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X-90 Solar V3 User Manual 2013-03-29
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1. Battery Chemistry Capacity Max Charge Solar Panel Typical Full Charge Ah Current Watts Time Hours 62 4 5 3 hrs 85 BB 2590 Li Ion 14 4 4A String 124 2 65 1 75 hrs 85 DC Source 2 5 1 5 hrs 85 BB 390 NiMH 9 8 2A String 62 3 BB 590 NiCd 4 8 2A String 62 1 5 62 5 25 UBBLO9 Li Ion 18 4 4A String 124 3 25 DC Source 3 UBBL36 Li Ion 8 7 4A 62 2 75 2 hrs 85 Table 3 Typical Charging Times Notes Only applies when charging certain BB 2590 type batteries Depending on the design limitations imposed by various manufacturers the X 90 will automatically charge some BB 2590 type batteries at 3 2A per string Preliminary 10 WWw apecor com Jays i OR X 90 V3 Solar Charger User Manual A pn J VURI Tavorced Powe tecroncetanost 85 CHARGED O X 90 SOLAR maan snnt MULTI CHEMISTRY BATTERY CHARGER POWER SOURCES BATTERIES SOLAR Vmpp 17V 45V Voc lt 60V BB 2590 BB 590 DC SOURCE Vin 20V 6OV 110W BB 390 LED Status Information 85 Fault Status Charged Meaning Action to take Red Green Green Off Off Off Ready to connect Connect battery Off Charging Optional Disconnect battery and Blinking i connect a lower charged battery In a On ee aa 1 the time it takes to charge the last 15 the first 50 of an empty battery could be charged o Off On On Finished charging Disconnect battery Off Check connections make sur
2. taken to observe the indicated polarity on the wires to assure a proper connection Preliminary 13 Www apecor com abs AR EGR X 90 V3 Solar Charger User Manual Temperature Protection The X 90 provides the full charge current up to a certain internal temperature Above that temperature it will linearly de rate the charge current up to a maximum allowable internal temperature in order to protect its circuitry to safe limits The auxiliary output circuit also features temperature protection independent of the battery charging protection functions If the auxiliary output is overloaded and the temperature protection trips the battery will still continue to charge After the temperature has fallen to an acceptable level the functionality will resume Over Current Protection The X 90 is protected against over current and short circuit conditions Normally it will limit the maximum charge current to 4A for a BB 2590 battery or to 2A for a BB 390 BB 590 battery If under some condition the current exceeds that value a fault may be triggered After a fault the software of the X 90 can successfully reset the fault in case it was only a temporary condition If in the case of a failure where the high current could not be stopped because the circuitry of the X 90 is damaged an internal fuse will break and disconnect from the battery In that case the X 90 would be permanently non operational This behavior is preferred as the battery i
3. 0 NiMH Batteries 00 ee eeeeeseeceeneeceeeeeseeeeeeeeees 9 Typical Charging Times cess ceeetc sc toscenaae envi ete ea iiss occ ne wee aeen oo ev sumone penance coi aemooeneacnenees 10 Label and LED Status Indicators anc 25ssssesasecauneasnsacsenesabaoseensosssnaninansosadauantiansonrtaneseeunanenintesions 11 LED Stat s Tin rt Att Ot ss cse5sssozescadansssvsantensveleeeacesd ses saseuante lege ocenaceusnionpactaauenyonctauacsayasaeucamevese 11 Troubleshooting zqcccescrssscetanestyeoptevacess saaguentendeassantesedsedansanautevustiesedsctisssasuannaateniobacdlatiniasiaceetersene 12 Maintenan e sses csaceadacag beutumt oreinen ee e ee E EEE EE EE ES Ta e e EEn Ea a aas e 12 Features ois y acc dec sta vecncaceccdusasaisnivay e EEE E EAEN e EETRI aaee reh EEEE nE Sn aTi 13 Fast Maximum Power Point Tracking MPPT ccccscciscccsecssssseceeseesssseseaceeensesonceaeeccssasseeeacesoens 13 Reverse Polarity Protection Electrically and Mechanically sssessseesseeeeesssssesssresresserssssse 13 Temperature PROCS OM ss iccccsssasicetaciaiisivdeutatbunsneecencasiessduausciuysiecenctandssgaweteasenyenetauatsajpaceamesaese 14 Cover C rrent Proto CO icici sisesececacennssanncedansuievssncegediusass cauctaveetietecedadetssstenteitonnemeaduediadssaaecaaannynt 14 Automatically Dimming LED Imig Catons 5 saciiessaccecesesssassawivagelseeseesassaseauvensvoubsscetisassonanacasis 14 Wa tranty Statement spictziaicc sonaasstsasreceetaninedoanaandubeteedetetandasdamann
