Truecharge2 User Manual
Contents
1. 3 11 Troubleshooting 3 12 A Specifications Physical Specifications A 2 Electrical Specifications A 3 AC Input Specifications A 5 DC Output Specifications A 6 Temperature Specifications A 6 Protection Features A 7 Approvals A 8 Warranty and Return Information WA 1 xii 975 0401 01 01 Introduction Chapter describes the standard features of a Truecharge 2 Battery Charger as well as its protection features It also provides information on the different parts of the Truecharge 2 Battery Charger including information on the optional remote panel Truecharge 2 Battery Charger The Truecharge 2 Battery Charger ships with the following items one Truecharge 2 Battery Charger unit installation and operation guides rubber boots for DC terminals ring terminals nuts and washers integrated strain relief clamp for AC input cables Introduction Standard and Protection Features The Truecharge 2 Battery Charger provides the following standard features e three full current rated outputs e battery monitoring functions while in float mode or rest mode e correct charging voltage for your batteries when connected to almost a2. 8 AC wiring line neutral and ground input wires Important When installing only a single bank or one battery for Truecharge 2 Battery Chargers that have multiple outputs positive bank 1 must be utilized Bypassing bank 1 and using any of the other banks bank 2 or bank 3 may render the charger to function improperly 975 0401 01 01 1 7 Introduction Onboard Control and Status Display Panel This section describes the parts of the onboard control and status display panel of the Truecharge 2 Battery Charger Important A press and hold action on any panel button means that the button must be held down for more than three seconds then released in order to send the instruction A press action on any panel button means that the button must be pressed and released before two seconds have elapsed Be VM Ss lt 5 5 10 20 40 60 80 100 Ready Charging Equalize Fault 3 Stage 2 Stage Flooded Gel Lead Calc Warm Hot Figure 1 3 Onboard Control and Status Display Panel To reduce current draw from the connected battery when AC power is not present the panel s LED control and status lights are automatically turned off and the buttons are disabled 1 8 975 0401 01 01 Onboard Control and Status Display Panel Item Description 1 Charging Output LEDs e The LEDs illuminate like a progress bar displaying the present total output charge current as a percentage of the
3. 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 LOSSES DAMAGES COSTS OR EXPENSES WHETHER SPECIAL 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 AND C REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION THE ACCURACY CANNOT BE GUARANTEED APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW XANTREX COM Date and Revision June 2008 Rev A Part Number 975 0401 01 01 Product Numbers 804 1210 804 1215 804 1220 804 1230 804 1240 804 1250 804 1260 804 2415 804 2420 804 2430 804 2450 Contact Information Telephone 1 800 670 0707 toll free North America 1 408 987 6030 direct Fax 1 800 994 7828 toll free North America Email customerservice xantrex com Web www xantrex com About This Guide Purpose The purpose of this Owner s Guide is to provide explanations and procedures for operating maintaining and troubleshooting the Xantrex Truecharge 2 Series Battery Charger Scope The Guide provides safety and operating guidelines as well as information about troubleshooting the unit It d
4. The charger automatically exits equalization to float mode or rest mode after one cycle To manually exit equalization mode early repeat Step 3 5 Check the battery electrolyte level If necessary refill with distilled water only and repeat a normal charge cycle 975 0401 01 01 Transitioning the Truecharge 2 Battery Charger to ON Standby or Disabled Transitioning the Truecharge 2 Battery Charger to ON Standby or Disabled There are two ways to turn ON the Truecharge 2 Battery Charger e Connect the batteries to the charger i e charger is on standby then connect AC power at the source charging begins or e Press ON STANDBY on the remote panel while batteries and AC power are both connected to the charger from Standby The charger begins to charge the batteries from Standby There are two ways to put the Truecharge 2 Battery Charger in Standby see Warning below e Disconnect AC power at the source i e only the batteries are connected or e Press ON STANDBY on the remote panel while batteries and AC power are both connected to the charger from ON The charger stops charging but continues to monitor the batteries AN WARNING Shock hazard The Truecharge 2 Battery Charger contains hazardous voltages while in Standby Even when AC power is removed if the Truecharge 2 Battery Charger is connected to a battery on bank 1 the charger will be energized by the battery The Truecharge 2
5. Battery capacity is too high for the Truecharge 2 Battery Charger model Load connected to battery is draining charge current so that battery does not recharge Battery has a damaged cell or has reached the end of its useful life Symptom Use a higher capacity charger Disconnect all loads or switch loads off Replace battery The Truecharge 2 Battery Charger appears to have quickly charged the battery Ready indicator LED illuminates sooner than expected Possible Cause Solution Battery capacity is too low for the Truecharge 2 Battery Charger model Battery has a damaged cell or has reached its useful life 3 14 Use a lower capacity charger Using the optional remote panel if installed reduce the output current delivered to the smaller battery Replace battery 975 0401 01 01 Symptom Troubleshooting The Truecharge 2 Battery Charger will not transition to equalization mode Possible Cause Solution Battery is the wrong type or set to the wrong type to equalize Not all batteries are fully charged An active fault is present on the bank you are attempting to equalize 975 0401 01 01 Determine if the battery type is set to GEL or AGM These battery types cannot be equalized The charger will wait for all batteries to be in float stage of three stage charging or rest stage of two stage charging before attempting to equalize the ready indic
6. Ready and Charging LEDs illuminate solid The charger is in float mode of three stage charging All batteries have been fully charged Charging LED illuminates solid The charger is charging in bulk or absorption mode Equalize LED flashes The charger will perform an equalization cycle after the absorption stage Equalize LED illuminates solid The charger is currently implementing an equalization cycle for all batteries Fault LED flashes A warning condition See Interpreting Fault and Warning Indicators on Table 3 1 Fault LED illuminates solid A fault condition See Interpreting Fault and Warning Indicators on Table 3 1 975 0401 01 01 Replacing the DC Output Fuse Replacing the DC Output Fuse To replace the DC Output Fuse l 2 975 0401 01 01 Disconnect all AC and DC sources to the charger Locate the fuse cover on the charger s top panel see Figure 1 1 Truecharge 2 Battery Charger on page 1 4 Loosen the screw on the fuse cover using a Phillips screwdriver NOTE The screw will not separate from the cover Pull out the blown fuse s gently using the provided fuse puller NOTE The fuse puller is located on the inside of the cover Install a brand new fuse s with same type and rating as the old one NOTE Choose Littlefuse type 257 or equivalent Replace the fuse cover making sure that it aligns and fits perfectly leaving no space for
7. 2 positives and 1 common negative for battery cable ring terminals and one M6 mm DC equipment ground TC2012 TC3012 TC4012 TC5012 TC6012 TC1524 TC2024 TC3024 TC5024 Four M6 studs 3 positives and 1 common negative for battery cable ring terminals and one M6 mm DC equipment ground 975 0401 01 01 Electrical Specifications Electrical Specifications Number of isolated battery bank outputs TC1012 1 output TC1512 2 separated outputs TC2012 TC3012 TC4012 TC5012 TC6012 TC1524 TC2024 TC3024 TC5024 3 separated outputs Nominal battery voltage 12 V units 12 Vdc 24 V units 24 Vdc Normal operating output range 12 V units 0 16 Vdc 24 V units 0 32 Vdc Nominal operating AC input voltage 110 250 Vac Maximum DC output current total TC1012 10 10 A TC1512 15 10 A TC2012 20 10 A TC3012 30 10 A TC4012 40 10 A TC5012 50 10 A TC6012 60 10 A TC1524 15 10 A TC2024 20 10 A TC3024 30 10 A TC5024 50 10 A Absorption voltage 0 1 V for 12 V units 0 2 V for 24 V units 12 V units 25 C 77 F Flooded 14 4 GEL 14 2 AGM 14 3 Lead calcium 15 5 24 V units 25 C 77 F 28 8 28 4 28 6 31 0 975 0401 01 01 Specifications Float voltage 0 1 V for 12 V units 0 2 V for 24 V units 12 V units 25 C 77 F Flooded 13 5 GEL 13 8 AGM 13 4 Lead calcium 13 5 25 C 77 F 24 V uni
