Xantrex PathMaker User manual
XantrexXantrex
XantrexXantrex
Xantrex
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Automatic Battery SwitchAutomatic Battery Switch
Automatic Battery SwitchAutomatic Battery Switch
Automatic Battery Switch
PathMaker
Owner's Manual
The Easy-to-Install Automatic Battery Switch
For Marine, RV, Alternative Energy
and ar Audio use.
Pick the unit thats right for your installation:
100 Amps - 2 Battery Banks
100 Amps - 3 Battery Banks
250 Amps - 2 Battery Banks
250 Amps - 3 Battery Banks
Manual Contents
Operations 4
Installation 7
Remotes 13
2
Notice of Copyright
Xantrex PathMaker Automatic Battery Switch © March 2004 Xantrex International. All rights
reserved. Xantrex is a registered trademark of Xantrex International.
Disclaimer
UNL SS SP CIFICALLY AGR D TO IN WRITING, XANTR X T CHNOLOGY INC.
(XANTR X)
(a) MAK S NO WARRANTY AS TO TH ACCURACY, SUFFICI NCY OR
SUITABILITY OF ANY T CHNICAL OR OTH R INFORMATION PROVID D IN ITS
MANUALS OR OTH R DOCUM NTATION.
(b) ASSUM S NO R SPONSIBILITY OR LIABILITY FOR LOSS OR DAMAG ,
WH TH R DIR CT, INDIR CT, CONS QU NTIAL OR INCID NTAL, WHICH MIGHT ARIS
OUT OF TH US OF SUCH INFORMATION. TH US OF ANY SUCH INFORMATION WILL
B NTIR LY AT TH US RS RISK.
Date and Revision March 2004, Revision B Part Number 975-0119-01-01
Contact Information Web: www.xantrex.com mail: [email protected]
Phone: 1 800 670 0707 (toll free in North America) 1 360 925 5097 (direct) Fax: 1 360 925 5143
Introduction
The PathMaker provides automatic battery switchin in a wide ran e of
environments and applications includin marine, recreational vehicles,
renewable ener y, military, and mobile audio. The PathMaker has two
primary functionsfirst, it automatically parallels (connects to ether)
multiple batteries (combining them) when char in sources are avail-
able, and second, it automatically disconnects the startin battery from
the system loads when there are no active char in sources. This en-
sures that the en ine startin battery is only used for startin . Addition-
ally, the PathMaker can be used to connect loads and sources.
The PathMaker consists of the followin major components:
A control module that provides user-adjustable set points, operator
indicators, and a local control switch. Additionally, a telephone jack
on the ri ht hand side of the module allows the user to plu in an op-
tional remote control panel.
A terminal strip is fitted on the control module. This terminal strip is
where the user connects a ne ative wire to the terminal labeled ne a-
tive (system ground), and makes optional connections. All other con-
nections are pre-wired at the factory and require no chan es.
The PathMaker Power Switch(es) are mounted below the terminal
strip. They provide the connection for the path of battery current flow
when enabled by the control module.
Remote Control Panel (optional) Use of this optional panel is stron ly
recommended, as the PathMaker may be mounted where access to
the local control switch may not be convenient.
3
Operations
The PathMaker has power switch(es) that connect batteries,
loads or sources together.
Connected Light
The Connected light turns on to indicate that the batteries, loads or
sources are connected.
Disabled Light
The Disabled light is on whenever the power switch(es) is(are) not on.
igh Voltage Disconnect Light
The High Voltage Disconnect light is on solid whenever the batteries
are not connected due to a voltage higher than the High Voltage
Disconnect set point. The High Voltage Disconnect light will lash
based on the ollowing condition. I a charge source is connected to
a smaller battery bank, it is possible that when the Pathmaker
connects the banks together, the larger battery bank (or depleted
battery bank) will pull the battery voltage down below the Low Voltage
Disconnect Setpoint. This will cause the unit to disconnect. I this
happens more than ive times, the unit will shut down and the High
Voltage Disconnect light will begin to lash. A ter six minutesto
allow the battery connected to the charge source to charge longer
the unit will try to reconnect and resume normal operation.
