XS Power IntelliCHARGER User manual

Microprocessor Controlled Multi-Stage 12V/14V/16V
Automatic Battery Charger
P/N 1005
USER GUIDE

XS Power IntelliCHARGER
User Guide
About XS Power
XS Power designs and manufactures custom charging solutions for street rods, racing
applications, and the mobile audio industry. These products include high performance
batteries, chargers, and related accessories.
Trademarks
Trademarks, registered trademarks, and product names are the property of their respective
owners and are used herein for identification purposes only.
Notice of Copyright
IntelliCHARGER User Guide © January 2006-2013 by XS Power. All rights reserved.
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, XS POWER:
(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.
The following conventions are used in this guide.
WARNING
Warnings identify conditions that could result in personal injury or loss of life.
CAUTION
Cautions identify conditions or practices that could result in damage to the charger
or battery.
*Important*: These notes describe an important item that you must pay
attention to.

XS Power IntelliCHARGER User Guide
Chapter 1, Introduction.............................................................. p. 1-4
Quick Start Guide
Chapter 1 contains information on safety guidelines, and the features,
switches, and indicators on the front panel of the IntelliCHARGER.
Chapter 2, Operation ..............................................................................p. 5
Chapter 2 explains how to operate the IntelliCHARGER correctly to charge a
performance battery.
Chapter 3, Troubleshooting........................................................... p. 6
Chapter 3 will help you identify and correct the common problems than can
occur with the IntelliCHARGER.
Appendix A, Specifications........................................................... p. 7
Appendix A lists the specifications for the IntelliCHARGER.
Appendix B, Battery Charging....................................................... p. 8
Appendix B describes battery charging in more detail.
FAQs.........................................................................................p. 9-10
Warranty......................................................................................p. 11
Contact Information......................................................................p. 12
Contents