8. Allow the Truecharge 2 Battery Charger to cool Improve ventilation or install in cooler location 975 0401 01 01 Troubleshooting Symptom Fault indicator LED illuminates Temp 8 and Battery H indicator LEDs flash Possible Cause Solution Battery temperature is either too If battery is too hot allow battery to cool hot or too cold for safe Improve ventilation or install in cooler charging location If the optional remote panel is available you may reduce the output current using the Set Max Output button If battery is too cold allow batteries to warm up WARNING Do not charge a frozen battery Charging a frozen battery is a potential explosion hazard Symptom Truecharge 2 Battery Charger completes a charging cycle but the battery voltage seems too low Possible Cause Solution Battery has a shorted cell Check the battery Verify you are attempting to charge a battery correctly rated at 12 volts nominal all 12 V chargers or 24 volts nominal all 24 V chargers Re check the battery voltage with all loads removed and the battery is at rest for about an hour Replace the battery The battery has reached its usefulness and can no longer accept a charge 975 0401 01 01 3 13 Troubleshooting Symptom The Truecharge 2 Battery Charger appears to be taking too long to charge battery Ready indicator LED does not illuminate after 24 hours of charging Possible Cause Solution
9. Other battery types may burst causing personal injury and damage 2 Do not expose the Truecharge 2 Battery Charger to rain snow spray or bilge water To reduce risk of fire hazard do not cover or obstruct the air intake vent openings Do not install the Truecharge 2 Battery Charger in a zero clearance compartment Overheating may result This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Children should be supervised to ensure that they do not play with the appliance Safety vi To avoid a risk of fire and electric shock make sure that existing wiring is in good condition and that wire is not undersized Do not operate the Truecharge 2 Battery Charger with damaged or substandard wiring The use of any attachments not recommended or sold by Xantrex may result in risk of fire electric shock or injury to persons Do not operate the Truecharge 2 Battery Charger if it has received a sharp blow been dropped has cracks or openings in the enclosure especially when the fuse cover has been damaged and will not close or otherwise damaged in any other way If the Truecharge 2 Battery Charger is damaged see the Warranty section Do not disassemble the Truecharge 2 Bat
10. but may not be sufficiently short to prevent battery damage 975 0401 01 01 Equalizing Flooded Batteries Performing An Equalization AN CAUTION Risk of equipment damage Turn off or disconnect all DC loads on the battery during equalization The voltage applied to the battery during equalization may be above safe levels for some loads but the absolute maximum is 16 V for 12 V chargers and 32 V for 24 V chargers within operational temperature range If this level of equalization voltage does not comply with the battery manufacturer s recommendation DO NOT EQUALIZE AN WARNING Risk of fire burn or explosion Use proper precaution when working with batteries Wear proper non absorbent gloves complete eye protection and clothing protection Avoid touching your eyes and wiping your forehead while working near batteries 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 To equalize your batteries Important Remember that all connected batteries will undergo the equalization If only one bank is intended to undergo equalization then the other banks must be disconnected prior to equalization 1 Check the battery electrolyte level If necessary refill with distilled water only All the cells should have similar electrolyte levels If the
11. 0401 01 O1 Indicator LEDs on the Onboard Display Panel and Optional Rente Panel Table 3 1 Interpreting Fault and Weaming Indicators Fault or Warning Condition Locked Fan fault Temp Fan 8 amp Fuse puca Ch 1070 307 f Fault Solution Check for anything impeding the fan located between the DC output terminals and AC wiring cavity Safely remove any obstructions when the charger is off No further action required The fan will resume its operation automatically and the charger will resume charging after one minute If the fault remains call Xantrex for support Loss of Remote Connection warning Reconnect the communication cable to the port It takes 15 minutes to re establish communication Reverse Polarity Fuse fault Check for reverse battery polarity negative connected to negative positive connected to positive is correct at battery and charger output terminals Disconnect AC and DC sources before replacing the fuse on the charger See Replacing the DC Output Fuse on page 3 11 Internal fault Call Xantrex for support Flashing LED 975 0401 01 01 Solid LED Troubleshooting Table 3 2 Charger Status LED Sequences on the Truecharge 2 Battery Charger Charger Status LED Activity Charger status Ready LED illuminates solid The charger is in rest mode of two stage charging All batteries have been fully charged
12. 975 0401 01 01 2 15 Troubleshooting Chapter 3 contains information and procedures for troubleshooting your Truecharge 2 Battery Charger Troubleshooting Care and Maintenance 3 2 WARNING Risk of electric shock The Truecharge 2 Battery Charger contains no user serviceable components Attempting any kind of service will void your warranty Contact your dealer or the manufacturer for service information The Truecharge 2 Battery Charger contains solid state electronic components that require no maintenance The best care you can give the charger is to protect it from contact with liquids spray or fumes which may cause corrosion and by keeping the air intake vent clean and free from any obstructions Disconnect all AC and DC power and using proper gloves clean the outside of the case and wiring with a damp cloth if you suspect it has come in contact with battery fluid salt water gasoline or oil or other corrosive material Do not operate if the charger contains moisture of any kind Periodically check all DC and AC wiring connections to be sure they have not loosened or deteriorated Also check all cable clamps to ensure they are tightly fastened Loose battery terminals and lugs exposed to open air corrode rapidly The corrosion appears as a white powder or granular foam on the terminals and any nearby exposed metal parts If it contacts your skin it will cause burns unless you rinse it off immediately M
13. Battery Charger is de energized completely only after all AC and DC sources have been disconnected for five minutes There is only ONE way to safely turn the Truecharge 2 Battery Charger off Disable Disconnect the AC power at the source and disconnect all DC batteries This is the only state where the Truecharge 2 Battery Charger is completely de energized When the Truecharge 2 Battery Charger is disabled the optional remote panel is inactive 975 0401 01 01 2 13 Operation Accessing Charger Information The Truecharge 2 Battery Charger provides a lot of information about the status of the charger and the batteries Reading Remote Panel and Onboard Display LEDs The remote panel and onboard display panel show what is happening during the charging process and are also helpful in troubleshooting Refer to Chapter 3 Interpreting Fault and Warning Indicators on page 3 5 for information about interpreting the onboard display panel and the optional remote panel if installed indicator LEDs Reporting While Charging or Equalizing After configuring the charger and during charging the remote panel and the optional remote panel if installed will show the following information about the charger and the battery e Charging Output Current e Charger Status e Battery Status optional Remote Panel only If there is a fault or warning related to one of the banks the fault or warning information will d
14. Protection Features 1 2 Truecharge 2 Battery Charger 14 Rear Panel 1 6 Onboard Control and Status Display Panel 1 8 Remote Panel Sold Separately 1 15 2 Operation About Truecharge 2 Battery Charger 2 2 Three Stage Charging 2 3 Two Stage Charging 2 4 Charging Voltage Setpoints 2 5 Charging Overview 2 6 Charging Batteries 2 8 Equalizing Flooded Batteries 2 10 About Equalization 2 10 Performing An Equalization 2 11 Transitioning the Truecharge 2 Battery Charger to ON Standby or Disabled 2 13 Accessing Charger Information 2 14 Reading Remote Panel and Onboard Display LEDs 2 14 Reporting While Charging or Equalizing 2 14 Reporting Without AC Power or While on Standby 2 15 Using A Generator As Source Power 2 15 Xi Contents 3 Troubleshooting Care and Maintenance 3 2 Indicator LEDs on the Onboard Display Panel and Optional Remote Panel 3 4 Replacing the DC Output Fuse
15. Start of l REST Standby charging cycle I eee timeout max 21 days Total ABS timeout max 8 hrs Figure 2 3 Two Stage Charging Process 2 4 975 0401 01 01 About Truecharge 2 Battery Charger Charging Voltage Setpoints The Truecharge 2 Battery Charger charging process enables the battery or battery banks to reach the following voltage setpoints Table 2 1 Charging Maximum Voltages for 12 V Chargers Bulk Absorption Equalization Battery Type Volts Float Volts Volts Flooded 14 4 13 5 16 0 GEL 14 2 13 8 not applicable AGM 14 3 13 4 not applicable Lead Calcium 15 5 13 5 16 0 Table 2 2 Charging Maximum Voltages for 24 V Chargers Bulk Absorption Equalization Battery Type Volts Float Volts Volts Flooded 28 8 27 0 32 0 GEL 28 4 27 6 not applicable AGM 28 6 26 8 not applicable Lead Calcium 31 0 27 0 32 0 975 0401 01 01 2 5 Operation Charging Overview The Truecharge 2 Battery Charger will perform a battery qualification on each application of AC to determine if battery banks are present and healthy To force a battery detection sequence 1 Turn off AC 2 Wait approximately 20 seconds or until all lights on the charger or remote have gone out 3 Turn on AC The charger will then perform a battery detection when AC is reapplied The Truecharge 2 Battery Charger charges all banks at the same time but the bank in most need of charging is