The Control Module Switch
The switch on the Control Module should normally be in the Auto
position. I it is in the O (Disabled) position, the batteries will not
connect when a charge source is available. To test the PathMaker
hold the switch in the I (ON) position. While the switch is in the I (ON)
position, the power switch(es) will be on and the green Connected
light will turn on. I emergency starting is required, pushing the
switch to the I (ON) position will momentarily connect the battery
switches as long as the switch is held. I two batteries are connected
to the PathMaker, this provides a jump start or the starter.
Remember: The local switch on the PathMaker must be in the AUTO
position or any remote switch to work.
4
5
Setup and Operation
See Pa e 14
CONNECT THE SYSTEM
NEGATIVE (ground) TO
THIS TERMINAL LAST.
(Use #14 AWG wire or larger)
Factory Installed
Optional Remote
See Pa e 13
*Multiply voltage values times 2
for use on 24 V systems.
igh Voltage Disconnect*
Above this volta e, the power
switch(es) are disabled. The
default volta e settin is 15.0 V. The
red Hi h Volta e Disconnect
li ht is on solid when active.
Low Voltage
Disconnect*
Below this volta e, the
PathMaker power switch(es)
is(are) disabled (the batteries
are not connected to ether).
The default volta e is set at
13.0 V. The yellow disabled
li ht will be lit whenever the
batteries level falls below the
set point.
Connect Voltage*
Above this volta e the PathMaker
power switch(es) are enabled: thus the
batteries are in parallel for char in .
The default volta e settin is 13.3 V.
The reen connected li ht is on
whenever the banks are connected.
(Li ht may flicker below 12.6 V.)
Adjustments
Default settin s are at the
12 oclock position.
Negative
6
Connecting with a Remote
You can force the PathMaker to Connect for five minutes for
emer ency startin by momentarily pressin the Manual On switch
on the remote panel. You may cancel the forced connection only by
pressin the Manual On switch a second time (for less than one
second).
While in the forced Connect mode, placin the switch to the
Disabled position will break the connection. However, returnin
the switch to the Auto position will allow the forced Connect to
resume until the five-minute timer expires or until the switch is a ain
placed over to the ON for at least one second to cancel the five-
minute timer.
Troubleshooting
The PathMaker is internally protected a ainst most faults. If the Green
li ht does not come on when the switch on the unit is held in the ON
position, disconnect the wire connected to the system ne ative
terminal, wait one minute and reconnect it.
7
The terms battery and bank are used interchan eably. A bank means
a roup of batteries that are connected, in series or parallel, to create a
hi her capacity, or hi her volta e, battery. Installation requires three wires
for two bank units and four wires for three bank units. Generally no set up
is required.
Connect the wire to system negative (ground) to the PathMaker
terminal strip last.
All wiring to PathMaker power switch terminals must be sufficiently
sized. Starter current of several hundred amps may pass through
these wires. If in doubt, please consult a professional.
Battery cables must be properly strain relieved. Although no
exposed contacts are used, the PathMaker is NOT approved for
explosive environments.
CAUTION!! If B+ (Battery Positive) is shorted to the NEGATIVE
terminal of the Control Module, COIL NEGATIVE, the electronics
may be destroyed. T IS IS NOT COVERED BY T E WARRANTY!
Fuses, Battery Switches, and Protective Terminal Caps
To simplify installation dia rams we have not included fusin or op-
tional on/off battery switches. Check the latest ABYC (American Boat
and Yacht Council) and NEC (National Electrical Code) for fusin
requirements for your installation. Install protective terminal caps
as needed to protect a ainst shortin of terminals.
Alternator Protection
An alternator may be dama ed if operated with no battery (or load)
attached. For this reason, we recommend the use of a Xantrex
ZapStop to protect an alternator that experiences a brief open out-
put condition. The ZapStop prevents momentary overvolta e.
