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Summary of Contents for Xantrex XC1524
- Page 1 Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Charger Owner’s Guide 12 V / 30 A 12 V / 50 A 24 V / 15 A 24 V / 25 A...
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Page 3: Battery Charger
Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Charger Owner’s Guide... - Page 4 About Xantrex Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one MW 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.
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Page 5: About This Guide
Consult individual battery manufacturers for this information. Audience The Guide is intended for anyone who needs to install and operate the Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Charger. Installers should be certified technicians or electricians. Organization This Guide is organized into 4 chapters and 1 appendix: Chapter 1, “Introduction”: Chapter 1 describes the XC Series standard features. -
Page 6: Conventions Used
The Xantrex XC5012 Battery Charger (12 V, 50 A) will be referred to as the XC5012 when it is being referenced individually. The Xantrex XC1524 Battery Charger (24 V, 15 A) will be referred to as the XC1524 when it is being referenced individually. -
Page 7: Important Safety Instructions
RV and marine applications. Read and keep this Owner’s Guide for future reference. 1. Before installing or using the Xantrex XC3012, XC5012, XC1524 or XC2524 Battery Charger (XC Series), read all instructions and cautionary markings on the XC Series, the batteries, and all appropriate sections of this guide. - Page 8 Safety 8. The XC Series is provided with an AC ground conductor that must be connected to the AC input ground and a DC ground stud which must be connected to the DC system ground. 9. For marine applications in the United States, external connections to the charger shall comply with the United States Coast Guard Electrical Regulations (33CFR183, Sub part 1).
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Page 9: Fcc Information
10. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes. 11. Wear complete eye protection and clothing protection. Avoid touching your eyes while working near batteries. 12. 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. - Page 10 viii...
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Page 11: Table Of Contents
1 Introduction Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Charger Features - - - - - - 1–2 XC Series Appearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Information Centers of the XC Series- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4... - Page 12 Contents Installing Optional Accessories- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13 Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13 Drip Protection Rubber Boots - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14 Configuring the XC Series - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–15...
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Page 13: Introduction
Introduction Chapter 1 describes the XC Series standard features. It also provides information to prepare for installation of the XC Series. -
Page 14: Xantrex Xc3012, Xc5012, Xc1524 And Xc2524 Battery Charger Features
Introduction Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Charger Features The XC Series provides the following standard features: • three full current rated, independently controlled outputs which enable it to charge three different batteries or battery banks. Each bank can be of a different battery type, stage of charging, and temperature compensation •... -
Page 15: Xc Series Appearance
XC Series Appearance This section describes the parts of the XC Series. Figure 1-2 shows the XC Series. Figure 1-1 XC Series Item Description Remote display for all programming functions and monitoring of the XC Series. Onboard status panel for monitoring charger status and charging current at the XC Series when the remote display is mounted remotely from the charger. -
Page 16: Information Centers Of The Xc Series
Introduction Information Centers of the XC Series Remote Display This section describes the parts of the remote display of the XC Series. The remote display can be rotated 180°, or it can be removed and remotely mounted up to 20 m (65 ft) from the XC Series for convenience. - Page 17 Item Description Alpha-numeric display shows • Configuration • Fault or warning messages (see Table 4-2 on page 4–4) • Battery bank voltage and current • Type of charging (2 stage or 3 stage) • State of charge Units indicator lights •...