4. AR a EDR X 90 V3 Solar Charger User Manual X 90 V3 AUX Solar Charger User Manual Issue 3 March 2013 ZEOR 3267 Progress Dr Orlando FL 32826 www apecor com Preliminary 1 WWwW apecor com General Information cccccccccccccecccccccssssssessesecccccecescssssessssssuccececeesessesesssssucecesessesseseeeuessesness 3 TjtroductH On rasene naene E E E E E Ee E E E aeeai 3 PeatUrES ora enan e a E A ea a E Ea En 3 Specification Summary ssseeseeeseseesseesersesettstesssrsstesseesttsesisseststesetestessstssteestessesstesstesseeseresseset 4 EEE D E AE E E E A E ET 4 Solar Panel Selection amp Input Power Considerations sssssessessssssessssereseesserssressesseeseresseses 5 Battery Selection and Typical Operating Temperatures during Charging esesceeecssereseeee 5 OUR a psec E O core Sen cet sda E EE O A nse EENES 7 Connections and Configuration siciecese5odsntatiereeteannseseanen sasadeaaandancaneasesdendnnndseamsanenetiohioensatnlaannacd q Charging PC SUS oes cerca ac occa nc edccecenecercosenae ekec as aiwbaoseceasois en ven eadeesddacednaneantecaneadedosanceeoreennnes 9 General Considerations for Maximum Charging and Battery Performance eeeeseeeeeees 9 Special Considerations for Charging BB 2590 Li Ion Batteries eee eeeeeeeeneeceeeeeeneeeneeeeees 9 Special Considerations for Charging BB 590 NiCd Batteries eee eeeeseecesteeceseeeeneeeneeeeees 9 Special Considerations for Charging BB 39
5. In order to use the full potential of the charge algorithm implemented in the X 90 the following things have to be considered e Don t charge a battery if it is already known to be full In some conditions a fully charged battery might overheat if charged again If possible record the date of the last full charge of the battery and use it before recharging again e If possible discharge the two battery strings inside the BB 590 equally Don t repeatedly unplug the X 90 and connect it back to the battery Those conditions might confuse the X 90 and it might terminate the charge too early Special Considerations for Charging BB 390 NiMH Batteries The BB 390 has an internal temperature sensor which allows the X 90 to charge the battery more accurately and protect it from over charge Prior to charging the battery should be kept in a cool place because the charge cannot be started if its temperature is already above 40 C 104 F in order to protect the battery from over temperature Therefore it is also not recommended to repeatedly unplug the X 90 from the battery and put it back on only to see the state of charge display This is because once the battery s temperature during charge is above 40 C 104 F the X 90 will not start charging the battery again unless its temperature has dropped below that point Preliminary 9 Www apecor com Typical Charging Times X 90 V3 Solar Charger User Manual
6. atures during Charging Table 2 shows a list of BB XX90 type batteries that can be charged with the X 90 Make sure that each battery is charged at its allowable ambient temperature range which is typically between 5 C 41 F and 38 C 100 F Refer to the label on each battery for exact values Please note that the datasheets of most of the batteries list only the operating and storage temperature ranges which are more extended and not the same as the charging temperature range Company Part aae my Chemistry Voltage BB 2590 SMBus 4A Lilon 14 4 28 8 Mathews BB 2590 U 3 2A Lilon _14 4 28 8 Associates Inc BB 390A U or BB 390 U 2A NiMH 12 0 24 0 BB 590 U 2A NiCd 12 0 24 0 BB 2590 U 4A Li lon 14 4 28 8 Bren Tronics BB 390B U 2A NiMH 12 0 24 0 BB 590 U 2A NiCd 12 0 24 0 r hae BB 2590 U 4A Lilon 14 4 28 8 UBBLO2 UBI 2590 3 2A Lilon 14 4 28 8 UBBL10 UBI 2590 SMBus 3 2A Lilon _14 4 28 8 UltraLife Batteries UBBLO9 UBI 2590 12V 24V 3 2A Lilon 12V 24V UBBL36 1 2 UBI 2590 3 2A Lilon 144V UBBL13 UBI 2590 HC 3 2A Li lon 14 4 28 8 Table 2 Recommended Batteries Due to design or protection limitations certain Li Ion batteries cannot be charge at the full 4A capability of the X 90 V3 These batteries are detected and charged at a safe 3 2A current level This will increase the charge time for the affected batteries Preliminary ww