16. don t cause an arc Never charge a frozen battery PREPARING TO CHARGE viii 10 11 12 13 14 Make sure the area around the battery is well ventilated Make sure the voltage of the batteries matches the output voltage of the battery charger Clean battery terminals Be careful to keep corrosion from coming into contact with your eyes and skin Study and follow all of the battery manufacturer s specific precautions such as removing or not removing cell caps while charging whether equalization is acceptable for your battery and recommended rates of charge Add distilled water in each cell until battery acid reaches the level specified by the battery manufacturer This helps to purge excessive gas from cells Do not overfill For a battery without removable cell caps carefully follow manufacturer s instructions 975 0401 01 01 Safety BATTERY CHARGER LOCATION 15 16 17 18 19 20 975 0401 01 01 Locate the Truecharge 2 Battery Charger unit away from batteries as practical in a well ventilated compartment Never place the Truecharge 2 Battery Charger unit directly above batteries gases from a battery will corrode and damage the charger Never allow battery acid to drip on the charger when reading gravity or filling battery Do not operate the charger in a closed in area or restrict the ventilation in any way Do not place a battery on top of the charger For North
17. exchanged under warranty What does this warranty not cover Claims are limited to repair and replacement or if in Xantrex s discretion that is not possible reimbursement up to the purchase price paid for the product Xantrex will be liable to you only for direct damages suffered by you and only up to a maximum amount equal to the purchase price of the product This Limited Warranty does not warrant uninterrupted or error free operation of the product or cover normal wear and tear of the product or costs related to the removal installation or troubleshooting of the customer s 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 WA 2 975 0401 01 01 Warranty and Return 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 but not limited to 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 e
18. levels are widely different it will influence the relative concentration of acid thereby affecting the specific gravity measurements 2 Verify that all banks are in either float or rest mode before programming or initiating an equalize cycle 975 0401 01 01 2 11 Operation Important If equalization is programmed prior to float or rest mode the Equalize LED will flash and equalization will start prior to reaching float or rest mode 3 Press and hold for five seconds the Charger Mode Select button and Battery Temp Select button at the same time to put the Truecharge 2 Battery Charger into equalization mode Important The onboard display and remote panel buttons will not allow selection of equalization for AGM and GEL batteries When the charger is performing the equalization the Equalize LED illuminates as a solid light It will flash intermittently when programmed prior to reaching float or rest mode 4 Monitor the specific gravity of each cell of the battery during equalization with a battery hydrometer Note The equalization cycle is preset to last for one hour It is not possible to program another equalization cycle when the present cycle has not ended yet Carefully check the specific gravity of each cell and repeat the equalization cycle until they all meet the battery manufacturer s specifications for specific gravity or until the specific gravity stabilizes relative to each other for an hour
19. moisture or small debris to enter the compartment Tighten the screw on the fuse cover but do not over tighten Reconnect all AC and DC sources to the charger 3 11 Troubleshooting Troubleshooting In the event that you have a problem with your Truecharge 2 Battery Charger the following tables will help you to identify the problem and offer possible solutions to the problem Symptom Indicator LEDs do not illuminate when charger is connected to an AC power source Possible Cause Solution No power at AC source or no battery connected on bank 1 Defective AC wiring or switches breakers Symptom Ensure that power is available at charger AC input and a battery or bank is connected on bank 1 Wiring must be inspected and replaced by a qualified technician Fault indicator LED illuminates Truecharge 2 Battery Charger stops functioning Possible Cause Solution Truecharge 2 Battery Charger does not detect battery for one of following reasons e poor connection e reverse polarity connection blown fuse e damaged wiring e open DC breaker or external fuse Truecharge 2 Battery Charger internal temperature too hot 3 12 Check quality of battery connection and wires Ensure correct polarity negative connected to negative positive connected to positive Also check the type of fault from Table 3 1 Interpreting Fault and Warning Indicators on page 3 5
20. products that are not being repaired in the field and are being returned to Xantrex 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 e The serial number of your product e Information about the installation and use of the unit e Information about the failure and or reason for the return e A copy of your dated proof of purchase Record these details on page WA 6 Return Procedure 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 Include the following e The RMA number supplied by Xantrex Technology Inc clearly marked on the outside of the box e A return address where the unit can be shipped Post office boxes are not acceptable e A contact telephone number where you can be reached during work hours e A brief description of
21. set maximum charge current The numbers below the LEDs represent the percentage values See Figure 1 4 on page 1 11 e A single LED may flash intermittently in combination with a solid Fault LED indicating a fault or with a flashing Fault LED indicating a warning The icons above the LEDs represent the various types of fault and warning conditions See Figure 1 4 on page 1 11 2 Fault LED The LED may illuminate a solid light indicating a fault or flash intermittently indicating a warning in combination with flashing Charging Output LEDs See Table 1 1 Fault and Warning Indicators on page 1 11 for details 3 Charger Status LEDs Displays the current status of the charger e Ready a solid light indicates batteries are fully charged and in rest stage e Ready and Charging solid lights indicate batteries are fully charged and in float stage e Charging a solid light indicates charger is performing a normal charge cycle e Equalize a solid light indicates that the charger is performing an equalization cycle a flashing light indicates that the equalization cycle will begin after the absorption stage is done 4 Charger Mode Select button e Press and hold the button for three seconds to select either of two settings An indicator LED corresponds to each setting Each setting optimizes the charging sequence differently in charging the batteries by stages eThree stage Bulk Absorption and Float default setting Two
22. stage Bulk and Absorption only e When setting or cancelling an Equalization program Press and hold both the Battery Temp Select and Charger Mode Select buttons 975 0401 01 01 1 9 Introduction Item Description 5 Battery Type Select button Press and hold the button for three seconds to select either of five settings An indicator LED corresponds to each setting Each setting maximizes charger performance for its corresponding battery type AGM Absorbent Glass Mat lead acid battery Flooded Lead acid battery default setting GEL Gel type lead acid battery Lead Cale Lead calcium battery Custom If a custom battery type has been programmed then all LEDs will illuminate Battery Temp Select button Press and hold the button for three seconds to select one of three settings An indicator LED corresponds to each setting Each setting will change the charger s internal threshold to compensate for variance in battery voltage due to a change in temperature Cold for battery temperature below 5 C 41 F Warm for battery temperature between 5 and 30 C 41 and 86 F default setting Hot for battery temperature above 30 C 86 F When setting or cancelling an Equalization program Press and hold both the Battery Temp Select and Charger Mode Select buttons The Fault LED works in conjunction with the Charging Current LEDs The icons at the top row above the Charging Current L
