X-PORT+ CHARGE CONTROLLER INSTALLATION INSTRUCTIONS
X-PORT+ CHARGE CONTROLLER INSTALLATION INSTRUCTIONS
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PLEASE READ THOROUGHLY BEFORE INSTALLING
DO NOT ATTEMPT INSTALLATION OF CHARGE CONTROLLER
UNLESS YOU HAVE BASIC AUTO-ELECTRICAL
KNOWLEDGE!
The X-PORT+ is only suitable for electrical systems with negative earth return in the
range of either 12 volt or 24 volt systems.
The power input and output studs are BriNi plated brass studs care must be taken during installation that undue force is not applied which would snap the studding. The input/output studs must not be used as a termination point for any high current connection any additional connections should be made at the battery terminals or at a proper bus bar connection.
Disconnect Battery negative (-) leads first, followed by the positive (+) lead. (This is to prevent
accidental damage by shorting positive lead to earth return).
Locate a suitable position for charge controller and fit securely.Choose a position near to the charging source which affords protection from extremes of heat and ingress of oil and water. Ensure there is a free flow of air around and under the unit.
Connect the charge controller 0 volt (-ve) M4 stud terminal to the charging source 0 volt negative. NOTE. 0 volt (negative) should preferably be connected directly to 0 volt (negative) of charging sources and not to battery earth
return unless a good electrical contact can be guaranteed.
Connect an ignition feed
to the M4 'SENSE' terminals via a 5 amp fuse for each alternator system.
Where the alternators are operated from a single engine the sense terminals
can be connected to the same source but via separate fuses. On dual engine/alternator
systems the ignition feeds must be from their retrospective ignition systems.
Failing to fuse this ignition feed may destroy the internal diode associated
with the sense circuit and will make the warranty void.
Where only one alternator
is used and a separate charging system i.e. wind generator is connected
to the second input ensure that the correct inputs are terminated to each
input. By default on dual systems that have only one alternator input INPUT
1 will always be the 'alternator input'. For the second input an ignition feed
is not necessary if it is being used solely as a charge splitter. This
secondary charge source must be switched off before the ignition is switched
on and whilst the engine is running else the alternator may not contribute
to the charging as the battery sensing is determined by the voltage at the output studs..
Connect the Outputs OP1
& OP2 and where fitted OP3 to separate battery banks. NOTE. Ensure
all current carrying cables are of sufficient capacity and all terminations
are made with copper tube terminals of the correct cable and crimp size.
Where a 3 output unit is installed but only 2 batteries are connected in
the first instance the redundant output must be connected to an output
which has a battery connected to it.
Connect the inputs IP1 & IP2 to the alternator outputs. These should be the only cables connected
to the input studs.
When fitting an X-PORT+
to an alternator access to the brush / regulator module will be required.
On alternators such as old style Lucas, Bosch or Valeo alternators
this can be accomplished by simply removing the brush / regulator module,
on other models such as Hitachi, Vetus or Mitsubushi it will require the
alternator to be removed from the engine for ease of modification.
Once you have gained access to the brush/regulator module attach a
wire to each brush, this wire should be minimum 24/02 (0.75 mm Tri rated)
or a short length of the X-PORT+ white and black control wires. Either refit
or re-assemble the alternator bringing the two control wires to the outside
of the alternator as appropriate.
To measure the resistance's as referred to below a digital multi meter
capable of measuring low resistance's is preferred.
Determining the type of alternator control configuration.
The basic difference between positive and negative controlled alternators is where the regulator is installed with respect to the rotor. On positive controlled alternators the regulator is connected between the energisation feed and the rotor with one side of the rotor being connected directly to earth. The negative controlled alternator has the regulator connected between the rotor and earth with one side of the rotor being connected directly to the energisation feed.
Measure the resistance between each wire and earth or B- for insulated return alternators. If a short circuit is measured between any one brush it indicates that it is a positive controlled alternator (this is assuming that any regulator fitted is not short circuit which could provide false information). If a high resistance is measured it will be a negative controlled alternator.
Positive controlled alternators
Measure the resistance between each brush and earth, one brush will
show a short circuit, 0 ohms, the other will show a resistance of 4 - 12
ohms, connect the X-PORT+ black control wire to the (positive) brush which
indicates the resistance reading. If the alternator has a terminal marked,
D+ or 61 connect the X-PORT+ white control wire to this terminal. If these
terminals do not exist connect the white wire to a live ignition feed,
this must not be permanently powered when the ignition is switched off,
this can be the same connection where the electronics supply wire "pink"
is connected. If the alternator does not have an internal regulator or
the existing regulator is being removed and control of the alternator is
relying on the X-PORT+ control unit, a 3 Amp 400 volt diode must be
wired across the brushes, with the Cathode (the lead with the identification
band) connected to the brush with the black control wire. This diode is
not necessary if the control unit is wired in parallel with the alternator's
existing regulator.
Positive controlled alternators are mainly American origin i.e. Balmar,
Powerline, Ample Power though early Bosch and some Valeo alternators were
also of this type.
Negative controlled alternators.
Measure between each brush and the terminals marked D+ or 61 or if these terminals do not exist B+. In one instance a short circuit will be measured, in the second instance a resistance 4 - 12 ohms should be detected, on the (negative) brush where the resistance is measured connect the X-PORT+ white control wire, the X-PORT+ black control wire should be wired to the alternator's earth or B-. In all instances of the two wires added for test purposes the wire not used should be either be removed or insulated to stop it shorting out. If the alternator does not have an internal regulator or the existing regulator is being removed and control of the alternator will rely on the X-PORT+; a 3 Amp 400 volt diode must be wired across the brushes with the Cathode (the lead with the identification band) connected to the brush which does not have the white wire attached.
Method 2
This method requires the alternator to be re-installed on the engine
with all cables and drive belts attached.
Do not allow cables the additional cables to short out to each other or
to any other point.
Start engine and run at a fast tick over.
With a multi meter, set on DC volts, connect multi meter negative lead
(-) to alternator B- terminal (chassis/ground).
Then with the multi meter positive lead (+), measure the voltage on each
cable in turn.
The two types of alternators will show the following readings.
A Positive controlled type will show :- one cable will give a constant 14v (28v) and the
other cable will show a varying voltage higher than 14v (28v). The cable
with the constant voltage will be cable 1 (negative brush), discard the
or insulate the other cable (it is not used). Then follow instructions
in section 3 for Positive controlled type.
A type Negative controlled type will show :- one cable will give a constant 14 volts (28v)
and the other cable 0 volts. The cable which reads the constant 14 volts
will be cable 1 (positive brush), discard or insulate the other cable (it
is not used). Then follow the instructions in section 3 for a Negative controlled type.
SECTION 3
If Negative controlled connect as follows: Connect X-PORT+ White to cable 1 (which is normally called the negative brush). Connect X-PORT+ Black to alternator B- terminal (battery negative/ground).
If type Positive controlled connect as follows: Connect X-PORT+
White to alternator D+ (61) terminal (exciter diodes).
Connect X-PORT+ Black to cable 1.
positive brush.
In case of query, please contact Technical Support at address below.