Important Safety Instructions
The IntelliCHARGER generates a low DC voltage and high DC current to the battery being charged.
Operating the IntelliCHARGER incorrectly or misusing it may damage the charger or create hazardous
conditions for the user.
Save these instructions. This guide contains important safety and operating instructions.
WARNING: Explosion hazard
 • TheIntelliCHARGER is designed to charge 12V, 14V and 16V lead-acid batteries of all types.
Do not attempt to use with batteries of other voltages.
 • Donotusethisproductwherethereareflammablefumesorgases.
 • Donotusethisproductinanenclosurecontaininglead-acidbatteries.Thesebatteriesvent 
explosive hydrogen gas, which can be ignited by sparks from electrical connections.
 • Neverattempttochargeafrozenbattery.
 • DonotconnectDCclampstothecarburetor,fuellines,orsheetmetalbodyparts.
WARNING: Shock hazard. Keep away from children.
 • DonotexposetheIntelliCHARGER to water or rain.
 • DonotopentheIntelliCHARGER. There are no user serviceable parts inside the unit. For
service see the Returns policy in the back of this guide.
WARNING: Heated surface
• Ensureatleast2"(5cm)airspaceismaintainedonallsidesoftheIntelliCHARGER.
CAUTION
• Anextensioncordshouldnotbeusedunlessabsolutelynecessary.Useofanundersized 
extension cord will adversely affect the output of the product and could prove to be
dangerous. If an extension cord must be used, make sure that pins on the plug of the
extension cord are the same number, size and shape as those of the plug on the charger. We
recommend a minimum of a 16AWG cord for lengths up to 50’ and a minimum of a 14AWG
cord for lengths up to 100’. We do not recommend cords over 100’. Do not use this
product with an ungrounded extension cord.
•DonotexposetheIntelliCHARGERtotemperaturesover104°F(40°C).
• BesureACandDCcordsarenotpinchedorotherwisedamagedbyhoods,doors,orother
moving engine components.
• Observebatterypolarity.
*IMPORTANT*
• Ifthischargeristobeusedwithaportablegenerator,itshouldbeequippedwithautomatic 
voltage regulation to ensure consistent output of the product.
XS Power IntelliCHARGER User Guide
Chapter 1
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Features of the XS Power
IntelliCHARGER
The IntelliCHARGER is an advanced battery charger designed specifically for high performance lead-
acid batteries. This charger combines the reliability of a transformer and MOSFET rectifier assembly
with an advanced microprocessor control board to create a battery charger that can rapidly and safely
recharge12V,14Vand16Vflooded,maintenancefree,deepcycle,gel-cell,andAGM(AbsorbedGlass
Mat)batteriesinseveralsizes.Thefrontpanelswitches,LEDindicators,andchargemetermakethe
IntelliCHARGER very easy to use.
Multi-Stage Charging
At the heart of the technology in the XS Power IntelliCHARGER are the threedistinctchargingstages.During
the first stage, called “Bulk” charging, the current is fixed according to the charge rate switch on the front
panel and the voltage is allowed to float. During this stage, 80% of the battery’s capacity is restored.
When the battery’s cell voltage comes up to the correct level, the second stage called “Absorption” charging is
engaged.Duringthisstagethevoltageisfixedaccordingtothebatterytypeandvoltageswitchesonthefrontpanel
andthecurrentisallowedtofloat.Thebatteryisbroughtto100%duringthisstageandthecellsareequalized.
The third stage is float charging. During this stage the voltage and current are reduced to a level that will
maintain the battery indefinitely.
Severalmicroprocessorsareusedtotightlycontroltheentireprocess.Thisisthesametechniquethat
battery manufacturers recommend and use in the production of new batteries and it is the fastest and
safesttechniqueforbatterycharging.
Compatible With All 12V, 14V &16V AGM and Gel-Cell Batteries
Lead-acidbatterieshavedifferentchargingrequirementsbasedontheirspecificdesign.Floodedand
maintenancefreebatteriesrequireahighervoltagepercellthandosealedvalveregulatedtypessuchasAGM
and gel-cell batteries. Overcharging will reduce the life of any battery as sealed valve regulated batteries are
especially sensitive to high charging voltages and overcharging. Some sealed valve regulated batteries are
more sensitive to overcharging than others. If in doubt as to which battery setting to use for your application,
contact the manufacturer of the battery being charged. Overcharging an AGM or gel-cell battery will cause
permanent damage.
Output Display
The battery charger features a digital output dispaly allowing the user to monitor the volts and amps.
Voltage Monitoring
The battery’s terminal voltage is measured every five minutes by the on-board microprocessors and
this information is analyzed in addition to the elapsed time to dynamically control the Battery Charger for
optimum charging performance.
Automatic Computer Analysis/Auto Shutdown
Themicroprocessorswillanalyzethebatterywhenconnected. Ifthebattery’svoltageisbelow4Vorthebattery
will not come up to the correct voltage in a ten-hour period the charger will automatically shut off.
UL Approved Battery Cables
Six feet of durable battery cables are provided that are resistant to cuts and abrasion. The copper plated
battery clamps are compact and custom designed easy connections. All clamp connections are soldered
for maximum current flow.
Internal Cooling Fan
Acoolingfanautomaticallyoperatesduringchargingto keepthetransformerand otherinternalcomponents
at a constant safe temperature.
XS Power IntelliCHARGER User Guide
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1) Volt & AMP Output Display:(Selectable)Indicateseithervoltageoramperageoutputof
charger. During stage 1 “Bulk Charging”, amperage will display the selected charge rate.
During stage two or absorption charging, this rate will naturally fall to zero as the battery
percent of charge approaches 100%. During float charge, this will read close to zero.
2) Display Mode: Allows the user to select displaying voltage and amperage. LED indicators
illuminate when either voltage or amperage is selected.
3) Voltage Select: Allows the user to select the appropriate battery voltage. LED indicators
illuminateforeither12V(sixcell),14V(sevencell)or16V(eightcell)batteriesrespectively.
4)Charging Rate: Selects 5A, 15A, or 25A as base rate for stage one or bulk charging. In general,
the rate should match the size of the battery, See Appendix B for more details.
5) Power Switch: Illuminates when the input AC power is applied.
6)Charging Indicator: Illuminates when the charger is in stage one bulk charging or stage two
absorption charging.
7)Float Charge Indicator: Illuminates when the charger is in stage three or float charge mode.
8) Error Indicator: Illuminates when the battery cannot be completely charged in a 10 hour period at
the selected charge rate. Switch the charger OFF and remove the battery connections. Insure the
battery polarity is correct, and if so, replace battery.
9)Fuse Holder: Contains a 10A fuse in case of overload.
10)AC Cord: Grounded 3-pin 110V cord for use with grounded outlets only.
11)Battery Clamps and Cord: Allow for connection to the battery.
Front and Rear Panel
Switches and Indicators
Rear PanelFront Panel
CAUTION: It is important to select the correct battery type.
XS Power IntelliCHARGER User Guide
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8765

