Xantrex XPower Charger 2 User manual

XPower Charger 2
Owner's Guide
975-0135-01-01 REV. B Printed in China
t 1-800-670-0707 (toll free in North America)
 1-360-925-5097 (direct)
f 1-800-994-7828 (toll free in North America)
 1-360-925-5143 (direct)
e [email protected]
www.xantrex.com
by

by
About Xantrex
Xantrex Technology Inc. is a world-leading supplier of
advanced power electronics and controls with products
from 50 watt mobile units to MW 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.
XPower Charger 2
Owner’s Guide

Trademarks
XPower by Xantrex is a trademark of Xantrex
International. Xantrex is a registered trademark of
Xantrex International.
Other trademarks, registered trademarks, and product
names are the property of their respective owners and are
used herein for identification purposes only.
Notice of Copyright
XPower Charger 2 Owner’s Guide
© July 2004 Xantrex International. All rights reserved.
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING,
XANTREX TECHNOLOGY INC. (“XANTREX”)
(a) MAKES NO WARRANTY AS TO THE ACCURACY,
SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR
OTHER INFORMATION PROVIDED IN ITS MANUALS OR
OTHER DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY
FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT,
CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT
ARISE OUT OF THE USE OF SUCH INFORMATION. THE
USE OF ANY SUCH INFORMATION WILL BE ENTIRELY
AT THE USER’S RISK.
Date and Revision
July 2004 Revision B
Part Number
975-0135-01-01
Contact Information
Telephone: [phone] (toll free North America)
1 360 925 5097 (direct)
Fax: [phone] (toll free North America)
1 360 925 5143 (direct)
Email: [e-mail]
Web: www.xantrex.com

Contents
1. Introduction . . . . . . . . . . . . . . . . . . . . . 1
About the XPower Charger 2 . . . . . . . . . 1
About This Guide . . . . . . . . . . . . . . . . . . 1
2. Important Safety Information. . . . . . . 2
Warnings and Cautions . . . . . . . . . . . . . . 2
Personal Precautions . . . . . . . . . . . . . . . . 5
Preparing to Charge . . . . . . . . . . . . . . . . . 7
Charger Location . . . . . . . . . . . . . . . . . . . 8
DC Connection Precautions . . . . . . . . . . . 8
3. XPower Charger 2 Features . . . . . . . 10
Front Panel . . . . . . . . . . . . . . . . . . . . . . 10
DC Cable Connections . . . . . . . . . . . . . 12
4. Charging a 12 volt Battery . . . . . . . . 14
Using the Lighter Plug Adapter . . . . . . 14
Using the Battery Clip Adapter . . . . . . 16
Using the Ring Terminal Adapter . . . . . 21
5. Troubleshooting . . . . . . . . . . . . . . . . . 23
6. Specifications . . . . . . . . . . . . . . . . . . . 25
7. Warranty and Return . . . . . . . . . . . . 26
8. Other Xantrex Products . . . . . . . . . . 33

1
1Introduction
Thank you for purchasing a Xantrex XPower
Charger 2. The XPower Charger 2 is part of a
family of ultra-compact, light weight and
modern power inverters and chargers from
Xantrex Technology.
About the XPower Charger 2
The 2 amp XPower Charger 2 is designed to
charge 12 volt rechargeable batteries. The
XPower Charger 2 regulates the charging
process, ensuring the battery is always fully
charged, but never overcharged.
About This Guide
To get the best performance from your
XPower Charger 2, Xantrex recommends
that you read this guide before connecting
and using the charger, and then save it for
future reference.
This guide contains:
• Important safety information (page 2)
• Features of the XPower Charger 2
(page 10)
• Battery charging instructions (page 14)
• Troubleshooting guidelines (page 23)
• Specifications (page 25)
• Warranty and service information
(page 26)

2
2 Important Safety
Information
Misusing or incorrectly connecting the
XPower Charger 2 may damage the
equipment or create hazardous conditions for
users. Read the following safety instructions
and pay special attention to all Caution and
Warning statements in the guide.
Warnings identify conditions that may result
in personal injury or loss of life.
Cautions identify conditions or practices that
may damage the unit or other equipment.
Warnings and Cautions
WARNING:
This guide contains important safety and
operating instructions in how to use the
XPower Charger 2, to recharge 12 volt
batteries. Read this guide fully for safe
operation of this charger. Save this guide for
future reference.