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Page 18: Onboard Status Panel
Introduction Onboard Status Panel This section describes the parts of the onboard status panel of the XC Series. Figure 1-3 shows the panel. Figure 1-3 XC Series Onboard Status Panel Item Description Charge Current • Displays the output charge current in % of charger maximum for the bank being charged •... -
Page 19: Rear Panel
Rear Panel This section describes the parts of the rear panel of the XC Series. Figure 1-4 shows the rear panel. Figure 1-4 XC Series Rear Panel Item Description Remote display communication connector BTS1 (battery temperature sensor for bank 1) connector BTS2 (battery temperature sensor for bank 2) connector BTS3 (battery temperature sensor for bank 3) connector Battery negative, common for all 3 banks (6 mm stud) -
Page 20: Preparing For Installation
Introduction Preparing for Installation The XC Series is designed to be permanently mounted. Figure 1-1 shows a typical installation with three batteries, a BTS and a remote display. It also shows the AC and DC wiring and protection devices required for a successful installation. Figure 1-5 XC Series System AC mains source with correct size and type of circuit breaker AC input wiring compartment... -
Page 21: Tools And Materials
Tools and Materials To mount and connect the XC Series you need the following tools: • 10 mm wrench or socket for the DC terminals and ground stud • Phillips screwdriver for securing the AC wiring compartment cover • power drill •... -
Page 22: Location
Introduction Location Install the XC Series in a location that meets the following requirements: Condition Requirement The XC Series must be installed in a dry location not subject to rain, spray or splashing bilge water. Clean The XC Series should not be exposed to metal filings or any other form of conductive contamination. - Page 23 Vertical Horizontal Figure 1-6 XC Series Mounting Orientations 975-0187-01-01 Preparing for Installation Vertical - this configuration is unsafe and should not be used Vertical - this configuration may be used in an environment which is dry and clean only (non-marine) 1–11...
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Page 24: Wiring Requirements
13 mm No. 8 No. 6 8 mm 13 mm No. 6 No. 4 13 mm 19 mm XC2524 XC1524 No. 10 No. 12 5 mm 3 mm No. 10 No. 12 5 mm 3 mm No. 10 No. 12... -
Page 25: Ac Wiring
Over-current protection disconnect The DC circuit from the battery to the charger must be equipped with a disconnect and over-current protection device. The device usually consists of a DC-rated circuit breaker, a “fused disconnect”, or a separate fuse and disconnect. These devices must be rated for DC voltage and current. -
Page 26: Battery Bank Size Requirements
Introduction Battery Bank Size Requirements The XC Series is designed to work with a minimum battery bank size. Each bank should meet the minimum Ah rating shown in Table 1-2. Table 1-2 Minimum Battery Bank Size Models Minimum Battery Bank Size (Ah) 1–14 XC 1524 XC 2524... -
Page 27: Installation
Installation Chapter 2 provides procedures for installing, testing and configuring the XC Series. The unit is packed with the following materials: • Owner’s Guide • AC cable strain relief • Two DC cable boots • Blank plate for remote display cavity •... -
Page 28: Installing The Xc Series
Installation Installing the XC Series WARNING: Shock and Energy Hazards Be sure to read the safety guidelines and pay attention to all cautions and warnings throughout the installation procedure. The installer is responsible for ensuring compliance with the installation codes for your particular application. Disconnect all sources of AC and DC power before proceeding. -
Page 29: Pre-Installing Dc Wiring
Pre-Installing DC Wiring The procedure for installing the DC wiring applies to a single battery or multiple batteries or battery banks. WARNING: Shock or arc burn hazard To help prevent accidental shorts or sparks, leave the DC disconnects or breakers in the Off position or fuses removed from their fuse holders until installation is complete. -
Page 30: Pre-Installing Ac Wiring
Installation 5. Route the wiring to the batteries and to the XC Series, but don’t connect it yet. Avoid routing wiring through an electrical distribution panel, battery isolator, or other device that will add voltage drops. 6. Install crimp lugs on each end of the battery cables using the crimp manufacturer’s instructions and tool. - Page 31 5. Install the cable strain relief on the XC Series end of the source AC cable. 6. Carefully remove 50 – 75 mm (2 – 3 in.) of the outer jacket, being careful not to cut or nick the insulation on the individual conductors. 7.
- Page 32 Installation To connect AC wires with the crimp-on butt-splice connector: Important: crimp tool recommended by the manufacturer for the connector used. a) Using a wire stripper, carefully strip 8 mm (5/16 in.) from the ends of the two wires being connected. b) Insert one wire into one end of the butt-splice, until the insulation hits the internal metal crimp section, insert the butt-splice into the crimping tool, and crimp firmly.