7. ave been completely charged if there are any fault conditions and an estimate of the amount of time remaining until the battery is fully charged or discharged depending on operating conditions Features e Maximum Power Point Tracking Up to 30 more power e Universal Charging Algorithm Identifies chemistry automatically No User Input Required Fully Ruggedized Design Field Replaceable Sense Pins Fully Protected including Reverse Polarity Over Temperature Active Current Limiting and MIL 810F Compliant 12V or 24V Solar Panel Input No Minimum Maximum Solar Panel Wattage Polarized SAE plug to connect to solar panel or source Available extension input cable for use with other solar panels or DC sources Available Y adapter to parallel multiple solar panels for maximum charge speed Compatible with Smart X 90 adapters allowing expanded operation with numerous batteries and adapters Auto dimming LED indicators reduce the LED Supported batteries Chemistry o o o brightness when there is no input power BB UBI 2590 U Li Ion BB 590 U NiCd BB 390B U NiMH UBBLO9 Li Ion UBBL36 Li Ion X 90 Smart Adapter Numerous Preliminary 3 WWwW apecor com EDR X 90 V3 Solar Charger User Manual Specification Summar Maximum Input Voltage 60V Minimum Input Voltage 20V Rated Charge Current 8A total 4A per battery string Maximum Ambient Temperature 60 C Conve
8. e that D operation of converter is within the Blinking running maximum ratings On Fault converter not Table 4 LED status information Notes S Only applies when charging Li Ion Blinking speed changes based on charging current 0 5 to 20 blinks sec for a total charge current of 0 to 8 A Preliminary 11 www apecor com Abs na EGR X 90 V3 Solar Charger User Manual Troubleshooting Condition Possible Causes Solutions Fault light blinking for a Input power may be low Wait for more sunshine long period of time Orient panel perpendicular to sun Table 5 General Trouble Shooting Condition Possible Causes Solutions X 90 finishes charge but The X 90 might have stopped early Unplug X 90 from the battery and plug state of charge display because of changing input power back onto it to top off battery doesn t show all 5 bars Internal battery SOC meter not accurate A full discharge and charge cycle of the battery might recalibrate the gauges 85 light turning on and Available power changes a lot while This is normal no action needs to be off battery is approximately 85 done taken Table 6 Trouble Shooting for BB 2590 Li Ion Condition Possible Causes Solutions There is no power Battery was charged at higher Let battery cool down after it cools power available from battery temperatures than recommended which will be available again after finished charging trigger
9. ed an internal safety switch Make sure that battery is not being charged beyond recommended charging temperatures Table 7 Trouble Shooting for BB 590 NiCd Condition Possible Causes Solutions X 90 finishes charge but The battery hasn t been discharged Discharge battery completely before state of charge display completely for a longer period of time charging again doesn t show all 5 bars which causes offsets Battery temperature got too high Find a cool and ventilated place to charge because of ambient temperature being the battery above 38 C 100 F therefore charge Battery temperature needs to be below was terminated early to protect the 40 C 104 F for the X 90 to start battery charging again Fault light blinking Temperature of battery is above 40 C Let battery cool down X 90 will start 104 F charging battery once temperature is good Table 8 Trouble Shooting for BB 390 NiMH Maintenance The X 90 has no user serviceable parts except for the spring sense pins Check for broken corroded or otherwise damaged cable or battery contacts Make sure that all battery contacts are straight and that the three spring pins can be pushed in and come out again if released If a defect has been found discontinue use of the X 90 and contact APECOR The input cable may be repaired if necessary however do NOT attempt to repair battery contacts Make sure that all contacts are free of mud dirt dust oil and grease If found dirty
