Xantrex PathMaker Automatic Power Switch
Contents
1. 2 Include the following The RMA 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 Canada 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 Center ASC A Xantrex return material authorization RMA 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 19 Specifications Electrical all units DC Input Voltage Range 7 33 V 24 V operation if turned on gt 18 0 Low Voltage Disconnect Range 12 8 13 2 x 2 for 24 V Connect Voltage Range 13 1 13 5 V x 2 for 24 V High Voltage Disconnect Range 14 16 V x 2 for 24 V Current Ratings 100 A units 100 A continuous 400 A peak 150 A units 150 A continuous 500 A peak 200 A units 200 A continuous 600 A peak 250 A units 250 A continuous 1200 A peak 500 A units 500 A continuous 2400 A peak Idle Power Consumed 0 2 0 352. place the switch in the O OFF position In this position the battery banks are separated The yellow Disabled light is ON To manually energize the PathMaker power switch es momentarily press the switch to the I ON position until the green ON light is lit about one second This connects the batteries for five minutes Moving the switch momentarily to the ON position for at least one second will cancel the five minute connect timer User Remote Switch You may use your own momentary pushbutton switch installed between the terminal labeled Negative and Neg at Remote to manually energize the PathMaker power switch es Hold the pushbutton down for about two seconds to energize the PathMaker power switch es They will stay energized for five minutes Momentarily use the pushbutton again to de energize the power switch es PathMaker 200 2 12 24V Momentary ON Pushbutton Negative To DC Negative The Control Module Switch The local switch on the PathMaker must be the AUTO position for the remote 7 High Voltage Connected Disconnect switch to work Xantrex 200 2 Battery 2 Automatic Switcl 2 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 Power Switch This warra
3. Number 445 0203 01 01 Contact Information Web www xantrex com Email CustomerService xantrex com Phone 1 800 670 0707 toll free in North America 1 604 422 2777 direct Fax 1 604 420 2145 Introduction The PathMaker provides automatic battery switching in a wide range of environments and applications including marine recreational ve hicles renewable energy military and mobile audio The PathMaker has two primary functions first it automatically parallels connects together multiple batteries combining them when charging sources are available and secondly it automatically disconnects the starting battery from the system loads when there are no active charging sources This ensures that the engine starting battery is always full Additionally it can be used to connect loads and sources The PathMaker consists of the following major components A control module that provides user adjustable set points operator indicators and a local control switch Additionally a telephone jack on the right hand side of the module allows the user to plug in the optional remote control panel A terminal strip is fitted under the control module This terminal strip is where the user connects a wire to system negative system ground and makes optional connections All other connections are pre wired at the factory and require no changes The PathMaker Power Switch es are mounted below the terminal strip They provide the connection for t
4. W 12 V 0 4 0 7 W 24 V Connected Power 100 A 2 Bank 5 4 W 12 V 5 8 W 24 V 100 A 3 Bank 10 4 W 12 V 10 8 W 24 V 200 A 2 Bank 4 3 W 12 V 4 7 W 24 V 200 A 3 Bank 8 2 W 12 V 8 6 W 24 V 500 A 2 Bank 5 2 W 12 V 5 6 24 V All other 2 Bank 6 W 12 V 6 W 24 V All other 3 Bank 11 W 12 V 11 W 24 V 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 W x 0 75 D Optional 3 W x 1 625 H cut out Splashproof front 25 cable included Environmental Not approved for explosive environments Operating Ambient Temp Range 40 to 65 C Size 100A 6 3 H x 7 4 W x 3 6 D 200 A 7 6 H x 7 4 W x 3 2 D Xantrex Technology Inc Toll free 1 800 670 0707 Direct 1 604 422 2777 Fax 1 604 420 2145 CustomerService xantrex com Www xantrex com 445 0203 01 01 Printed in the U S A
5. 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 100 Amp Two Seed Bank PathMaker VB1 Batt Load or Source 2 VB2 200 Amp Two Bank PathMaker Batt Load or Source 1 Batt Load or VB1 Source 2 VB2 100 Amp Three Bank PathMaker Batt Load or Source Batt Load or 2 VB2 Source 1 Batt Load or Source VB1 3 VB3 200 Amp Three 6 Bank PathMaker 5 6 Battery Load or Source 3 VB3 Battery Load or Source 2 VB2 Batt Load or Source 1 VB1 Diagram Table Many configurations are possible with a PathMaker This table is a guide to help select the correct diagram for your installation System Use Diagram Page 2 Banks single or multi engine Diagram 1 10 Marine RV Renewable Energy or Car Audio 3 Banks 2 House 1 Start Diagram 2 11 1 House 2 Start Diagram 3 12 Marine or RV Sources such as battery chargers solar panels wind generators or alternators may be wired to any battery When a battery s voltage rises above the Connect Voltage all batteries are paralleled and charged by the source If there are multiple sources conn