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Page 33: Mounting The Remote Display
Mounting the Remote Display WARNING: Shock hazard Even if you intend to leave the remote display in the shipped orientation in the XC Series, you must remove the remote display and secure it in place by removing the non-stick backing on the rear and pressing the remote display flanges in place. If you do not use the non-stick backing, the XC Series will not be drip protected. -
Page 34: Mounting
Installation To remotely mount the display: 1. Remove the display as described on page 2–7. 2. Secure the blank plate in the display socket as described. 3. Ensure that the extension cable used for the remote display is long enough to suit the installation. -
Page 35: Grounding
3. Secure the enclosed mounting template to the mounting surface with tape. 4. Drill the six pilot holes for the mounting screws, taking care that there is nothing behind the surface that can be damaged by the drill. 5. Mount the XC Series using corrosion resistant, #6 (3 mm) round, pan head (or similar) screws. -
Page 36: Final Connections
Installation Final Connections Once the DC cables, AC cables and XC Series are all in place the final connection may be made. Figure 2-1 shows the connection order. Figure 2-1 DC Wiring Connection Order 2–10 975-0187-01-01... -
Page 37: Final Dc Connections
Final DC Connections WARNING: Shock hazard Make sure that the DC fuse or circuit breaker is still open. To make the last DC connections: 1. Connect the negative cable from the negative terminal on the battery (if you are using only one battery or bank), or the negative ground bar or bus (if you are using more than one battery or bank), to the negative DC terminal on the XC Series (Figure 2-1). -
Page 38: Final Ac Connections
Installation 8. Secure cables in place using tie-wraps, P-clamps or cable straps according to electrical codes. Coil and tie any extra BTS or remote display extension cable. 9. The DC breakers may be closed or fuses inserted at this time. Final AC Connections To make the last AC connections: 1. -
Page 39: Installing Optional Accessories
Installing Optional Accessories The XC Series ships with a battery temperature sensor (BTS) and drip protection rubber boots for the DC cables. Battery Temperature Sensor Xantrex strongly recommends that you install a Battery Temperature Sensor (BTS) to protect your battery and improve charging accuracy. It is best to use a separate BTS with each individual battery bank, to provide optimal charging and protection of each bank. -
Page 40: Drip Protection Rubber Boots
Installation Drip Protection Rubber Boots Xantrex recommends that you install the supplied rubber boots over the XC Series DC terminals to provide drip protection. To install rubber boots: 1. Before making the DC connections to the charger, feed the rubber boot over the charger end of the DC cables. -
Page 41: Configuring The Xc Series
Configuring the XC Series Once the charger is connected to a battery on bank 1 or to AC, it is live and it may be configured. There will be a short delay of about 15 seconds before the remote display begins reporting. The remote display will use this time to query the charger for the current operating conditions. - Page 42 Installation To configure the charging type: 1. Press and hold 2. Press MODE selected a charging type that is different from the present configuration, the bank indicator light flashes. See “About Charging” on page 3–2. 3. Press and hold 4. At any time during setup, you can press change and return to charging or battery monitoring.
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Page 43: Operation
Operation Chapter 3 describes the operating states and provides procedures for charging a battery and performing an equalization. -
Page 44: About Charging
Operation About Charging The XC Series has three full current rated, independently controlled outputs which enable it to charge three different batteries or battery banks. Each output can accommodate any one of the four allowable battery types, regardless of what battery types are connected to the other outputs. -
Page 45: Sequential 2-Stage Charging
Sequential 2-Stage Charging In sequential charging mode the charger will check all battery banks every 15 minutes to determine which banks are present, healthy, and in most in need of charge. The bank most in need of charge will then be charged for the next 15 minutes. - Page 46 Operation Disqualified Batteries The XC Series can identify when a battery will not accept a charge (battery is damaged) or when it is fully charged (healthy) and does not require further charge. Batteries that will not accept a charge will be removed (disqualified) from the charging sequence until all banks are checked again (every 15 minutes).
- Page 47 1. Wait 15 minutes for the next battery detection cycle. The warning may be temporary. 2. Verify that the battery meets the minimum AmpHour rating (XC1524: 30 Ah, XC2524: 50 Ah, XC3012: 60 Ah, XC5012: 100 Ah) 3. Try adding a small DC load.