Installation
Power Switch Connections
When wiring to the power switch(es), remove the supplied volt-
age sense leads and place your heavy battery wiring on the
terminal post first. Then replace the supplied voltage sense
wire on top of the heavy battery wires. This eliminates voltage
sensing errors under high current conditions. The drawings below
indicate the terminal designations for each model. ay not be
exactly as shown.
Batt, Load or
Source #1
(VB1) Batt, Load or
Source #2 (VB2)
Batt, Load or Source
#3 (VB3)
Batt, Load or
Source #1
(VB1)
Batt, Load or Source
#2 (VB2)
Batt, Load or
Source #1
(VB1)
Battery, Load or
Source #3 (VB3)
Batt, Load or
Source #2 (VB2)
Batt, Load, or
Source #1
(VB1)
100 Amp Two-
Bank PathMaker
250 Amp Two-
Bank PathMaker
100 Amp Three-
Bank PathMaker
250 Amp Three-
Bank PathMaker
Battery, Load or
Source #2 (VB2)
8
9
Dia ram Table
Many confi urations are possible with a PathMaker. This table is a
uide to help select the correct dia ram for your installation:
System: Use Diagram Page
2 Banks sin le or multi-en ine Dia ram 1 10
(Marine, RV, Renewable Ener y or Car Audio)
3 Banks
2 House, 1 Start Dia ram 2 11
1 House, 2 Start Dia ram 3 12
(Marine or RV)
Sources such as battery char ers, solar panels, wind enerators, or
alternators may be wired to any battery. When a batterys volta e rises
above the Connect Volta e all batteries are paralleled and char ed by
the source. If there are multiple sources connected, the source with the
hi hest volta e will char e the batteries to that level. Alternators will
not fi ht a ainst each other; the batteries will simply char e at the volt-
a e of the alternator havin the hi hest output volta e.
10
Dia ram 1 (2 Banks)
This is the recommended installation method. In this dia ram the
starter is wired directly to the startin battery. The battery switch al-
ways stays in the #1 position, the house battery supplies the DC
loads. The en ine startin battery always supplies startin . The
PathMaker connects the batteries in parallel when a char in source
is present and disconnects them when there is no char in source
present.
The battery switch shown is not required but may be left installed as
a redundant switch, if desired.
Note: Install Negative (ground) to PathMaker last.
Fusing, breakers, wire size, and optional battery switches that may be
required by ABYC or NEC are not shown
- +
START
+ -
HOUSE
ENGINE
PATHMAKER STARTER
VB2
VB1
NEGATIVE
12
C
TO DC LOADS
+
ALT
TO ENGINE(S)
11
Dia ram 2 (3 Banks)
This dia ram shows an installation with one en ine startin battery
and two house banks. This type of installation uses a three-bank
version of the PathMaker.
Note: Install Negative (ground) to PathMaker last.
Fusing, breakers, wire size, and optional battery switches that may be
required by ABYC or NEC are not shown
+ -
START
- +
HOUSE 2
+ -
HOUSE 1
ENGINE
PATHMAKER
ALT
STARTER
VB2 VB3
VB1
NEGATIVE
12
C
TO DC LOADS
+
12
Dia ram 3 (3 Banks)
In this twin en ine, three-battery bank installation, each en ine has a
dedicated startin battery. All batteries are char ed when either of
the en ines is runnin , or when there is any char in source on the
system. In an emer ency all batteries may be connected to ether
usin the optional Remote Switch. This dia ram is shown without
any battery switches, since a PathMaker can replace battery switches.
Note: Install Negative (ground) to PathMaker last.
Fusing, breakers, wire size, and optional battery switches that may be
required by ABYC or NEC are not shown
+ -
START 1
- +
START 2
+ -
HOUSE
ENGINE
# 1
PATHMAKER
ALT
STARTER
VB2 VB3
VB1
NEGATIVE
TO DC LOADS
+
ENGINE
# 2
ALT
STARTER
13
Optional PathMaker Remote
Using the PathMaker Remote
Control Panel
The PathMaker Remote switch
is normally left in the AUTO
position. In this position the
power switch(es) are
ener ized (connectin the
batteries to ether) when the
Connect volta e is reached,
and de-ener ized below the
Disconnect volta e.