3
1. Do not expose the XPower Charger 2 to
rain or snow.
2. Use of an attachment not recommended
may result in a risk of fire, electric shock,
or injury to persons.
3. To reduce risk of damage to electric plug
and cord, pull by plug rather than cord
when disconnecting the XPower
Charger 2.
4. An extension cord should not be used
unless absolutely necessary. Use of an
improper extension cord could result in a
risk of fire and electric shock. If an
extension cord must be used, make sure
that:
a) pins on plug of the extension cord
are the same number, size, and shape
as those of plug on the XPower
Charger 2;
b) the extension cord is properly wired
WARNING: Shock and fire hazard
The battery clip adapter, lighter plug adapter,
and ring terminal adapter accessories are to
be used individually with the XPower
Charger 2 as specified in this manual.
Connecting adapters together for other, non-
specified use will result in reverse polarity
and may result in damaged equipment and
personal injury.

4
and in good electrical condition; and
c) wire size is No. 18 AWG (mini-
mum) with a maximum length of 50
ft. (15.2 m).
5. Do not operate XPower Charger 2 with
damaged cord or plug—replace the cord
or plug immediately.
6. Do not operate XPower Charger 2 if it
has received a sharpblow, been dropped,
or otherwise damaged in any way; take it
to a qualified service technician.
7. Do not disassemble XPower Charger 2;
take it to a qualified service technician
when service or repair is required.
Incorrect re-assembly may result in a
risk of electric shock or fire.
8. To reduce risk of electric shock, unplug
XPower Charger 2 from the electric
outlet before attempting any
maintenance or cleaning.

5
Personal Precautions
1. Someone should be within range of your
voice or close enough to come to your
aid when you work near a lead-acid
battery.
2. Have plenty of fresh water and soap
nearby in case battery acid contacts skin,
clothing, or eyes.
3. Wear complete eye protection and
clothing protection. Avoid touching eyes
while working near battery.
4. If battery acid contacts skin or clothing,
wash immediately with soap and water.
If acid enters eye, immediately flood eye
WARNING: Risk of explosive
gases
Working in the vicinity of a lead-acid battery
is dangerous. Batteries generate explosive
gases during normal battery operation. For
this reason, it is of utmost importance that
each time before using a battery charger, you
read this guide and follow the instructions
exactly.
To reduce risk of battery explosion, follow
these instructions and those published by
battery manufacturer and manufacturer of
any equipment you intend to use in the
vicinity of the battery. Review cautionary
marking on these products and on any
engine.

6
with running cold water for at least 10
minutes and get medical attention
immediately.
5. NEVER smoke or allow a spark or flame
in the vicinity of battery or engine.
6. Be extra cautious to reduce risk of
dropping a metal tool onto a battery. It
might spark or short-circuit the battery
or other electrical part that may cause an
explosion.
7. Remove personal metal items such as
rings, bracelets, necklaces, and watches
when working with a lead-acid battery.
A lead-acid battery can produce a short-
circuit current high enough to weld a
ring or the like to metal, causing a severe
burn.
8. Use XPower Charger 2 for charging a
LEAD-ACID battery only. It is only
intended to charge lead-acid batteries or
batteries, such as those used in specific
integrated products. Do not use XPower
Charger 2 for charging dry-cell batteries
that are commonly used with home
appliances. These batteries may burst
and cause injury to persons and damage
to property.
9. NEVER charge a frozen battery.

7
Preparing to Charge
1. If necessary to remove the battery from
the vehicle to charge, always remove the
grounded terminal from the battery first.
Make sure all accessories in the vehicle
are off, so to minimize chances of an arc.
2. Be sure area around the battery is well-
ventilated while battery is being
charged. Gas can be forcefully blown
away by using a piece of cardboard,
other nonmetallic material or a fan.
3. Clean battery terminals. Be careful to
keep corrosion from coming in contact
with eyes.
4. Add distilled water in each cell until
battery acid reaches level specified by
the battery manufacturer. This helps
purge excessive gas from cells. Do not
overfill. For a battery without cell caps,
carefully follow manufacturer’s
recharging instructions.
5. Study all battery manufacturer’s specific
precautions such as removing or not
removing cell caps while charging and
recommended rates of charge.
6. Determine the voltage of battery by
referring to the vehicle owner’s manual
and make sure it matches the output
rating of the battery charger.

8
Charger Location
1. Place the battery charger as far away
from the battery as the output DC cable
permits.
2. Never place the battery charger directly
above a battery being charged; gases
from battery will corrode and damage
the charger.
3. Never allow battery acid to drip on the
charger when reading specific gravity or
filling battery.
4. Do not operate the charger in an
enclosed area. Do not restrict ventilation
in any way.
5. If the ring terminal adapter accessory is
connected permanently to the battery
terminals, be sure the safety cap is put on
when the adapter is not in use.
6. Do not set a battery on top of the
charger.
DC Connection Precautions
1. Connect and disconnect the DC cable
only after removing the AC cord from
the electric outlet.
2. If the DC cable has the cable adapter
accessory clips connected, never allow
the clips to touch each other. When
attaching the clips to the battery posts,
twist or rock back and forth several
times to make a connection. This tends

9
to keep the clips from slipping off the
terminals and helps to reduce the risk of
sparking.
Failure to follow these safety guidelines may
cause personal injury and/or damage to the
XPower Charger 2. It may also void your
product warranty.