10. elsttuteteetarscs Eee e EE EREE Ennan E 15 Claim PROC SUIS cccicedassasceuac vasseatevaceasusstaeesusstesvancoseacaaeosiaante EKOE REEE EE E E EEEn a Eat 15 Warranty Exclusions and Limitations scccccaiecssevsccsdsessiiecaseistessedeasedavecoseeateasssseoseeegessansacentevyens 15 Preliminary 2 www apecor com ise OR X 90 V3 Solar Charger User Manual General Information Introduction The X 90 V3 Aux Solar Charger is a portable solar battery charger capable of fast charging a wide array of typical portable rechargeable batteries while also providing uninterruptable DC voltage for operating numerous devices The charger features numerous advanced and proprietary digital control algorithms which enables automatic battery detection maximum power point tracking MPPT of the solar panel value added features and X 90 Smart Adapters The charger is able to operate from any solar panel configuration with Vopen circuit lt 60V The charger directly plugs onto the top of the supported batteries and the only wiring needed is the connection to the solar panel or DC source using a polarized SAE plug The advanced charge controller minimizes charge time by charging two battery strings simultaneously while monitoring critical parameters to ensure safety and reliability The implementation of high speed MPPT delivers maximum charging current even in low light or poor weather conditions The simple LED interface informs the user when the batteries h
11. he panel This makes the X 90 superior to other MPPT battery chargers that look for the MPP every once in a while This is because the X 90 finds the new MPP very quickly during changing conditions whereas other MPPT chargers don t operate at the new MPP until their next scan This is especially important during days with lots of clouds and wind which lead to fast variations in available power Since the X 90 can operate longer at the maximum power than other chargers it can charge the battery faster The changes in available solar power reaching the panel is usually shading caused by objects blocking the sun such as clouds people or trees If there is more power available from the solar panel than needed to charge the respective battery then the X 90 will drop out of MPPT mode This can happen for all batteries if there is a higher power solar panel connected or it could mean that the battery only for BB 2590 batteries is nearly full Reverse Polarity Protection Electrically and Mechanicall In order to protect the entire system the X 90 has a reverse polarity protection RPP on the input and output connections If there is no positive voltage seen on the terminals of the X 90 it won t allow any current to flow which is the electrical RPP In addition there is a mechanical RPP which means that the solar panel and battery cannot be plugged in the wrong way Even though the input and output ports have reverse polarity protection care should be
12. ial number and detailed reason for the failure the module type solar panel size type of batteries This information is critical to a rapid disposition of your warranty claim e ApECOR will pay the return shipping charges if the repairs are covered by the warranty Warranty Exclusions and Limitations This warranty does not apply under the following conditions Damage by accident negligence abuse or improper use PV or load currents exceeding the ratings of the product Unauthorized product modification or attempted repair Damage occurring during shipment THE WARRANTY AND REMEDIES SET FORTH ABOVE ARE EXCLUSIVE AND IN LIEU OF ALL OTHERS EXPRESS OR IMPLIED APECOR SPECIFICALLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE No ApECOR distributor agent or employee is authorized to make any modification or extension to this watranty APECOR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO LOST PROFITS DOWNTIME GOODWILL OR DAMAGE TO EQUIPMENT OR PROPERTY 3267 Progress Dr Orlando FL 32826 Email ask apecor com Website www apecor com Preliminary 15 Www apecor com
13. ld be separate for each X 90 It is permissible to use a single DC source as long as the power rating is great enough to supply all connected X 90 units Do not remove the X 90 unit from a charging battery to check the progress by looking at the state of charge indicator of the battery This will reset the charge algorithm and increase the charge time The X 90 unit will inform the user when the battery is fully charged Preliminary 4 Www apecor com X 90 V3 Solar Charger User Manual Solar Panel Selection amp Input Power Considerations Use 12V or 24V solar panels or any other panel as long as its maximum power voltage Vip is greater than 17V and its open circuit voltage Voc is below 60V If available the X 90 will use up to 140W to charge a BB 2590 with its maximum rated charge current or 65W for a BB 390 BB 590 The available SAE Y cable can be used to parallel two solar panels in order to increase charge speed There is no minimum input power requirement but charge speed will decrease when used with lower power solar panels A list of recommended panels is shown in Table 1 below Company Part Max Power 25 C Nominal System Voltage P3 124W 12V 124W 12V P3 124W 24V 124W 24V P3 62W 12V 62W 12V Global Solar Energy Inc P3 62W 24V 62W 74V P3 30W 12V 30W 12V P3 30W 24V 30W 24V Table 1 Recommended Solar Panels Battery Selection and Typical Operating Temper