To disable the PathMaker
place the switch in the O
Momentarily press switch in
MANUAL ON position to turn on
power switch(es).
[OFF] position. In this position the battery banks are separated. The
yellow Disabled li ht is ON.
To manually ener ize the PathMaker power switch(es), momentarily
press and hold the switch to the I [ON] position until the reen ON
li ht is lit (about one second). This connects the batteries for five minutes.
Movin the switch momentarily to the ON position for at least one
second will cancel the five-minute connect timer.
We hi hly recommend usin the optional Remote Control Switch to
provide a clear indication of the PathMaker status and to simplify
emer ency startin . Please contact your dealer to purchase the
Remote Control Switch panel.
Emergency Starting
If you cannot start the en ine, momentarily press the Manual On
switch. The PathMaker then connects all batteries to ether (for five
minutes) to provide maximum startin power.
To disable PathMaker
switch to off position.
14
Low Voltage
Disconnect Connect
Voltage H i gh Vo l t a ge
Di s c on ne c t
13 0
13 1
13 2128
12 9
13 3
13 4
13513 1
13 2
150
155
160140
145
Disable d Conn ected
High V oltag e
Disconnect Auto
Mutp y votage settngs X2 for 24V use
Monitor Solenoid Wiring
1B U I.BL F S
7
OI
250 A mp, 3 Bat tery
Automatic Switch
www xa nt re x com
User Remote Switch
You may use your own momentary
pushbutton switch installed between the
terminal labeled (Ne ative) and (Ne at
Remote) to manually ener ize the PathMaker
power switch(es) . Hold the pushbutton down
for about 2 seconds to ener ize the
PathMaker power switch(es). They will stay
ener ized for 5 minutes. Momentarily use the
pushbutton a ain to de-ener ize the power
switch(es).
Monitor
1BUI.BLFS
7
Momentary ON
Pushbutton
To DC Ne ative
The Control Module Switch
The local switch on the PathMaker must
be in the AUTO position for the remote
switch to work.
Disabled Connected High Voltage
Disconnect Auto
Solenoid Wiring
OI
250 Amp, 3 Battery
Automatic Switch
www xantrex com
15
Warranty
What does this warranty cover? This Limited Warranty is provided by Xantrex Technology, Inc.
(Xantrex) and covers defects in workmanship and materials in your Xantrex PathMaker
Automatic Battery Switch. This warranty lasts for a Warranty Period of 12 months from the date
of purchase at point of sale to you, the original end user customer.
This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the
Warranty Period.
What will Xantrex do? Xantrex will, at its option, repair or replace the defective product free of
charge, provided that you notify Xantrex of the product defect within the Warranty Period, and
provided that Xantrex through inspection establishes the existence of such a defect and that it is
covered by this Limited Warranty.
Xantrex will, at its option, use new and/or reconditioned parts in performing warranty repair and
building replacement products. Xantrex reserves the right to use parts or products of original or
improved design in the repair or replacement. If Xantrex repairs or replaces a product, its warranty
continues for the remaining portion of the original Warranty Period or 90 days from the date of the
return shipment to the customer, whichever is greater. All replaced products and all parts removed
from repaired products become the property of Xantrex.
Xantrex covers both parts and labor necessary to repair the product, and return shipment to the
customer via a Xantrex-selected non-expedited surface freight within the contiguous United States
and Canada. Alaska and Hawaii are excluded. Contact Xantrex Customer Service for details on
freight policy for return shipments outside of the contiguous United States and Canada.
