoltageXEqualization TimeXIWarningAdvisory CodesXII TroubleshootingSample Wiring Diagrams1011WarrantyTABLE OF CONTENTSIIINSTALLATION Continuedging the RED wire canbe moved to the smaller battery terminal on the isolator The same is true in thecase of a dualoutput alternator The RED wire carries up to 6 amps and should beprotected with the 10Afuse included with the regulator Fusing should be as closeFigure 2 wires to the alternator If your alternator doesnt provide for a plug connection see alternator manual for installationIf your application utilizes an electric tachometer connect one end of the stator wire to the alternator and the other end to the regulator ATach Out terminalis provided for connection to your tachometer If a new alternator is being installedAttach optional Alternator Temp Sensor to the Alternator TempFigure 6 Observe polarity Attach sensorFigure 3between the positive and negative terminals of the AlternatorTemperature Sensor circuit allows you to reduce alternator output andAttach optional Battery Temp Sensor wires as shown in Figure 6Observe polarity Attach Battery Temp Sensor lug to negative batteryFigure 4mounted visual or audible system warnings Terminal output is 250high voltage 1Vover bulkcapacity small engine modeversion See label on side of regulatorAlternator TemperatureSensor Attach to midtemp sensor on batteryPrimary Program SettingsPRG1PRG2PRG3PRG4PRG5UniversalDeep CycleGelAbsorbedOptimaFactoryFloodedCellGlassSpiralModeProgramLead AcidMat AGMWoundStart Delay Seconds4545454545Ramp Up Seconds6060606060Bulk Voltage Max141146141144146Bulk Time Minimum30 min30 min30 min30 min30 minAbsorption Voltage139144139142144Absorption Time Minimum02 hr02 hr0220 hr0220 hr0220 hrFloat Voltage134134137134134Float Time Maximum6 hr6 hr6 hr6 hr6 hrHigh Voltage Alarm152156151154156Low Voltage Alarm128128128128128Max Battery Temperature125F52C125F52C125F52C125F52C125F52CMax Alternator Temperature225F107C225F107C225F107C225F107C225F107CEqualization YesYesNoConsult MfgConsult MfgGround attachment Bothgrounds connect together at preferredPreset program values Voltages may vary by 3 from values shown Connection of the WHITE statorused Do not connect the WHITEmechanically Doing so may resultin higherthanrecommended surfor full battery capacity If voltageIIIOPERATIONOnce the regulator is properly installed and connected to the rest of the charging system it is ready to use During operationcolorcoded LED lights willdiagnostic and advisory information At startFigure 7Arrows indicate illuminated LEDsFigure 8from amber LEDTwo green LEDs indicate Flooded Deep Cycle Three greencate Absorbed Glass Mat AGM Asingle green LED closest to the illuminated amber LED indicates Optima batteryThe display will then cycle through the various charging stages Figure 9indicates 45second start delay Two illuminatcharging stage Three illuminated green LEDsto occur After the initial start delay the regulator will ramp to charging voltage over a oneminute period Once bulk chargivoltage is reached the regulator will remain in the bulk stage for a minimum of 36 minutes At the end of the 36minute period the regulator will compare actual battery voltage with target voltage based on battery typeadvance to absorption stage or add additional 6minute increments at bulk voltage until target voltage is reachedOnce in absorption stage the regulator will remain at absorption voltage for a minimum of 36 minutes Additional 6minuteincrements will be added thereafter until target voltage is attained Regulator will remain in float stage for a minimum of twohours after which it will cycle back to absorption stage for a minimum of 36minutes This cycle will continue throughoutNote The regulatorwill automatically return to the beginning of the charging program if the engine isshut down and restarted IVPROGRAMMING FOR BATTERY TYPEfor DeepCycle flooded AGM Gel and Optima battery types Alist of detailed voltageFigure 5magnetic reed switch located beside the first green LED enables user adjustment TheTo select a program for your battery typeTurn ignition key to its position Allow the regulator toFigure 11ACTIVATEHOLD instructions at right The 5 amber light and 6 flashingFigure 10startupcharging stage StartFigure 11 ACTIVATERELEASEACTIVATEHOLDRELEASEon the display Once the desiredNOTE The cycle speed forthe displayis five seconds The regulatorcycles atthis rate to ensure adequate time toread LED codes and make adjustFlashingReed SwitchActivation TestSwitch ActivatedVADVANCED PROGRAMMINGAdvanced Programming modifies preset programming to suit specific charging needs Advanced programming includes voltEqualization is only suggested forbatteries noted as equalization friendly in Figure 5 on Page 2age recommendations Equalization must be initiated through the advanced programming