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Page 48: Charging Batteries
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 a disconnect switch, or by switching the loads off. - Page 49 Charging Batteries After charging is complete, the XC Series enters into one of these modes: Float mode When the ready indicator light illuminates, all batteries are fully charged and ready for use. If you selected the 3-stage charging mode, the XC Series is in float mode and will maintain the batteries’...
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Page 50: Equalizing Flooded Batteries
Operation Equalizing Flooded Batteries About Equalizing The XC Series equalizes only flooded lead-acid or lead-calcium batteries. It does not equalize sealed lead-acid batteries since they can be damaged by this process. In the following conditions the remote display will show n o and the XC Series will not enter equalization mode: •... - Page 51 Performing An Equalization Turn off or disconnect all DC loads on the battery during equalization. The voltage applied to the battery during equalization may be above the safe levels for some loads. To equalize your batteries: 1. Check the battery electrolyte level. If necessary, refill with distilled water only. All the cells should have similar electrolyte levels.
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Page 52: Transitioning The Xc Series To On, Disabled Or Off
Operation Transitioning the XC Series to On, Disabled or Off There are two ways to turn the XC Series on: • connect AC power at the source • press STANDBY There are two ways to disable the XC Series: WARNING: Shock hazard The XC Series still has live voltage while disabled. -
Page 53: Accessing Charger Information
Accessing Charger Information The XC Series can give you a lot of information about the status of the charger and the batteries. Reading Remote Display and Onboard Status Indicator Lights The remote display and onboard status panel show what is happening during the charging process and are also helpful in troubleshooting. - Page 54 Operation Table 3-1 Reading XC Series Status Charger Status Charging in bulk or absorption mode. Remote display shows scrolling display of charging state, battery voltage in volts and charging current in amps. Indicator lights indicate the charging current in % of full charge.
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Page 55: Reporting While Charging Or Equalizing
Table 3-1 Reading XC Series Status Charger Status Battery too hot fault Battery too cold fault Charger fault condition. The charger is damaged, contact service. Reporting While Charging or Equalizing After configuration, the XC Series defaults to a scrolling display. As long as there are no faults or errors to report, the remote will display the following information, in order, for the bank presently being charged: •... -
Page 56: Reporting While Battery Monitoring
Operation Reporting While Battery Monitoring The XC Series is considered to be battery monitoring if it is experiencing a charger level fault. If there is a charger level fault (affecting all banks), all charging will be suspended until the charger fault is resolved (see “Error Messages on Remote Display”... -
Page 57: Using A Generator As Source Power
◆ Press cycle. If AC power is connected, the XC Series will turn on, check which battery banks are present and healthy, and begin charging. While the XC Series is off, and a fault is present, the remote display will turn itself on approximately once per minute to show the fault and then turn itself off. - Page 58 3–16...
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Page 59: Troubleshooting
Troubleshooting Chapter 4 contains information on error codes and procedures for troubleshooting your XC Series charger. -
Page 60: Care And Maintenance
Troubleshooting Care and Maintenance WARNING: Risk of electric shock The XC Series contains no user serviceable components. Attempting any kind of service will void your warranty. Contact your dealer or the manufacturer for service information. The XC Series contains solid-state electronic components that require no maintenance. -
Page 61: Indicator Light Flashing Sequences
Indicator Light Flashing Sequences Table 4-1 Indicator Light Sequences on the XC Series Activity Charging indicator light illuminates Charging indicator light flashes Ready indicator light illuminates Fault indicator light illuminates Fault indicator light flashes Charging current indicator lights illuminate Charging current indicator lights flash Charging current indicator lights flash,... -
Page 62: Error Messages On Remote Display
Troubleshooting Error Messages on Remote Display Table 4-2 Error Messages Onboard Status Panel Display Indicator lights Red fault indicator light E R R flashing or illuminated A C L Red fault indicator light E r r illuminated b a t P o L Red fault indicator light E r r... - Page 63 Disqualified detection cycle. The warning may be Warning temporary. Verify that the battery meets the minimum AmpHour rating (XC1524: 30 Ah, XC2524: 50 Ah, XC3012: 60 Ah, XC5012: 100 Ah) Try adding a small DC load. Replace the battery. Over Voltage Check battery.