How do you get service? If your product requires troubleshooting or warranty service, contact your
merchant. If you are unable to contact your merchant, or the merchant is unable to provide service,
contact Xantrex directly at:
Phone: 1 800 670 0707 (toll free in North America), 1 360 925 5097 (direct)
Fax: 1 360 925 5143
Email: [email protected]
Direct returns may be performed according to the Xantrex eturn Material Authorization Policy
described in your product manual. For some products, Xantrex maintains a network of regional
Authorized Service Centers. Call Xantrex or check our website to see if your product can be repaired
at one of these facilities.
In any warranty claim, dated proof of purchase must accompany the product and the product must not
have been disassembled or modified without prior written authorization by Xantrex.
Proof of purchase may be in any one of the following forms:
· The dated purchase receipt from the original purchase of the product at point of sale to the
end user, or
· The dated dealer invoice or purchase receipt showing original equipment manufacturer (OEM)
status, or
· The dated invoice or purchase receipt showing the product exchanged under warranty
16
What does this warranty not cover?
This Limited Warranty does not cover normal wear and tear of the product or costs related to the
removal, installation, or troubleshooting of the customers electrical systems. This warranty does not
apply to and Xantrex will not be responsible for any defect in or damage to:
a) the product if it has been misused, neglected, improperly installed, physically damaged or
altered, either internally or externally, or damaged from improper use or use in an unsuitable
environment;
b) the product if it has been subjected to fire, water, generalized corrosion, biological
infestations, or input voltage that creates operating conditions beyond the maximum or
minimum limits listed in the Xantrex product specifications including high input voltage from
generators and lightning strikes;
c) the product if repairs have been done to it other than by Xantrex or its authorized service
centers (hereafter ASCs);
d) the product if it is used as a component part of a product expressly warranted by another
manufacturer;
e) the product if its original identification (trade-mark, serial number) markings have been
defaced, altered, or removed.
Disclaimer
Product
THIS LIMITED WA ANTY IS THE SOLE AND EXCLUSIVE WA ANTY P OVIDED BY
XANT EX IN CONNECTION WITH YOU XANT EX P ODUCT AND IS, WHE E PE MITTED BY
LAW, IN LIEU OF ALL OTHE WA ANTIES, CONDITIONS, GUA ANTEES, EP ESENTA-
TIONS, OBLIGATIONS AND LIABILITIES, EXP ESS O IMPLIED, STATUTO Y O OTHE WISE
IN CONNECTION WITH THE P ODUCT, HOWEVE A ISING (WHETHE BY CONT ACT, TO T,
NEGLIGENCE, P INCIPLES OF MANUFACTU E S LIABILITY, OPE ATION OF LAW,
CONDUCT, STATEMENT O OTHE WISE), INCLUDING WITHOUT EST ICTION ANY IMPLIED
WA ANTY O CONDITION OF QUALITY, ME CHANTABILITY O FITNESS FO A PA TICU-
LA PU POSE. ANY IMPLIED WA ANTY OF ME CHANTABILITY O FITNESS FO A
PA TICULA PU POSE TO THE EXTENT EQUI ED UNDE APPLICABLE LAW TO APPLY TO
THE P ODUCT SHALL BE LIMITED IN DU ATION TO THE PE IOD STIPULATED UNDE THIS
LIMITED WA ANTY.
IN NO EVENT WILL XANT EX BE LIABLE FO ANY SPECIAL, DI ECT, INDI ECT, INCIDENTAL
O CONSEQUENTIAL DAMAGES, LOSSES, COSTS O EXPENSES HOWEVE A ISING
WHETHE IN CONT ACT O TO T INCLUDING WITHOUT EST ICTION ANY ECONOMIC
LOSSES OF ANY KIND, ANY LOSS O DAMAGE TO P OPE TY, ANY PE SONAL INJU Y, ANY
DAMAGE O INJU Y A ISING F OM O AS A ESULT OF MISUSE O ABUSE, O THE
INCO ECT INSTALLATION, INTEG ATION O OPE ATION OF THE P ODUCT.
Exclusions
If this product is a consumer product, federal law does not allow an exclusion of implied warranties.