23. 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 WA 4 975 0401 01 01 Warranty and Return 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 and that the ASC repairs this particular Xantrex product Out of Warranty Service If the warranty period for your product has expired if the unit was damaged by misuse or incorrect installation if other conditions of the warranty have not been met or if no dated proof of purchase is available your unit may be serviced or replaced for a flat fee To return your product for out of warranty service contact Xantrex Customer Service for a Return Material Authorization RMA number and follow the other steps outlined in Return Procedure on page WA 4 Payment options such as credit card or money order will be explained by the Customer Service Representative In cases where the minimum flat fee does not apply as with incomplete units or units with excessive damage an additional fee wil
24. 0 C 122 F Battery over temperature protection Battery temperature as sensed by the battery temperature sensor if installed results in the charger no longer charging the individual battery or bank at a battery temperature of 70 C 158 F 975 0401 01 01 Specifications Approvals Safety NRTL approved to CSA E60335 2 29 and UL1236 including the marine supplement ignition protection and UL1564 CE marked complying with Low Voltage Directive 2006 95 EC complying with EN60335 2 29 Battery Chargers including Australian deviations ISO 8846 Ignition Protection for Small Craft ABYC El Alternating Current and Direct Current Electrical Systems on Boats ABYC A31 Battery Chargers and Inverters NFPA70 2008 US NEC for home and RV installation requirements EMC FCC Class B CE marked meeting EMC Directive 2004 108 EC Other KKK A 1822 Rev F Federal Specification for the Star of Life Ambulance A 8 975 0401 01 01 Warranty and Return Information Warranty What does this warranty cover and how long does it last This Limited Warranty is provided by Xantrex Technology Inc Xantrex and covers defects in workmanship and materials in your Xantrex Truecharge 2 Series Battery Charger This Warranty Period lasts for 24 months from the date of purchase at the point of sale to you the original end user customer unless otherwise agreed in writing You will be required to d
25. 401 01 01 1 15 Introduction Item e Limit the maximum charger output current 20 40 60 80 and 100 of charger rating to lower the current drawn from the generator or AC source e Set the charger to ON or on STANDBY e Set or cancel an equalization cycle e Display faults and warnings e Display basic battery level and settings Description ON STANDBY Button Press to enable or disable the charger while AC power is connected When in Setup Mode Press to select the Charger Mode two or three stage To set or cancel an Equalization program Press and hold both the Status and ON STANDBY buttons for more than five seconds Charging Output LEDs The LEDs illuminate a progress bar displaying the present total output charge current as a percentage of the maximum charge current The numbers below the LEDs represent the percentage values See 2a on Figure 1 7 on page 1 15 NOTE The charger maximum current can be set using the Remote Panel An LED may flash intermittently in combination with a solid Fault LED to indicate a fault or with a flashing Fault LED to indicate a warning condition The icons on the right side of the LEDs represent different types of faults and warnings See 6a on Figure 1 7 on page 1 15 975 0401 01 01 Remote Panel Sold Separately Item Description 3 Charger Status LEDs Displays the present status of the charger e Ready a solid light indicates that all batteries are fully cha
26. American marine installations external connections to the charger shall comply with the United States Coast Guard Electrical Regulations 33CFR183 Sub Part I Safety FCC Information to the User This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected Consult the dealer or an experienced radio TV technician for help X 975 0401 01 01 Contents Important Safety Instructions v 1 Introduction Truecharge 2 Battery Charger 1 1 Standard and
27. Canada Alaska Hawaii and outside of the United States and Canada are excluded Contact Xantrex Customer Service for details on freight policy for return shipments from excluded areas 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 Telephone 1 800 670 0707 toll free North America 1 408 987 6030 direct Fax 1 800 994 7828 toll free North America Email customerservice xantrex com Web www 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 What proof of purchase is required 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 e The dated purchase receipt from the original purchase of the product at point of sale to the end user or e The dated dealer invoice or purchase receipt showing original equipment manufacturer OEM status or e The dated invoice or purchase receipt showing the product
28. EDs represent the various types of fault and warning conditions For example a temperature warning is represented by a thermometer icon The Charging Current LEDs will normally illuminate as a solid progress bar when they are indicating the amount of output charging current If any of the LEDs start to flash intermittently at the same time that the Fault LED is either solid or flashing a fault or warning condition is indicated 975 0401 01 01 Onboard Control and Status Display Panel Important A warning condition notifies the user of an impending problem and will not stop the charger from charging while a fault condition will stop the charger from charging the battery Charging Output 5 ced ABg g Type of fault and warning OOO O O Charging Output LEDs lt 5 10 20 40 60 80 100 lt Charging Output values 4 Fault LED Fault Figure 1 4 Charging Output and Fault LEDs Table 1 1 on page 1 11 summarizes the various fault conditions that might occur during the operation of the charger For suggestions in what to do after a fault condition is detected see Truecharge 2 Battery Charger Installation Guide doc part number 975 0402 01 01 on Table 3 1 Interpreting Fault and Warning Indicators on page 3 4 in Chapter 3 Troubleshooting Table 1 1 Fault and Warning Indicators Fault or Warning mR Fan AC Battery Bg ed Fault Condition 8B S V A es el
29. QUENTIAL DAMAGES INCLUDING LOST PROFITS LOST REVENUES FAILURE TO REALIZE EXPECTED SAVINGS OR OTHER COMMERCIAL OR ECONOMIC LOSSES OF ANY KIND EVEN IF XANTREX HAS BEEN ADVISED OR HAD REASON TO KNOW OF THE POSSIBILITY OF SUCH DAMAGE B ANY LIABILITY ARISING IN TORT WHETHER OR NOT ARISING OUT OF XANTREX S NEGLIGENCE AND ALL LOSSES OR DAMAGES TO ANY PROPERTY OR FOR ANY PERSONAL INJURY OR ECONOMIC LOSS OR DAMAGE CAUSED BY THE CONNECTION OF A PRODUCT TO ANY OTHER DEVICE OR SYSTEM AND C ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE OR THE INCORRECT INSTALLATION INTEGRATION OR OPERATION OF THE PRODUCT IF YOU ARE A CONSUMER RATHER THAN A PURCHASER OF THE PRODUCT IN THE COURSE OF A BUSINESS AND PURCHASED THE PRODUCT IN A MEMBER STATE OF THE EUROPEAN UNION THIS LIMITED WARRANTY SHALL BE SUBJECT TO YOUR STATUTORY RIGHTS AS A CONSUMER UNDER THE EUROPEAN UNION PRODUCT 975 0401 01 01 WA 3 Warranty and Return WARRANTY DIRECTIVE 1999 44 EC AND AS SUCH DIRECTIVE HAS BEEN IMPLEMENTED IN THE EUROPEAN UNION MEMBER STATE WHERE YOU PURCHASED THE PRODUCT FURTHER WHILE THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS YOU MAY HAVE OTHER RIGHTS WHICH MAY VARY FROM EU MEMBER STATE TO EU MEMBER STATE OR IF YOU DID NOT PURCHASE THE PRODUCT IN AN EU MEMBER STATE IN THE COUNTRY YOU PURCHASED THE PRODUCT WHICH MAY VARY FROM COUNTRY TO COUNTRY AND JURISDICTION TO JURISDICTION Return Material Authorization Policy For those
30. aan anne xantrex TC1012 10A 12V TC1512 15A 12V TC2012 20A 12V TC3012 30A 12V Bue TC4012 40A 12V A Y TC5012 50A 12V TC6012 60A 12V TC1524 15A 24V TC2024 20A 24V i TC3024 30A 24V TC5024 50A 24V Owner s Guide TRUECHARGES Series Battery Charger www xantrex com xantrex Truecharge 2 Series Battery Chargers Owner s Guide About Xantrex Xantrex Technology Inc is a world leading supplier of advanced power electronics and controls with products ranging from small mobile units to utility scale systems for wind solar batteries fuel cells microturbines and backup power applications in both grid connected and stand alone systems Xantrex products include inverters battery chargers programmable power supplies and variable speed drives that convert supply control clean and distribute electrical power Trademarks Truecharge 2 Series Battery Charger is a trademark of Xantrex International Xantrex is a registered trademark of Xantrex International Other trademarks registered trademarks and product names are the property of their respective owners and are used herein for identification purposes only Notice of Copyright Truecharge 2 Series Battery Charger Owner s Guide June 2008 Xantrex International All rights reserved Exclusion for Documentation UNLESS SPECIFICALLY AGREED TO IN WRITING XANTREX TECHNOLOGY INC XANTREX