14. nd or power source can be disconnected or another battery can be charged General Considerations for Maximum Charging and Battery Performance Align solar panel perpendicular to the sun and avoid shading of the panel whenever possible for maximum power Place the X 90 with the battery in the shade wherever possible especially at high ambient temperatures Even though the X 90 won t be damaged when exposed to full sun while charging the battery has lower maximum temperature limits while being charged that are typically around 38 C 100 F One simple method of shading the X 90 while charging is to place it underneath a rucksack Special Considerations for Charging BB 2590 Li lon Batteries Besides the Status LED there is also a 85 Charged LED for BB 2590 batteries It will come on once approximately 85 of the battery s full capacity is reached To charge the last 15 it will take about 30 to 40 of the total charge time If there are more batteries to be charged it makes sense to take off the current battery and to charge another fully depleted BB 2590 which could be charged to 50 in the same time This allows the user to have a higher overall state of charge for all the batteries instead of only having one battery completely charged Special Considerations for Charging BB 590 NiCd Batteries The BB 590 battery is the hardest to accurately be charged to its full capacity using a variable power source such as a solar panel
15. rter Efficiency 96 The solar panel s open circuit voltage Voc must not exceed the maximum input voltage Safety This manual contains important safety and operating instructions for the X 90 Solar Battery Charger Read all the instructions and cautions of this manual and on the label of the X 90 before using it To reduce the risk of electrical shock fire or injury operate charger in only the prescribed manner and use only with recommended items General Safety Guidelines Observe polarity according to the label when connecting to the input Do not apply voltages higher than 60V on the input ONLY connect suggested batteries or X 90 smart adapters to the bottom of the X 90 NEVER apply any other power sources or loads to the bottom connections of the X 90 Only use recommended accessories with the X 90 Only charge recommended batteries not doing so may result in fire electrical shock or injury Do not charge a battery if the ambient temperature is outside of the recommended battery temperature limits Disconnect the X 90 cables by pulling on the plug not the cord Do not use the X 90 with damaged cables or connector pins Check for proper electrical connections to the cables and battery to avoid excessive heating and power loss from a loose or dirty connection Do not try to operate the X 90 if there is any visible damage Do not operate multiple X 90 units from a single solar source when using solar power the panels shou
16. s protected from short circuit currents that could have led to a catastrophic failure of the battery Automatically Dimming LED Indicators The X 90 will automatically reduce the brightness of the LED indicators to approximately 30 of the maximum brightness when there is no incoming power When charging from a solar source the LEDs are at full brightness so as to be visible in the sun In other cases the X 90 will save power by reducing the LED brightness which can also serve to reduce excess light emission in dark environments NOTE In tactical environments the soldier worn X 90 should be securely strapped into a pouch which will completely cover the indicator LEDs Preliminary 14 Www apecor com Ath he EDR X 90 V3 Solar Charger User Manual Warranty Statement The X 90 Solar Charger is warranted to be free from defects in material and workmanship for a period of TWO 2 years from the date of shipment to the original end user ApECOR will at its option repair or replace any such defective products Claim Procedure e Before requesting warranty service check the User Manual to be certain that there is a problem with the controller Contact ApECOR to request Returned Material Authorization RMA Return the defective product to your authorized ApECOR distributor with shipping charges prepaid Provide proof of date and place of purchase e To obtain service under this warranty the returned products must include the model ser