mode It is NOTa standard mode ofoperation Both EQ time and voltage must be set for equalization to occur Equalization will occur immediately after the program has been saved into memory Once equalization is complete the regulator will cycle to float mode The XAR also features an adjustable Amp Manager which enables you to control the percentage of total alternator output This feature can beProgramming modifications can be removed from the regulators memory by reselecting the original program foryourbattery type NOTE 2 The Advanced Programming Mode will cycle three times before saving new settings to memory To enter to Advanced programming1ACTIVATEHOLDFigure 15flashing then LED 7 illuminates ThisFigure 163RELEASEthe switch The 5 amberLED will go out The 7 amber LEDSystem Voltage Adjustment mode Figure 17The display will scroll three times through all of the Advanced Programming modes System Voltage System Time AmpManager EQ Voltage EQ TimeYou may wait until the desired adjustment mode is reached before activating theThe red LED will stop flashing and the 7 amber light will illuminate shortly thereafter to indicate the battery preset proFigure 12indicate battery type The first green LED on the left will indicate Program 1 Universal Factory ProgramAs you conCycleindicating Program 3 Gelindicating Program 4 AGMswitch has been deactivated The green LED lights will remain for several second before going out Figure 13The program choices will scroll inreverse order that the display will stop scrolling once it reaches selection one orfive depending on if you are ascending ordescending in the program mode Indicates program has been save to memory Regulatorwill reset and return to its basic operational displayFlashingentry to AdvancedFlashingentry into the AdvancedSystem VoltageSwitch ActivatedSwitch ActivatedSwitch ActivatedVISYSTEM VOLTAGE ADJUSTMENTThe Voltage Adjustment mode allows you to increase or decrease the voltage values built into the preset programs based on batNote Changes in charging voltages affect ALLstages of the charging programhas been programmed to provide approximately five seconds between value changes This time period is provided to ensurecorrect adjustments To adjust system voltage valuesFigure 17ACTIVATEHOLDFigure 18 The display will begin toFigure 19NOTE Toreverse scrolling direction release the switch wait until thegreen lights turn off and reactivate and hold the switch tocycle the opposite directionAfter several seconds the green indicator lights will turn offSystem TimeVIISYSTEM TIME ADJUSTMENTThe System Time Adjustment enables you to modify charging timevalues to meet your battery banks specific charging needs Keepchanges in charging times affect ALLcharging stages Tomodify charging time valuesFigure 20ACTIVATEthe switch with your magnet The display willFigure 22To reverse scrolling direction release the switch waituntil the green lights turn off and reactivate and holdthe switch to cycle the opposite directionAfter several seconds the green LEDs will turn off tion has been accepted The display will advance to theFigure 23System VoltageSwitch Activated Indicates Advanced System Time AdjustmentAmp Manager Adjustment Indicates entry into the Advanced SystemVoltage adjustment mode Adjustmentbegins at System Voltage settingSwitch Activated Indicates entry into Advanced System TimeVIIIAMP MANAGERThe Amp Manager function enables you to reduce the alternators output by controlling the voltage at the field wire This feature can be used as a method to minimize alternator overheating in warmer climates or to minimize difficulties with belt slippage To adjust Amp Manager valuesFigure 23 VATEHOLDthe switch with your magnetic tool The displaywill indicate initial entry into Amp Manager program mode asFigure 24When the display indicates your desired Amp Manager value asFigure 25off tion has been accepted The display will advance to theEqualization Voltage AdjustmentFigure 26IXEQUALIZATION VOLTAGEperiodic introduction of elevated voltage to the battery SeeFigure 5fit from equalization Voltage values are based on system voltCAUTION Consult with yourbattery manufacturerforrecommended equalization time and voltage Both timeand voltage values must be set forequalization to occur When the LED indicates entry into the EQ Voltage mode asFigure 27ACTIVATEHOLDFigure 28 The display will show system voltageFigure 28Figure 28After several seconds the green indicator lights will turn off been accepted The display will advance to theEqualization Time AdjustmentFigure 29Switch ActivatedAmp Manager AdjustmentField output reduction percentages are shown in Illustrates percentages of field voltage ascontrolled by the Amp Manager featureEqualization VoltageSwitch ActivatedEqualization VoltageField output reduction percentages are shown