31. ake sure the RPM is steady between 2700 and 3900 RPM o Flashing LED 975 0401 01 01 O Solid LED Troubleshooting Table 3 1 Interpreting Fault and Waming Indicators Fault or Warning Condition cu j Battery Fuse puca Ch 307 i 070 Fault Solution High Battery voltage fault gt 16 6V e Discontinue or disconnect AC power source from supplying power to the charger e Disconnect voltage sensitive DC loads from DC supply to prevent damage Ifthe DC bus voltage is still measuring high after AC power has been disconnected call a qualified and certified electrician High Charger Temp Sie warning gt 50 C e Check that the battery type and temperature settings match the actual battery e Allow the Truecharge 2 Battery Charger to cool e Improve ventilation or install in cooler location If the temperature increases the Truecharge 2 Battery Charger will display a fault and stop functioning e If the optional remote panel is installed set a lower limit on the output current to cool down the charger High Charger Temp sit fault gt 70 C e Check that the battery type and temperature settings match the actual battery e Allow the Truecharge 2 Battery Charger to cool while the AC is connected so the fan stays on e Improve ventilation or install the charger in cooler location Flashing LED Solid LED 3 8 975
32. argers or 25 V 24 V chargers for 15 minutes After 21 days the charger will automatically restart charging in order to refresh the batteries Vbat Vabs for 1 minute 10 Irati Battery Voltage lout lt 10 rating Vbat Vgas Vbat lt 12 5 V for 1 minute for 15 minutes Vgas voltage Charge start Time I ABS CV timeout l l max 5hrs 4 l St l FLOAT timeout art of 21d charging cycle I max ays lt gt AS Total ABS timeout max 8 hrs Figure 2 2 Three Stage Charging Process 975 0401 01 01 2 3 Operation Two Stage Charging The two stage charging mode employs the following sequence Bulk and Absorption It runs similar to the three stage sequence except that there is no float stage after the absorption stage the charger stops providing voltage and current to the battery and enters a rest or standby stage Like the three stage sequence the charger will restart the charging cycle in the Bulk stage if the lowest battery voltage of the three banks drops below 12 5V 12 V chargers or 25 V 24 V chargers for 15 minutes After 21 days the charger will automatically restart charging in order to refresh the batteries Vbat Vabs for 1 minute lout lt 10 lrating Battery Voltage Vbat Vgas for 1 minute 1 Vgas voltage GO TO BULK when Vbat lt 12 5 V for 15 minutes l l REST I yl Standby i l l l Time l ABS CV timeout l l l max 5 hrs y N
33. ator LED will illuminate Clear the active fault by disconnecting the AC power source and finding the cause of the fault from Table 3 1 Interpreting Fault and Warning Indicators on page 3 5 Specifications Appendix A contains physical electrical performance and regulatory approval specifications for the Truecharge 2 Battery Charger Note Specifications are subject to change without notice Specifications Physical Specifications Base Unit LxWxH Dimensions TC1012 TC1512 200 x 170 x 70mm 7 87 x 6 70 x 2 76 in TC2012 TC3012 TC4012 250 x 170 x 70mm 9 84 x 6 70 x 2 76 in TC5012 TC6012 350 x 170 x 70mm 13 78 x 6 70 x 2 76 in TC1524 TC2024 250 x 170 x 70mm 9 84 x 6 70 x 2 76 in TC3024 TC5024 300 x 210 x 125mm 11 81 x 8 27 x 4 92 in Weight TC1012 TC1512 2 0 kg 4 4 Ibs TC2012 TC3012 TC4012 2 2 kg 4 8 lbs TC5012 TC6012 4 5 kg 9 9 lbs TC1524 TC2024 2 2 kg 4 8 Ibs TC3024 TC5024 5 0 kg 11 0 Ibs AC input connections Two color coded No 14 AWG wires L N and one No 14 AWG G minimum 152 mm 6 in long in a separate AC wiring enclosure with 21 3 mm 0 84 in hole provision for connection of a 1 2 inch North American trade size cable clamp included DC output connections TC1012 Two M6 studs 1 positive and 1 common negative for battery cable ring terminals and one M6 mm DC equipment ground TC1512 Three M6 studs
34. batteries to warm up to a temperature that is above freezing before charging If the temperature decreases further the charger will indicate a fault and shut down Do not attempt to charge without warming See Appendix A Specifications Flashing LED Solid LED 975 0401 01 01 Indicator LEDs on the Onboard Display Panel and Optional Rente Panel Table 3 1 Interpreting Fault and Weaming Indicators Fault or Warning Condition Low Battery Temp fault lt 25 C T Saf Battery Fuse puca Ch 1070 307 f Fault Solution Check the batteries Do not charge a frozen battery Charging a frozen battery may present a risk of explosion Check that the battery type and temperature settings match the actual battery Allow the battery or batteries to warm up to a temperature that is above freezing before charging See Appendix A Specifications AC input out of range Warning lt 104V and gt 90V or lt 265V and gt 255V Change to a more stable AC power source and check that the voltage and voltage frequency are within acceptable operating range See Appendix A Specifications AC input out of range fault lt 90V or gt 265V Check AC connections Change to a more stable AC power source and check that the voltage and voltage frequency are within acceptable operating range See Appendix A Specifications When using a generator m
35. c 25 C 77 F 24 V units 40 2 Vdc at 28 8 Vdc 25 C 77 F Voltage regulation Uncompensated load voltage regulation lt 0 1 Vdc drop from 0 Amps to rated current output at charger output terminals adds in series with recommended 3 limit for user s battery cable voltage drop Temperature Specifications Nominal ambient 25 C 77 F Operating range full performance 20 50 C 4 122 F Current de rating above 50 C ambient temperature up to 80 derating Imax 50 65 C 122 149 F Storage 40 to 80 C 40 to 176 F Humidity 5 95 RH non condensing A 6 975 0401 01 01 Protection Features Protection Features Battery reverse polarity Protected by a replaceable DC output fuse Over voltage limits The Truecharge 2 Battery Charger will stop charging any bank if the output voltage is above 16 6 40 5 Vdc Output current limit TC1012 1010 A TC1512 1510 A TC2012 20 10 A TC3012 30 10 A TC4012 4010 A TC5012 5010 A TC6012 60 10 A TC1524 1510 A TC2024 20 10 A TC3024 30 10 A TC5024 5010 A Over temperature Internal charger temperature is measured Charger shuts down and restarts as follows e Shutdown at 70 C 158 F e Restart at 65 C 149 F Current derating in ambient temperatures Rated current to 50 C 122 F derating to 80 Imax above 5
36. d lights DC loads may vary in speed or intensity This is normal The Truecharge 2 Battery Charger will not harm any load connected to it as long as there is a battery present on that bank and the load can withstand the maximum voltage of 16 V 975 0401 01 01 2 7 Operation Charging Batteries Before you start to charge batteries read the Important Safety Instructions on page v and follow all safety precautions when working with batteries To charge your batteries 1 If possible disconnect all loads from the battery by opening disconnect switches or by switching the loads off Ventilate the area around the battery thoroughly Review the charging instructions supplied by the manufacturer of your batteries and follow all safety precautions and the required steps Apply AC power to the Truecharge 2 Battery Charger by closing the AC breaker or turning the generator on All onboard display indicator LEDs will illuminate for one second power on test as the initialization sequence runs After initialization the indicator LEDs will display present status and settings During charging the Charging Output LEDs will show the total current being delivered to the battery bank as well as any DC load applied The charger fan may activate as well 4 After charging is completed re connect all loads to the battery 2 8 See table next 975 0401 01 01 Charging Batteries The batteries can be in one of eigh
37. ded GEL Lead Calcium OEM 8 Max Output LED The LED illuminates a solid light corresponding to the Maximum Charger Output setting 975 0401 01 01 1 17 Operation WARNING The battery charger must be properly installed with in accordance with all local and application specific codes and ordinances before it is used For installation instructions see Truecharge 2 Battery Charger Installation Guide doc part number 975 0402 01 01 Chapter 2 describes the operating states and provides procedures for charging a battery and performing an equalization It covers the following e About Truecharge 2 Battery Charger on page 2 2 e Charging Batteries on page 2 8 e Equalizing Flooded Batteries on page 2 10 e Transitioning the Truecharge 2 Battery Charger to ON Standby or Disabled on page 2 13 e Accessing Charger Information on page 2 14 Operation About Truecharge 2 Battery Charger Most Truecharge 2 Battery Charger models have three outputs that share the full rated current enabling it to charge three different batteries or battery banks that either have the same chemistry or can tolerate the same charge sequence and thresholds Model TC1012 has only one output while model TC1512 has two outputs that share the full rated current output The Truecharge 2 Battery Charger can perform either three stage charging Bulk Absorption and Float or two stage chargin