17. they can be cleaned with a damp non abrasive cloth and allowed to air dry or wiped with a clean dry non abrasive cloth In case of oils and grease use a mild soap water solution on a cloth to clean the contacts then rinse the contacts with water If a spring sense pin is damaged contact ApECOR to purchase a spring pin replacement kit This can allow the user to make the repair without returning the X 90 unit Preliminary 12 Www apecor com IRE he EGR X 90 V3 Solar Charger User Manual Features The X 90 has many features that enhance its core functions make it safer to operate and increase its reliability and performance Fast Maximum Power Point Tracking MPPT A solar panel has a unique characteristic that is derived from the fact that as more current is drawn from the solar panel the more the voltage will decrease The respective curves IV Current vs Voltage PV Power vs Voltage in Figure 611 show that at a certain voltage the available power has a maximum Typical battery chargers use the battery s voltage to select where the solar panel is operating on the curve and this point of operation is mostly lower than the maximum power point MPP 40 w a Current in A Power in W nN Voltage in Y Figure 6 IV and PV curves for a typical solar panel The X 90 uses an advanced version of MPPT which is constantly running to make sure that it always operates at the MPP of t
18. w apecor com abs es EDR X 90 V3 Solar Charger User Manual Available X 90 Smart Adapters The X 90 V3 includes the capability to use adapter cables connected to the 6 pin XX90 barrel connector to allow the charging of numerous other batteries and accessories The adapters communicate with the X 90 V3 to indicate the type of adapter connected so as to allow the X 90 to implement the proper charge algorithm ApECOR has the capability to provide specific charging solutions for nearly all battery types please contact us at ask apecor com to request specific charging capability Preliminary 6 WWwW apecor com ise OR X 90 V3 Solar Charger User Manual Operation Connections and Configuration There are basically two main methods to power the X 90 for charging the BB X X90 type batteries Solar panels see Figure 16 and Figure 27 or a DC source such as other batteries Figure 38 to Figure 510 The most common setup is with one solar panel connected To increase charging speed or if clouds are limiting available power solar panels can be paralleled If available the X 90 will use up to 140W input power for BB 2590 batteries or up to 65W for BB 390 and BB 590 batteries to charge them at their respective maximum charge currents Other batteries can be used as power sources as long as they fulfill the input voltage and power requirements of the X 90 A 24V vehicle bus or two 12V lead acid batteries in series could serve as a po
19. wer source Furthermore if there is at least one partially discharged BB XX90 battery available it could potentially be used to recharge another BB XX90 so that at least one battery is fully charged for a mission s99 Figure 1 Charger Setup 1 with one Solar Panel as power source EP Figure 2 Charger Setup 2 with two Solar Panels in parallel as power source Preliminary T7 www apecor com X 90 V3 Solar Charger User Manual Figure 5 Charger Setup 5 with one BB x90 Battery as power source i using optional accessories Preliminary 8 www apecor com Abs AB EGR X 90 V3 Solar Charger User Manual Charging Procedures Connect the X 90 to the power source to be used and the battery to be charged in any order If the LEDs on top of the charger are still lit up from a previous charge wait until all lights are off before connecting to another battery Once everything is connected together the LEDs will blink at different speeds meaning that the X 90 is analyzing the connected battery for about 2 5 seconds to determine its chemistry If there was no fault the Status LED will continue to blink indicating that the battery is charging The 85 Charged LED only lights up when a BB 2590 Li Ion is connected and its capacity reached about 85 of the total capacity The charge is finished once the Status LED is on Then the battery a
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