10
3 XPower Charger 2
Features
This section describes the main features of
the XPower Charger 2.
Front Panel
Figure 1 shows the XPower Charger 2. Use
Table 1 to identify the function of items.
Figure 1 XPower Charger 2 Features
Table 1 XPower Charger 2 Features
Item Feature
1 Mounting Flanges
For permanent charger installation, use
the drilling template supplied with the
unit.
2
5
1
3
4
1

11
2 DC Cable
The DC cable provides 12 volts, 2 amp
charging current to the battery being
charged. Three types of adapter
accessories are provided for specific
needs. (See Figure 2.)
3 Power light
The green power light indicates that AC
power is connected to the unit and 12
volts are available at the output.
4 Charging light
The red charging light indicates that
charging is in progress. When the battery
is fullycharged, thered charging light will
turn off.
5 AC Cord
Connects the XPower Charger 2 to a
standard wall outlet
Table 1 XPower Charger 2 Features
Item Feature

12
DC Cable Connections
Figure 2 shows the DC cable connections
available for the XPower Charger 2. Use
Table 2 to identify the usage.
Figure 2 DC Cable Connections
Table 2 DC Cable Connections Usage
Item Function
1 Battery clip adapter
2 Lighter plug adapter
3 Ring terminal adapter
1 2 3

13
WARNING: Shock and fire hazard
The battery clip adapter, lighter plug adapter,
and ring terminal adapter are to be used
individually with the XPower Charger 2 as
specified in this manual. Connecting adapters
together for other, non-specified use will
result in reverse polarity and may result in
damaged equipment and personal injury.

14
4Charginga12volt
Battery
It is possible to use XPower Charger 2 to
charge most engine starting batteries when
the battery is installed in a vehicle. Before
attempting to charge a vehicle battery, make
sure the battery is a 12 volt, lead-acid type.
Using the Lighter Plug Adapter
Follow these steps to recharge a 12 volt
battery using the lighter plug adapter:
1. Turn off any lights, audio equipment, or
other 12 volt accessories that are
connected to your vehicle’s electrical
system. Make sure your vehicle is in the
park position and secured by the
emergency brake.
2. Connect the XPower Charger 2 DC
cable to the lighter plug adapter.
3. Insert the XPower Charger 2 DC plug
into the lighter socket or 12 volt outlet in
your vehicle. In some vehicles the
lighter socket or 12 volt outlet are
controlled by the vehicle’s ignition and it
CAUTION
The XPower Charger 2 is not recommended
for charging vehicle batteries over 50 amp-
hours.

15
may be necessary to switch the ignition
to the accessory setting to allow current
to flow from XPower Charger 2 to the
vehicle battery.
4. Plug the XPower Charger 2 AC cord into
a standard 115 volt AC outlet.
5. As the battery in your vehicle charges,
the green Power light and red Charging
light turn on.
6. When fully charged, the red Charging
light turns off and the green Power light
remains on. The recharge time will vary
based on the capacity and discharge state
of your vehicle’s battery.
7. Once the vehicle’s battery is fully
charged, disconnect XPower Charger 2
from the AC outlet and remove the DC
plug from the vehicle’s lighter socket or
12 volt outlet.
CAUTION
If the green Power light turns off and the red
Charging light turns on, immediately
disconnect it from the lighter socket or outlet.
The unit has detected an output short circuit
or reverse polarity on the DC connection.
Check the connection.

16
Using the Battery Clip Adapter
Follow these steps to recharge a 12 volt
battery using the battery clip adapter:
1. Turn off any lights, audio equipment, or
other 12 volt accessories that are
connected to your vehicle’s electrical
system. Make sure your vehicle is in the
park position and secured by the
emergency brake.
2. Position the AC and DC cords to reduce
the risk of damage by a hood, door, or
moving engine part.
3. Stay clear of fan blades, belts, pulleys,
and other parts that can cause injury to
persons.
4. Connect the XPower Charger 2 DC
cable to the battery clip adapter.
5. Check the polarity of the battery posts.
The POSITIVE (POS, P, +) battery post
usually has a larger diameter than the
NEGATIVE (NEG, N, –) post.
WARNING: Explosion hazard
A spark near the battery may cause an
explosion. Follow instructions carefully to
reduce the risk of spark near the battery.