Precautions Working With
Lead-Acid Batteries
Followallinstructionspublishedbythebatterymanufacturerandthemanufactureroftheequipmentin
which the battery is installed.
1) Makesuretheareaaroundthebatteryiswellventilated.
2) Neversmokeorallowasparkorflamenearthebattery(ies).
3) Usecautiontoreducetheriskofdroppingametaltoolonthebattery.
It could spark or short circuit the battery or other electrical parts and
thereby cause an explosion.
4) Removeallmetalitems,likerings,bracelets,andwatcheswhenworking
with lead-acid batteries. Lead-acid batteries produce a short circuit
current high enough to cause a severe burn.
5) Haveplentyoffreshwaterandsoapnearbyincasebatteryacidcontacts
skin, clothing, or eyes.
6) Wearcompleteeyeprotectionandclothingprotection.Avoidtouching
eyes while working near batteries.
7) Ifbatteryacidcontactsskinorclothing,washimmediatelywithsoapand
water. If acid enters your eye, immediately flood it with running cold
water for at least twenty minutes and get medical attention immediately.
8) Ifyouneedtoremoveabattery,alwaysremovethegroundterminal
from the battery first. Make sure all accessories are off to minimize the
potential of a spark.
9) Someoneshouldbeintherangeofyourvoiceorcloseenoughtocome
to your aid when working with a lead-acid battery.
10)Donotattempttoremovetheventcoversonsealedlead-acidbatteries
such as the XS Power 16V AGM battery. Sealed batteries operate on a
slight positive cell pressure. Venting this pressure will ruin the battery.
XS Power IntelliCHARGER User Guide
Chapter 1
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XS Power IntelliCHARGER User Guide
Chapter 2
Charging Lead-Acid Batteries
WARNING:Beforeyoustarttochargebatteriesreadthe“ImportantSafetyInstructions”onpage(1)
and take all safety precautions when working with batteries.
The IntelliCHARGER has been designed to provide fully automatic recharge of 12V, 14V and 16V AGM and
gel-cell batteries.
To charge your 12V, 14V or 16V battery:
1) If possible, disconnect all loads from the battery, by removing battery cables, opening a
disconnect switch, or switching loads off.
CAUTION!
Although this is best, in a racing environment this may not be possible. Supplemental
loads such as an electric water pump or cooling fans may be operated while charging
during stage one. Please note though that supplimental loads will reduce the amount of
amperage available to the battery. The charger detects that a battery is fully charged when
its charging current drops below a preset limit in a specific elapsed time. The presence of
electrical loads on the battery will interfere with this process. Therefore when the charger
is in stage two-absorption charging it is necessary for the battery to be isolated from loads.
The IntelliCHARGER is in stage-two when the charge rate is declining.
2) Selectthecorrectbatteryvoltage.
3) Select the correct charging rate.(TheXSPowerPerformance16VAGMbatteryshouldbecharged
at15Awhenattheshopor25Aforrapidchargingatthetrack.)
4) Connecttheredpositive(+)clipofthechargercablestothepositive(+)terminalofthe
vehicle battery.
5) Connecttheblacknegative(–)clipofthechargercablestoasolidchassisground.Ifthisis
notpossible,connectittothenegative(–)batteryterminal.
6) FlipthepowerswitchonthefrontpaneltoON.
The microprocessors will analyze the battery and then after a short delay, the “Charging Status”
indicatoronthefrontpanelwillilluminatebeginningthethree-stagechargingsequence.During
charging, the charging current can be reset to a different charge rate if necessary.
CAUTION: Do not change the voltage type during charging. Use the correct battery type at all times.
During stage one-bulk charging, the amperage will begin at 20A. During stage two-absorption
charging, the amperage will start to fall to zero as the battery comes up to 100%. When the
charging process is complete, the Charging indicator light will go out and the Float Charge
indicator will come on. The cooling fan inside the charger will stop and the battery can be left in
this state indefinitely.
*Notethatthechargerwillautomaticallyrestartthechargingsequenceifthechargecurrentrises
above a factory preset threshold.
7) Whencomplete,flipthepowerswitchtoOFF.
8) Removetheblacknegative(–)clipandtheredpositive(+)clipfromthevehicle’sbatteryterminals.
Operation
5

XS Power IntelliCHARGER User Guide
Chapter 3
Chapter 3 will help you identify and remedy the common problems than can occur with the
IntelliCHARGER. Please read this chapter before calling Customer Service. If you cannot solve the
problem with the IntelliCHARGER, record the information asked for on “Information About Your System”
on the back page and then call Customer Service.
WARNING: Electric shock hazard
Do not disassemble the IntelliCHARGER. The IntelliCHARGER does not contain any internal user-
serviceable parts and attempting to service the unit yourself could result in electrical shock or burn.
• Power light does not come on when the power switch is flipped ON:
- Check fuse.
- Check cord and input power.
• Voltage LED will not illuminate for 12V, 14V or 16V:
- The battery is not connected.
- The battery is below 4.0V.
• Charge rate does not come up to the selected charge rate initially:
- The battery charger has already moved into stage two charging.
- Input voltage is below 120VAC.
- The battery may be defective and resisting the charge current.
• “Error” indicator is illuminated:
- This illuminates when the battery cannot be completely charged in a 10 hour period at the
selected charge rate
To reset this error, switch the battery charger OFF and remove the battery connections. Insure the
battery polarity is correct. If you are charging a large battery at the 5A rate, try a higher charge rate. If
the error persists, replace the battery.
Troubleshooting
6

Important: Specifications are subject to change without notice.
Physical Specifications
- Dimensions ....................... 8 5/8” W x 7” H x 11 1/8” D
-Weight...............................24lbs(10.87kg)
-ACInputConnections........5.0’(1.5m)AWG16
-DCOutputConnections......6.0’(1.8m)AWG10
Electrical Specifications
12V 14V 16V
- Absorption Voltage ............. 14.40 VDC ... 16.80 VDC ... 19.20 VDC
- Float Voltage at no Load ..... 13.56 VDC ... 15.82 VDC ... 18.08 VDC
- Maximum Output Voltage ... 14.40 VDC ... 16.80 VDC ... 19.20 VDC
AC Input Specifications
- AC Input Voltage ................ 120 VAC, 60 Hz
- AC Input Current ................ 10A RMS fuse protected
Appendix A
Specifications
XS Power IntelliCHARGER User Guide
Appendix A
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