6. Smart choice for power Xa nt rex PathMaker 20012 121240 69 59 9 59 2 59 52 69 69 PathMaker Owner s Manual Xantrex PathMaker Automatic Power Switch www xantrex com 2 Easy to Install Automatic Battery Switch For Marine RV Alternative Energy and Car Audio use Pick the unit that s right for your installation 100 Amps 2 Battery Banks 100 Amps 3 Battery Banks 150 Amps 2 Battery Banks 150 Amps 3 Battery Banks 200 Amps 2 Battery Banks 200 Amps 3 Battery Banks 250 Amps 2 Battery Banks 500 Amps 2 Battery Banks Just mount and connect a negative wire and 2 or 3 battery cables Manual Contents Operations Installation Remotes Notice of Copyright Xantrex PathMaker Automatic Power Switch November 2002 Xantrex International All rights reserved Xantrex is a registered trademark of Xantrex International 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 November 2002 Revision 1 Part
7. UDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY MERCHANTABILITY OR FITNESS FOR A PARTICU LAR PURPOSE ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED WARRANTY IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES LOSSES COSTS OR EXPENSES HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND ANY LOSS OR DAMAGE TO PROPERTY ANY PERSONAL INJURY ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE OR THE INCORRECT INSTALLATION INTEGRATION OR OPERATION OF THE PRODUCT 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
8. ected the source with the highest voltage will charge the batteries to that level Alternators will not fight against each other the batteries will simply charge at the voltage of the alternator having the highest output voltage 10 Diagram 1 2 Banks This is the recommended installation method In this diagram the starter is wired directly to the starting battery The battery switch al ways stays in the 1 position the house battery supplies the DC loads The engine starting battery always supplies starting The PathMaker connects the batteries in parallel when a charging source is present and disconnects them when there is no charging 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 ALT TO ENGINE S Diagram 2 3 Banks This diagram shows an installation with one engine starting 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 DC loads 12 Diagram 3 3 Banks In this twin engine three battery bank installation each engine has a dedicated starting bat
9. he path of battery current flow when enabled by the control module Remote Control Panel optional that connects to the PathMaker via a telephone cable is available Use of this optional panel is strongly recommended as the PathMaker may be mounted where access to the local control switch may not be convenient t Operations The PathMaker has power switch es that connect the Disabled Connected Disconnect batteries loads or sources o together Connected Light Solenoid Wiring xantrex The Connected light is on when Automatic ever the power switch es is z indicating that the batteries loads or sources are connected Remote ive Negati www xantrex com Disabled Light The Disabled light is on whenever the power switch es is not on High Voltage Disconnect Light The High Voltage Disconnect light is on whenever the batteries are not connected due to a higher voltage than the High Voltage Discon nect set point This light flashes when the PathMaker is in a five minute timed disconnect due to battery voltage sag The Control Module Switch The switch on the Control Module should normally be in the Auto position If it is in the O Disabled position the batteries will never be connected To test the PathMaker hold the switch in the I ON posi tion While the switch is in the I ON position the power switch es will be on and the green Connected light will turn on If emergency s
10. is warranty does not apply to and Xantrex will not be responsible for any defect in or damage to a he 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 he 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 he product if repairs have been done to it other than by Xantrex or its authorized service centers hereafter ASCs d he product if it is used as a component part of a product expressly warranted by another manufacturer e he product if its original identification trade mark serial number markings have been defaced altered or removed Disclaimer Product THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS WHERE PERMITTED BY LAW IN LIEU OF ALL OTHER WARRANTIES CONDITIONS GUARANTEES REPRESENTA TIONS OBLIGATIONS AND LIABILITIES EXPRESS OR IMPLIED STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT HOWEVER ARISING WHETHER BY CONTRACT TORT NEGLIGENCE PRINCIPLES OF MANUFACTURER S LIABILITY OPERATION OF LAW CONDUCT STATEMENT OR OTHERWISE INCL