inEqualization Time Illustrates EQ Voltage settings tery manufacturerXEQUALIZATION TIMEThe final mode in the Advanced Programming cycle is Time Adjustment To change the duration of EQ timeTime AdjustmentFigure 29 ACTIVATEHOLDswitch Equalization Time Adjustment values will scroll up asFigure 31Figure 31After several seconds the green indicator lights will turn offhas been accepted The Advanced Programming display will cycle two more times If no other changes are made to yourprogramming selections the changes will be saved Aflashing 8 amber LED at the end of the final cycle indicates thatyour Advanced Programming selections have been savedEqualization will occur immediately after the EQ time and voltage values have been saved into memory and will be indifloat portion of the regular charge mode governed by your preset battery programAdvanced programming for System Voltage System Time and Amp Manager functions will remain in the regulators memory until they are modified within Advanced Programming or until the Preset Program for battery type is reselectedXIWARNING ADVISORY CODESLED display To access diagnostic dataACTIVATERELEASEFigure 33 Illustrates EQ Time settings CAUTIONContact your battery manufacturer for recommended EQtime and voltage values Do not attempt equalizationunless recommended by the battery manufacturerSwitch ActivatedEqualization Time EQ Time values are shown in Flashing RedDetermining the causes of failures in an electrical system is a step by step process We recommend that you inspect and cleanmain components of your charging system the alternator andor the voltage regulator Most charging system problems will be corrected by performing the following steps Remove and clean all charging system electrical connections from the alternator through the batteries this includes theAlso check the voltage regulators harness for resistance Wires and terminals can and will become corCharge all batteries to their proper fully charged state and determine if they are serviceable If your batteries are floodedCheck and tighten alternator belt If the belt shows signs of wear or damage now is an ideal time for replacement AlwaysAfter determining that your batteries and wiring are in suitable condition use the following tests to determine if charging prlems are a result of a faulty alternator or regulator The following tests provide an opportunity to isolate the alternator retor and wiring harness in order to determine which component may be malfunctioning In order to preform these tests you willneed an independent multimeter preferably a digital typegency a 12Vlight bulb can be used to help determine ifpower or working grounds exist An amp meter and a battery hydrometer with a thermometer are also helpful diagnostic toolsAlternator Regulator Field TestsTest AThe alternator and regulator can be tested for function by determining if a magnetic field exists at the alternators pulley shaft or rear bearing To testWith the ignition in the OFF position place the head of a steel screwdriver near the nut on the pulley shaft or near therear bearing of the alternator There should be no evidence of a magnetic field pulling the screwdriver toward the alternatorEngage the ignition without starting the engine to activate the voltage regulator If an oil pressure switch is used ajumper across the switch will activate the regulatorAfter allowing time for the regulators startup delay place the head of a steel screwdriver near the nut on the pulley shaftor near the rear bearing of the alternator There should be evidence of a magnetic field pulling the screwdriver toward thealternator If a magnetic field is present the voltage regulator alternator brushes and rotor are likely to be working properly If the system is not charging remove the alternator and have it inspected by a qualified alternator shopTest B With the key off and the engine off remove the large harness plug from the regulatorFigure 32This bypasses the regulator and tests the alternator and the harUsing your steel screwdriver inspect for a magnetic field as described aboveWith your voltmeter check for voltage on the blue wire at the alternator Ifharness but charging is not occurring the alternator is likely to be malfuncto be working properly If no magnetic field is present proceed with the next test Test C Testing the actual output of the alternator is known as Full Field Testingnal at the rear of the alternator This test eliminates both the regulator and the harness making it easier to isolate your investigation to the alternatorCAUTION Ensure that all voltage sensitive equipment is turned off priortostarting the engine Voltage is unregulated during this test and could damagesensitive electronicsDO NOTlet the engine run any longerthan necessary toAlternator and Regulator TroubleshootingTo