38. e 2 Battery Charger will only equalize flooded lead acid or lead calcium batteries It does not enter equalization when the battery type is set to sealed lead acid batteries GEL or AGM since they will be damaged by this process Use the correct settings for your battery types In the following conditions the Truecharge 2 Battery Charger will not enter equalization mode e the battery type is set to GEL or AGM e any battery is not fully charged all three battery banks must be charged to float or rest stage before equalization can be activated on any bank e there is an active fault on the battery you are trying to charge Xantrex recommends that you run a normal charge cycle on the batteries before you equalize them WARNING Explosion hazard During equalization the battery generates explosive gases Follow all the battery safety precautions listed in this guide Ventilate the area around the battery using brushless AC ventilators thoroughly and ensure that there are no sources of flame or sparks in the vicinity CAUTION Risk of battery damage The Truecharge 2 Battery Charger cannot automatically determine when to stop the equalization of a battery You must monitor the battery specific gravity throughout equalization to determine the end of the equalize cycle The one hour time out is intended as a safety feature to require the user to continually re activate it as necessary after checking batteries manually
39. emonstrate proof of purchase to make warranty claims This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the Warranty Period Subsequent owners also require original proof of purchase as described in What proof of purchase is required What will Xantrex do During the Warranty Period Xantrex will at its option repair the product if economically feasible 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 975 0401 01 01 WA 1 Warranty and Return 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
40. g Bulk and Absorption Important The battery banks are not galvanically isolated from each other They share a common negative as shown in the diagram below The negative bus to chassis connection as shown below may not be suitable in some applications Remote panel NOTE Not to scale For illustration purposes only optional SF L i cal AC source BTS optional J DN Re A F 5 Battery banks J 5 Xx a Negative S Z bus ia aes Figure 2 1 Typical Three Battery Installation 2 2 975 0401 01 01 About Truecharge 2 Battery Charger Three Stage Charging The three stage charging mode employs the following sequence Bulk Absorption and Float During the Bulk stage the batteries are accepting a constant maximum current In the Absorption stage the battery voltage is held constant and the current declines A battery will gas produce hydrogen and oxygen when its voltage exceeds the gassing voltage Finally in the Float stage the charger continues to provide voltage at a lower level to maintain the battery in a fully charged state If there is no load on the battery it will typically draw very little current The charger however is able to provide current to its full rating to power auxiliary DC loads on the battery The charger will restart the charging cycle in the Bulk stage if the lowest battery voltage of the three banks drops below 12 5 V 12 V ch
41. ipment Important These notes describe things which are important for you to know but not as serious as a caution or warning This Guide contains information for 11 product models of the Xantrex Truecharge 2 Series Battery Charger The 12V models are TC1012 TC1512 TC2012 TC3012 TC4012 TC5012 and TC6012 When being referred to individually the product will be referred to by its model name The 24V models are TC1524 TC2024 TC3024 and TC5024 When being referred to individually the product will be referred to by its model name When all models are being referred to they will be referred to as Truecharge 2 Battery Chargers Related Information You can find more information about Xantrex Technology Inc as well as its products and services at www xantrex com iv 975 0401 01 01 Important Safety Instructions READ AND SAVE THS OWNER S GUIDE FOR FUTURE REFERENCE This chapter contains important safety installation and operating instructions for the Xantrex Truecharge 2 Series Battery Chargers 1 Before installing and using a Truecharge 2 Battery Charger read all instructions and cautionary markings on a Truecharge 2 Battery Charger unit the batteries and all appropriate sections of this guide AN CAUTION Risk of injury To reduce the risk of injury charge only properly rated such as 12 V and 24 V lead acid GEL AGM Flooded or lead calcium rechargeable batteries
42. isplay in the form of illuminating or flashing Fault indicator LEDs Charging for all banks will stop and will only resume once the fault condition is cleared 2 14 975 0401 01 01 Accessing Charger Information Reporting Without AC Power or While on Standby If AC power has been disconnected or if you have used the optional remote panel to place the Truecharge 2 Battery Charger on Standby mode the onboard display and the optional remote panel if installed LEDs will be turned off to conserve battery power However present settings and battery status can be viewed momentarily using the procedures below From the remote panel Press the Status button to initialize a view cycle to view the status of the batteries The remote panel will turn itself off after 30 seconds of inactivity Using A Generator As Source Power The Truecharge 2 Battery Charger can be run from a regular AC power source or from an alternate power source such as a generator Refer to Appendix A Specifications for AC input current draw to determine the size of generator you need Many generators provide output voltage that is modified sine wave or modified square wave MSW rather than the true sine wave TSW that your utility provides The Truecharge 2 Battery Charger may be used with MSW generators but its lifetime may be reduced somewhat depending on the severity of any peak voltage overshoots and the severity of waveshape rise times
43. l be charged If applicable you will be contacted by Customer Service once your unit has been received 975 0401 01 01 WA 5 Warranty and Return Information About Your System As soon as you open your Xantrex Truecharge 2 Series Battery Charger package record the following information and be sure to keep your proof of purchase O Serial Number O Product 804 1210 804 1215 804 1220 804 1230 Nuikber 804 1240 804 1250 804 1260 804 2415 804 2420 804 2430 804 2450 O Purchased From O Purchase Date If you need to contact Customer Service please record the following details before calling This information will help our representatives give you better service o o Type of installation e g RV truck Length of time inverter has been installed Battery battery bank size Battery type e g flooded sealed gel cell AGM DC wiring size and length Alarm sounding Description of indicators on front panel Appliances operating when problem occurred Description of problem WA 6 975 0401 01 01 Xantrex Technology Inc 1 800 670 0707 Tel toll free NA 1 408 987 6030 Tel direct 1 800 994 7828 Fax toll free NA customerservice xantrex com www xantrex com 975 0401 01 01 Printed in China
44. n the Onboard Display panel and the optional remote panel if installed will illuminate for one second when AC or DC power is supplied to the Truecharge 2 Battery Charger or when the charger is turned on using the ON STANDBY button on the remote panel A power on test indicates that the charger is now receiving AC power and all LEDs are functioning The Truecharge 2 Battery Charger will recover from fault conditions automatically when the cause of the fault or warning has disappeared In most cases the charging process should be stopped allowing either the charger or the battery or both to return within acceptable operating ranges See Appendix A Specifications for more information on normal operating ranges To interrupt or cease the charging process disconnect the AC power source from the charger If you have a remote panel you can put the charger in Standby mode by pressing the ON STANDBY button to interrupt the charging process 3 4 975 0401 01 01 Indicator LEDs on the Onboard Display Panel and Optional Ren ote Panel Table 3 1 Interpreting Fault and Waming Indicators Fault or Warning Condition om Battery Fuse puca Ch 1070 307 i Fault Solution High Battery Temp ae warning gt 50 C Check the batteries Do not charge a battery that is rated other than 12 V nominal for all 12 V chargers or 24 V nominal for all 24 V chargers Check that the ba
45. nst short circuit conditions on the charger s output ignition protected rating enabling installation in engine spaces isolated design over temperature and short circuit protection for the BTS and communication connector ports drip proof rubber boots for DC terminals for added moisture protection IP 32 drip protection rating fan lockout protection The optional Battery Temperature Sensor BTS provides these pro tection features battery under temperature charging protection preventing battery charging at 20 C or below charging current compensation for different battery temperatures 1 In two specific installation orientations see Truecharge 2 Battery Charger Installation Guide doc part number 975 0402 01 01 Battery Charger Mounting Orientations on page 2 7 975 0401 01 01 1 3 Introduction Truecharge 2 Battery Charger This section describes the different parts of the Truecharge 2 Battery Charger 1 N i s A 0 lt lt 9 3 4 2 N ha 6 Figure 1 1 Truecharge 2 Battery Charger Item Description 1 Onboard control and status display panel or simply onboard display see Rear Panel on page 1 6 for more information for controlling the Truecharge 2 Battery Charger settings and for monitoring charger status and charging current 2 Mounting flanges are used to permanently install the product 3 DC wiring compartmen