11. l Remote See Page 13 CONNECT THE 5 5 596 Page 14 Factory Installed NEGATIVE ground TO THIS TERMINAL LAST Multiple voltage values times Use 14 AWG wire or larger 2 for use 24 systems Optional PathMaker Remote User Remote Switch You can force the PathMaker to Connect for emergency starting by momentarily pressing the Manual switch You may cancel the forced connection only by pressing the Manual On switch a second time for less than one second While in the forced Connect mode placing the switch to the Dis abled position will break the connection However returning the switch to the Auto position will allow the forced Connect to resume until the five minute timer expires or until the switch is again placed over to the ON for at least one second to cancel the five minute timer Troubleshooting The PathMaker is internally protected against most faults If the Green light does not come on when the switch on the unit is held in the ON position you must disconnect the wire connected to the system negative terminal wait one minute and reconnect it Installation The terms battery and bank are used interchangeably A bank means a group of batteries that are connected in series or parallel to create a higher capacity or higher voltage battery Installation re quires three wires for two bank units and four wires for three bank uni
12. nty 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 Uni
13. province 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 Return Material Authorization RMA 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 RMA 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
14. tarting is required pushing the switch to the I ON position momentarily will lock the power switch on for five minutes If two bat teries are connected to the PathMaker this provides a jump start for the starter Pushing the switch momentarily the ON position will release the power switch from being held on for five minutes Remember The local switch on the PathMaker must be in the AUTO position for any remote switch to work Setup and Operation Adjustments Default settings are at the 12 o clock position Connect Voltage Above this voltage the PathMaker power switch es are enabled thus the batteries are in parallel for charging The default voltage set ting is 13 3 V The green con nected light is on in this mode Light may flicker below 12 6 V High Voltage Disconnect Above this voltage the power switch es are disabled The default voltage setting is 15 0 V The red HV Disconnect light is on when active Low Voltage Disconnect Below this voltage the PathMaker power switch es are disabled the batteries are not con nected together The default voltage is set at 13 0 V The yellow dis abled light will be lit High Voltage Disabled Connected Disconnect Auto 16 0 i has Solenld Wing xantrex h k 200 Amp 2 Battery 2 Automatic Switch 200127 21630 8 28 www xantrex com ORSAAAAAAO Negative ptiona
15. ted 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 1 604 422 2777 direct Fax 1 604 420 2145 Email CustomerService xantrex com Direct returns may be performed according to the Xantrex Return 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 bs Warranty 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 customer s electrical systems Th
16. tery All batteries are charged when either of the engines is running or when there is any charging source on the system In an emergency all batteries may be connected together using the optional Remote Switch This diagram 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 To DC ALT loads START 1 13 Optional PathMaker Remote We highly recommend using the optional Remote Control Switch to provide a clear indication of the PathMaker status and to simplify emergency starting Please contact your dealer to purchase the Remote Control Switch panel Emergency Starting If you cannot start the engine momentarily press the Manual On switch The PathMaker then connects all batteries together for five minutes to provide maximum starting power Using the PathMaker Remote Momentarily press switch in Control Panel MANUAL ON position to turn on The PathMaker Remote switch power switch es is normally left in the AUTO PathMaker position In this position the power switch es 1 Manual On energized connecting the A batteries together when the ae Connect voltage is reached o or and de energized below the Disconnect voltage xantrex To disable PathMaker To disable the PathMaker switch to off position
17. ts 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 es terminals must be suffi ciently 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 THIS IS NOT COVERED BY THE WARRANTY Fuses Battery Switches and Protective Terminal Caps To simplify installation diagrams we have not included fusing or op tional on off battery switches Check the latest ABYC American Boat and Yacht Council and NEC National Electrical Code for fusing requirements for your installation Install protective terminal caps as needed to protect against shorting of terminals Alternator Protection An alternator may be damaged 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 output condition The ZapStop prevents momentary overvoltage Do not over torque connections Tighten sufficiently but not excessively Power Switch Connections When wiring to the power switch es remove the supplied
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