test the alternatorClip a jumper wire to the positive post of the alternator or on the battery side of the isolator if an isolator is in use seFigure 33tors Field terminal FAttach a female spade connector to the field end of the wire for a solid connection Do not allow the wire to contact the case while it is attached to the positive post The case is grounded and severe damage could occurThe regulator is now bypassed When the ignition is engaged and the motor is started the voltage should rise and chargThe motor should be run long enough to determine that charging voltage is present Unregulated voltage can rise quickly Do not allow extended unregulated charging to occur without carefully monitoring voltage levelsIf the alternator fails to generate voltage during field testing a malfunction of the alternator is likely Contact your local alternator repair shop or Xantrexs technical service staff for recommendations Voltage Regulator Testcharged set your voltmeter to 12Vand connect the voltmeters negative lead to theBLACK ground wire at the regulator Normally connection is accomplished by insertFigure 33iththe voltmeter securely connected to the regulators ground test for voltage at the pointslisted belowWith the ignition in the OFF position and your voltmeters ground wire connected to the regulators ground check for voltage on the RED sensingfieldand BROWN ignitionwires in the regulator plug by inserting the positivelead of the voltmeter alongside each wire in the regulator harness plug The voltRed WireBrown WireBlue WireExpected Reading12 V0 V0 VYourReadingWith the ignition in the ON position engine not runnings ground wire connected to the regulatorsground check for voltage on the RED sensingfieldand BROWN ignitionwires in the regulator plug TheRed WireBrown WireBlue WireExpected Reading12 V 12 V7 12 VYourReadingWith the ignition in the ON position with engine running at 1400 rpm fast idles ground wire connected to the regulators BLACK wire check for voltage on the RED sensingfieldand BROWN ignitionwires in the regulator plug The voltmeter should readRed WireBrown WireBlue WireExpected Reading12 14V12 V4 12 VYourReading 115 128 VDC battery voltage at rest no charging occurringe isolated and your RED sensingeshows voltages other than those shown above make sure that the wire is connected on the battery side of the isolator TheREDwire must see the battery directly 135 145 VDC battery voltage when chargingIf your readings differ substantially from the Expected Readings listed in the charts above the regulator may be malfunctioning or there may be a continuity problem Contact our technical support staff If you determine that repair service is necessary for either your alternator or regulator please gather the following information before contacting our service techniciaModel of alternatorModel of voltage regulatorVoltage readings on red brown and blue wire at regulator with engine off key onVoltage readings on red brown and blue wire at regulator with engine running at a fast ideal 1400 rpm Regulator voltage testTYPICAL SYSTEM WIRING Single Output AlternatorTYPICAL SYSTEM WIRING Dual Output Alternator 11 WarrantyWhat does this warranty cover to new in accordance with industry standard practices This warranty covers any defects in workmanship or materialsHow long does the coverage last altered either internally or externally or damaged from improper use or use in an unsuitable environment Xantrex does notconsequential or economic loss even though caused by the negligence or fault of Xantrex Some jurisdictions do not allowWhat will Xantrex do Xantrex will at its option repair or replace the defective product free of charge Xantrex will at itsTo qualify for the warranty dated proof of purchase must be provided and the product must notPhone18004466180Fax13609255143EMailtechhelpxantrexcomReturn Material Authorization PolicyYou must obtain a Return Material Authorization RMAProducts returned without an RMAnumber or shipped collect will be refused When you contact Xantrex to obtain serviceThe model number of your productThe date of purchaseInformation about the installation and use of the productIf you are returning a product from the USAor Canada follow this procedure1Contact Xantrex to obtain an RMAnumber and a shipping address2Package the unit safely preferably using the original box and packing materials Include the followingThe RMAnumber supplied by XantrexAcopy of your dated proof of purchaseAreturn address where the repaired unit can be shippedAcontact telephone number3Ship the unit freight prepaid to the address provided in Step 1 Collect shipments will be refusedHow do otherlaws apply ForourCanadian customersD20011206102811ZD201405021804540400Acrobat Distiller 405 for Windows
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