- Page 64 Troubleshooting Table 4-2 Error Messages Onboard Status Panel Display Indicator lights Green 100% indicator light H o t flashes Display green bank indicator light for the affected battery bank illuminated Red fault indicator light E r r illuminated H o t Green 100% indicator light flashes Display green bank indicator...
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Page 65: Problem Solving
Problem Solving If the remote display is not functioning, troubleshoot your XC Series using the tables below. In the event that you have a problem with your XC Series, the following tables will help you to identify the problem and offer possible solutions to the problem. - Page 66 Verify you are attempting to charge a battery correctly rated at 12 volts nominal (XC3012, XC5012) or 24 volts nominal (XC1524, XC2524). Re-check the battery voltage with all loads removed and the battery is at rest for about an hour.
- Page 67 Symptom The XC Series appears to be taking too long to charge battery. Ready indicator light does not illuminate after 24 hours of charging. Possible Cause Battery capacity is too high for the XC Series model. Load connected to battery is draining charge current so that battery does not recharge.
- Page 68 4–10...
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Page 69: Specifications
Specifications Appendix A details the specifications for the XC Series. -
Page 70: Physical Specifications
Nominal operating AC voltage Rated DC output current (total) Absorption voltage (in VDC for XC3012 and XC5012) (Multiply VDC by 2 to get the absorption voltage for XC1524 and XC2524) A–2 Base unit: 367 mm x 240 mm x 106 mm 14.45 in. -
Page 71: Ac Input Specifications
Float voltage (in VDC for XC3012 and XC5012) (Multiply VDC by 2 to get the float voltage for XC1524 and XC2524) Equalize mode current Equalize mode—maximum output voltage Off-state current draw (with remote installed) AC Input Specifications AC input voltage range... -
Page 72: Temperature Specifications
It will restart when this voltage is + 0.2 V. XC3012: 30 – 33 ADC XC5012: 50 – 55 ADC XC1524: 15 – 16.5 ADC XC2524: 25 – 27.5 ADC Internal charger temperature is measured. Unit shuts down and restarts as follows: •... -
Page 73: Approvals
Approvals Safety CSA/NRTL approved to CSA107.2 and UL1236, including the marine supplement, ignition protection, and UL1564 EN60335-1, EN60335-2-29 Battery Chargers ISO 8846: Ignition Protection for Small Craft ABYC E11 - Alternating Current and Direct Current Electrical Systems on Boats ABYC A20 - Battery Charging Devices NFPA70/1996 US NEC for home and RV installation requirements FCC Class B CE marked, meeting EMC Directive 89/336/EEC (referencing EN55014-1,... - Page 74 A–6...
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Page 75: Warranty And Product Information
What does this warranty cover and how long does it last? Xantrex Technology Inc. ("Xantrex") and covers defects in workmanship and materials in your Xantrex XC Series product. This warranty lasts for a Warranty Period of 24 months from the date of purchase at point of sale to you, the original end user customer. - Page 76 Warranty and Product Information What does this warranty not cover? 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 : 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;...
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Page 77: Return Material Authorization Policy
This warranty will not apply where the product is damaged due to improper packaging. 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. •... -
Page 78: Information About Your System
Warranty and Product Information Information About Your System As soon as you open your Xantrex XC3012, XC5012, XC1524 or XC2524 Battery Charger package, record the following information and be sure to keep your proof of purchase. ❐ Serial Number ❐... - Page 80 Xantrex Technology Inc. Phone: 1 800 670 0707 (toll free North America) +34 93 470 5330 (Europe) 1 360 925 5097 (direct and rest of world) Fax: 1-800 994 7828 (toll free North America) +34 93 473 6093 (Europe) 1 360 925 5143 (direct and rest of world) Email: customerservice@xantrex.com (North America)
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