46. ny single phase AC power outlet in the world e low electromagnetic interference EMI e automatic charge resumption after AC power interruption e programmable custom charge sequence e fully discharged battery charging e an optional remote panel which can be mounted up to 15 m 50 ft away for remote control and monitoring e an optional battery temperature sensor BTS provides battery temperature voltage compensation from 25 to 70 C 13 to 158 F 1 Model TC1012 has one output and model TC1512 has two outputs All other models have three outputs Each output for models with 2 or 3 outputs can charge different bat teries that either have the same chemistry or can tolerate the same charge sequence 2 The charger can be programmed with custom charge setpoints using PC interface This programming can only be done using a special configuration tool operated by Xantrex or a designated OEM 3 The charger can initiate charging a non damaged but zero voltage battery 4 Part number 808 8040 00 5 Part number 808 0232 01 1 2 975 0401 01 01 Standard and Protection Features The Truecharge 2 Battery Charger provides the following protec tion features reverse polarity protection via an output fuse to guard against reverse battery polarity AC input out of range protection shutdown ambient over temperature protection shutdown battery over charging protection electronic current limiting provides protection agai
47. o High Battery Temp i i warning gt 50 C See Figure 1 6 High Battery Temp i fault gt 70 C See Figure 1 6 Low Battery Temp warning lt 0 C See Figure 1 6 P 1 Flashing LED Solid LED 975 0401 01 01 1 11 Introduction Table 1 1 Fault and Warning Indicators Temp Fan AC Battery Fuse Charger Remote Fault Fault or Warning Condition 6 Bi 2 O mucn a s0 Low Battery Temp fault lt 25 C O O See Figure 1 6 n k AC input out of range Warning lt 104V and gt 90V or lt 264V and gt 255V See Figure 1 5 AC input out of range fault O O lt 90V or gt 265V l See Figure 1 5 AC frequency out of range fault O O lt 45 Hz or gt 65 Hz High Battery voltage fault gt 16 6V High Charger Temp EF warning gt 50 C O High Charger Temp fault gt 70 C Locked Fan fault Loss of Remote Connection warning Flashing LED Solid LED 1 12 975 0401 01 01 Onboard Control and Status Display Panel Table 1 1 Fault and Warning Indicators Fault or Warning Temp mn AC Battery Fuse Charger Remote Fault 3 F E R Condition iela ali aJo Reverse Polarity Fuse fault Internal fault p 1 z Flashing LED Solid LED Fault LED blinks if currentis dera
48. oes not provide details about particular brands of batteries Please consult individual battery manufacturers for this information Audience The Guide is intended for users and operators of the Xantrex Truecharge 2 Series Battery Charger If a professional installer is used the installer should be a certified technician or electrician and should use the Truecharge 2 Battery Charger Installation Guide doc part number 975 0402 01 01 Organization This Guide is organized into three chapters and one appendix Chapter 1 describes the standard features of a Truecharge 2 Battery Charger as well as its protection features It also provides information on the different parts of the Truecharge 2 Battery Charger including information on the optional remote panel Chapter 2 describes the operating states and provides procedures for charging a battery and performing an equalization Chapter 3 contains information and procedures for troubleshooting your Truecharge 2 Battery Charger Appendix A contains physical electrical performance and regulatory approval specifications for the Truecharge 2 Battery Charger About This Guide Conventions Used The following conventions are used in this guide WARNING Warnings identify conditions or practices that could result in personal injury or loss of life CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equ
49. ost textiles that are exposed to this corrosive eventually dissolve To clean battery terminals 1 Disconnect all loads and charging sources 2 Using the appropriate tool remove the negative battery cable first and re install it last 3 Remove the positive battery cables 975 0401 01 01 Care and Maintenance WARNING Risk of chemical burn Avoid chemicals coming from the battery to contact with skin Wear protective clothing like proper gloves and goggles 4 To remove any stubborn residue sprinkle baking soda directly on the area scrub with a wet toothbrush or other soft bristle brush add water as required and then rinse uN CAUTION Battery damage Take care not to allow any washing solution to enter the battery filling caps as any contamination into a cell will chemically damage it 5 Reconnect the positive battery cable terminals to the battery lugs and tighten 6 Reconnect the negative battery cable terminals to the battery lugs and tighten 7 After tightening the cables evenly coat all the exposed metal surfaces of the battery terminals and lugs with liquid neoprene If liquid neoprene is not available use a light coating of anti corrosion grease or other non adhesive sealant Do not let anything come between the mating surfaces of the lugs and terminals 975 0401 01 01 3 3 Troubleshooting Indicator LEDs on the Onboard Display Panel and Optional Remote Panel All indicator LEDs o
50. rged and in rest stage e Ready and Charging solid lights indicate that batteries are fully charged and in float stage e Charging a solid light indicates that the charger is performing a normal charge cycle e Equalize a solid light indicates that the charger is performing an equalization cycle a flashing light indicates that the equalization cycle will begin after the absorption stage is done 4 Battery Status LEDs Displays the present status of each battery or each battery bank Each row represents the battery or battery bank number designation 1 2 or 3 Each column represents Low Medium or Full battery capacity NOTE This feature is available only on the Remote Panel 5 Status Button e Press and hold to enter or exit Setup Mode e When in Setup Mode Press to select the Battery Temperature Cold Warm or Hot e When setting or cancelling an Equalization program Press and hold both the Status and ON STANDBY buttons 6 Fault Warning LED The LED displays a solid light to indicate a fault condition or flashes intermittently in combination with a flashing Charging Output LED to display a warning condition 6a See Table 1 1 Fault and Warning Indicators on page 1 11 for details 7 Set Max Output Button e Press to select the desired maximum charging output current NOTE This feature is available only on the Remote Panel e When in Setup Mode Press to select the Battery Type AGM Floo
51. t cover protects the DC terminals as well as the communication and BTS ports Remove and replace when installing cables 1 4 975 0401 01 01 Truecharge 2 Battery Charger Item Description 4 Fuse access panel cover provides access to the DC fuse in the event of an accidental reverse polarity installation 5 AC wiring compartment cover provides the installer with easy access to the AC wiring compartment to allow for a trouble free installation Remove and replace when installing the product 6 DC ground stud for connecting the charger s chassis to ground 975 0401 01 01 1 5 Introduction Rear Panel This section describes the parts of the rear panel of the Truecharge 2 Battery Charger 40 A model TC4012 shown Other models may vary Figure 1 2 Truecharge 2 Battery Charger Rear Panel Item Description 1 BTS port battery temperature sensor port Communication port remote panel port Battery positive for bank 3 6 mm stud Battery positive for bank 2 6 mm stud Nn BL WwW N Battery positive for bank 1 6 mm stud See Important note below 6 Battery negative common for all three banks 6 mm stud common for both banks in model TC1512 model TC1012 has a single bank only one positive terminal and one negative terminal 1 6 975 0401 01 01 Rear Panel Item Description 7 Air intake vent located inside is the fan assembly
52. t different modes which will be indicated on the onboard display in the Charger Status LEDs Mode Charger Status LED ON Bulk Charging Absorption Charging Rest two stage charging Ready Float three stage charging Ready and Charging Equalize in progress Equalize solid light Equalize waiting for absorption to end Equalize flashing Fault Fault solid light Warning Fault flashing a In combination with one or more flashing Charging Output LEDs After charging is complete the Truecharge 2 Battery Charger enters into one of these modes Float mode When the ready and charging indicator LEDs both illuminate all batteries are fully charged and ready for use If you selected the three stage charging mode the Truecharge 2 Battery Charger is in float mode and will maintain the batteries charge Rest mode Or Standby mode If you selected the two stage charging mode the ready indicator LED shows the charger is now in rest mode and is checking battery voltage and elapsed time since the last charge cycle With either charging mode the Truecharge 2 Battery Charger will begin a charging cycle 21 days after the last completed cycle or when battery voltage drops to below 12 5 V 12 V chargers or 25 V 24 V chargers for 15 minutes 975 0401 01 01 2 9 Operation Equalizing Flooded Batteries About Equalization A CAUTION Risk of battery damage The Truecharg