To the extent you are entitled to implied warranties under federal law, to the extent permitted by
applicable law they are limited to the duration of this Limited Warranty. Some states and provinces
do not allow limitations or exclusions on implied warranties or on the duration of an implied warranty
or on the limitation or exclusion of incidental or consequential damages, so the above limitation(s) or
exclusion(s) may not apply to you. This Limited Warranty gives you specific legal rights. You may
have other rights which may vary from state to state or province to province.
Warranty
17
Warranty
Warning: Limitations On Use
Please refer to your product user manual for limitations on uses of the product. Specifically, please
note that the Xantrex PathMaker Automatic Power Switch is not intended for use in connection with
life support systems and Xantrex makes no warranty or representation in connection with any use of
the product for such purposes.
Return Material Authorization Policy
Before returning a product directly to Xantrex you must obtain a eturn Material Authorization ( MA)
number and the correct factory Ship To address. Products must also be shipped prepaid. Product
shipments will be refused and returned at your expense if they are unauthorized, returned without an
MA number clearly marked on the outside of the shipping box, if they are shipped collect, or if they
are shipped to the wrong location.
When you contact Xantrex to obtain service, please have your instruction manual ready for reference
and be prepared to supply:
· The serial number of your product
· Information about the installation and use of the unit
· Information about the failure and/or reason for the return
· A copy of your dated proof of purchase
Return Procedure
1. Package the unit safely, preferably using the original box and packing materials. Please
ensure that your product is shipped fully insured in the original packaging or equivalent. This
warranty will not apply where the product is damaged due to improper packaging.
2. Include the following:
· The MA number supplied by Xantrex Technology Inc clearly marked on the outside of the
box.
· A return address where the unit can be shipped. Post office boxes are not acceptable.
· A contact telephone number where you can be reached during work hours
· A brief description of the problem
Ship the unit prepaid to the address provided by your Xantrex customer service representative.
If you are returning a product from outside of the USA or anada
In addition to the above, you MUST include return freight funds and are fully responsible for all
documents, duties, tariffs, and deposits.
If you are returning a product to a Xantrex Authorized Service enter (AS )
A Xantrex return material authorization ( MA) number is not required. However, you must contact
the ASC prior to returning the product or presenting the unit to verify any return procedures that may
apply to that particular facility.
18
Specifications
Electrical: (all units DC)
Input Voltage Range: 1032 V (24 V operation if turned on >18.0 V)
Low Voltage Disconnect Range: 12.813.2 V (x 2 for 24 V)
Connect Voltage Range: 13.113.5 V (x 2 for 24 V)
High Voltage Disconnect Range: 1416 V (x 2 for 24 V)
Current Ratings: 100 A units: 100 A continuous, 400 A peak
250 A units: 250 A continuous, 2000 A peak
Idle Power Consumed: 0.4 @ 12 V, 0.8 @ 24 V
Connected Power: 100 A/2 Bank 6.5 @12 V, 11 @ 24 V
100 A/3 Bank 13 @12 V, 23 @ 24 V
250 A/2 Bank 2.3 @12 V, 2.7 @ 24 V
250 A/3 Bank 4.2 @12 V, 4.6 @ 24 V
Physical
Dimensions: 6.3" H x 7.4" x 3.4" D (100 A)
6.3" H x 7.4" x 3.2" D (250 A)
Indicator Lights: Disabled: Yellow, Connected: Green; HV
Disconnect: Solid Red
Timed lockout: Flashing Red
External Control: User supplied momentary on/off switch
Remote Panel: Flush mount, 2.25'' H x 3.65'' x 0.75'' D
(Optional)(3'' x 1.625" H cut out)
Splashproof front, 25' cable included
Operating Am ient Temp Range: -40 to +65 °C
Environmental: Not approved for explosive environments!
19
Xantrex Technology Inc.
Toll free 1 800 670 0707
Direct 1 360 925 5097
Fax 1 360 925 5143
Customerservice@xantrex com
www xantrex com
975-0119-01-01 Printed in the U S A
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