53. ted in this region Input Voltage 80 8590 104 108 255 265 270 volts Figure 1 5 Input Voltage Operating and De rating Curve 975 0401 01 01 1 13 Introduction Charger Charger ALARM set FAULT set Charger Charger ALARM reset FAULT reset 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 C Ambient Temperature derating to 80 Imax D Figure 1 6 Battery and Charger Temperature Thresholds 1 14 975 0401 01 01 Remote Panel Sold Separately Remote Panel Sold Separately This section describes the parts of the optional remote panel Part number 808 8040 00 of the Truecharge 2 Battery Charger The remote panel can be mounted using a communications cable up to 15 m 50 ft from the Truecharge 2 Battery Charger connected via the communication port for convenience Important A press and hold action on any panel button means that the button must be held down for more than three seconds then released in order to send the instruction A press action on any panel button means that the button must be pressed and released before two seconds have elapsed Ready Charging _ Equalize 1 7 Figure 1 7 Truecharge 2 Battery Charger Remote Panel optional The Remote Panel can be used to e Program the charger for battery type and temperature e Set the charger mode two or three stage charging e Activate and terminate equalization not allowed for GEL and AGM 975 0
54. tery Charger there are hazardous voltages within It contains no user serviceable parts See Warranty for instructions on obtaining service Attempting to service the Truecharge 2 Battery Charger yourself may result in a risk of electrical shock or fire and will void your warranty Internal capacitors remain charged after all power is disconnected To reduce the risk of electrical shock disconnect both AC and DC power from the Truecharge 2 Battery Charger before attempting any maintenance or cleaning or working on any circuits connected to the Truecharge 2 Battery Charger Turning off using the on standby button on the remote panel will not reduce this risk The Truecharge 2 Battery Charger must be provided with equipment grounding conductors connected to the AC and input ground and from chassis to the DC ground 975 0401 01 01 Safety AN WARNING Explosion hazard 10 Working in the vicinity of lead acid batteries is 11 dangerous Batteries generate explosive gases during normal operation Therefore it is of utmost importance that each time before servicing the unit in the vicinity of the battery that you read this manual and follow the instructions exactly To reduce the risk of battery explosion follow these instructions and those published by the battery manufacturer and the manufacturer of any unit you intend to use in the vicinity of the battery Review cautionary markings on these products and on
55. the engine Personal Precautions When Working With Batteries WARNING BATTERIES PRESENT RISK OF ELECTRICAL SHOCK BURN FROM HIGH SHORT CIRCUIT CURRENT FIRE OR EXPLOSION FROM VENTED GASES OBSERVE PROPER PRECAUTIONS 1 975 0401 01 01 Have someone within range of your voice or close enough to come to your aid when you work near a lead acid battery Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear proper non absorbent gloves complete eye protection and clothing protection Avoid touching your eyes and wiping your forehead while working near batteries vii Safety 9 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 Never smoke or allow a spark or flame near the engine or batteries Use extra caution to reduce the risk or dropping a metal tool on the battery It could spark or short circuit the battery or other electrical parts and could cause an explosion Remove all personal metal items like rings bracelets and watches when working with batteries Batteries can produce a short circuit current high enough to weld metal to skin causing a severe burn If you need to remove a battery always remove the ground terminal from the battery first Make sure all accessories are off so you
56. the one that receives the most charge For example if Bank 1 and Bank 2 are both charged but Bank 1 has a load and Bank 2 does not then the charger may rarely charge Bank 2 Measuring Battery Voltage at Charger Terminals Use a voltmeter that has a stated accuracy of 0 5 or better on DC voltage Place the probes of the meter directly on the studs or plates of the charger terminals Do not probe on the wire lugs or other places in the battery wiring system as this will introduce error into the measurement the charger monitors battery voltage as measured at the charger terminals Battery voltage should be measured when the battery is resting i e on the second stage of charging 2 6 975 0401 01 01 About Truecharge 2 Battery Charger Temperature Considerations Xantrex strongly recommends that you purchase and install the optional Battery Temperature Sensor BTS to protect your battery and improve charging accuracy Attach the BTS to the warmest battery If no BTS is connected the charger defaults to the Battery Temp selection on the onboard display and remote panel AN WARNING Fire hazard and battery damage Ensure that the battery temperature setting Cold Warm or Hot is set to the environment where the battery will be installed If the temperature is set incorrectly battery damage and possible fire may occur because of overcharging Important When the Truecharge 2 Battery Charger is operating fans an
57. ts 27 0 27 6 26 8 27 0 Equalize mode current 50 rated output 6 Equalize mode maximum output voltage 12 V units 16 40 1 Vdc 24 V units 32 0 2 Vdc Off state current draw without remote installed 12 V units lt 35 mA 24 V units lt 20 mA 975 0401 01 01 AC Input Specifications AC Input Specifications AC input voltage range Nominal 120 Vac 230 Vac 240 Vac Full Performance 105 265 Vac 4 Vac Automatic derating to 80 90 104 4 Vac Maximum AC input current at 104 Vac at 208 Vac TC1012 25A TC1012 15A TC1512 3 5 A TC1512 2 0A TC2012 45 A TC2012 2 5 A TC3012 7 0A TC3012 3 5A TC4012 9 0 A TC4012 45A TC5012 11 5 A TC5012 55A TC6012 13 5 A TC6012 6 5 A TC1524 7 0A TC1524 3 5A TC2024 90A TC2024 45A TC3024 13 5A TC3024 7 0A TC5024 22 5A TC5024 11 5 A Power factor at rated load 20 95 Frequency 47 63 Hz Efficiency peak 12 V units 77 120 Vac 80 230 Vac 24 V units 85 120 Vac 87 230 Vac Surge protection Line to neutral surge protector rated at 275 Vac 975 0401 01 01 Specifications DC Output Specifications DC output voltage range including dead battery charging voltage 12 V units 0 15 5 Vdc 24 V units 0 31 Vdc Maximum equalization voltage 12 V units 16 Vdc no BTS installed 24 V units 32 Vdc Voltage accuracy no load 12 V units 0 1 Vdc at 14 4 Vd
58. ttery type and temperature settings match the actual battery and its conditions Disconnect the battery or batteries to stop charging Allow the battery or batteries to cool to normal operating temperature If the temperature increases further the battery charger will display a fault and shut down The battery or batteries may become damaged if overheated See Appendix A Specifications Flashing LED Solid LED 975 0401 01 01 Troubleshooting Table 3 1 Interpreting Fault and Waming Indicators Fault or Warning Condition Battery Fuse puca Ch 070 307 i Fault Solution High Battery Temp fault gt 70 C 7 St 1 e Check the batteries Do not charge a battery that is rated other than 12 V nominal for all 12 V chargers or 24 V nominal for all 24 V chargers Check that the battery type and temperature settings match the actual battery and its conditions e Disconnect or turn off other charging sources such as the alternator or the charger on a generator with electric start e Allow the battery or batteries to cool to normal operating temperature See Appendix A Specifications Low Battery Temp EP warning lt 0 C e Check the batteries Do not charge a frozen battery Charging a frozen battery may present a risk of explosion Check that the battery type and temperature settings match the actual battery e Allow the battery or
59. xpressly warranted by another manufacturer e component parts or monitoring systems supplied by you or purchased by Xantrex at your direction for incorporation into the product f the product if its original identification trade mark serial number markings have been defaced altered or removed g the product if it is located outside of the country where it was purchased and h any consequential losses that are attributable to the product losing power whether by product malfunction installation error or misuse 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 REPRESENTATIONS 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 INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY MERCHANTABILITY OR FITNESS FOR A PARTICULAR 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 A ANY SPECIAL INDIRECT INCIDENTAL OR CONSE
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