Xantrex TC1012 Owner's Manual
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Xantrex TC1012 Owner's Manual

True charge 2 series
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See also: Installation Manual
Series Battery Charger
TC1012
10A–12V
TC1512
15A–12V
TC2012
20A–12V
TC3012
30A–12V
TC4012
40A–12V
TC5012
50A–12V
TC6012
60A–12V
TC1524
15A–24V
TC2024
20A–24V
TC3024
30A–24V
TC5024
50A–24V
Owner's Guide

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  • Page 1 TC1012 10A–12V TC1512 15A–12V TC2012 20A–12V TC3012 30A–12V TC4012 40A–12V TC5012 50A–12V TC6012 60A–12V TC1524 15A–24V TC2024 20A–24V TC3024 30A–24V TC5024 50A–24V Owner’s Guide Series Battery Charger...
  • Page 3 Truecharge ™ Series Battery Chargers Owner’s Guide...

  • Page 4: Contact Information

    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.

  • Page 5: About This Guide

    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™...
  • Page 6 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 975-0401-01-01...

  • Page 7: Important Safety Instructions

    WNER UIDE 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.
  • Page 8 Charger with damaged or substandard wiring. 5. The use of any attachments not recommended or sold by Xantrex, may result in risk of fire, electric shock, or injury to persons. 6. Do not operate the Truecharge™ 2 Battery Charger if it...
  • Page 9 Safety WARNING: Explosion hazard 10. Working in the vicinity of lead-acid batteries is 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.
  • Page 10 Safety 4. 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. 5. Never smoke or allow a spark or flame near the engine or batteries.
  • Page 11 Safety BATTERY CHARGER LOCATION 15. Locate the Truecharge™ 2 Battery Charger unit away from batteries as practical in a well ventilated compartment. 16. Never place the Truecharge™ 2 Battery Charger unit directly above batteries; gases from a battery will corrode and damage the charger 17.
  • Page 12 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.

  • Page 13: Table Of Contents

    Contents Important Safety Instructions - - - - - - - - - - - - - - - - - - - - v 1 Introduction Truecharge™ 2 Battery Charger - - - - - - - - - - - - - - - - - - - - - 1–1 Standard and Protection Features - - - - - - - - - - - - - - - - - - - - 1–2 Truecharge™...
  • Page 14 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 - - - - - - - - - - - - - - - - - - - - - -3–11 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12...

  • Page 15: Introduction

    Introduction 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. Truecharge™...

  • Page 16: Standard And Protection Features

    -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.
  • Page 17 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 •...

  • Page 18: Truecharge™ 2 Battery Charger

    Introduction Truecharge™ 2 Battery Charger This section describes the different parts of the Truecharge™ 2 Battery Charger. Figure 1-1 Truecharge™ 2 Battery Charger Item Description Onboard control and status display panel or simply onboard display (see “Rear Panel” on page 1–6 for more information) for controlling the Truecharge™...
  • Page 19 Truecharge™ 2 Battery Charger Item Description Fuse access panel cover provides access to the DC fuse in the event of an accidental reverse polarity installation. AC wiring compartment cover provides the installer with easy access to the AC wiring compartment, to allow for a trouble free installation.

  • Page 20: Rear Panel

    Battery positive (+) for bank 1 (6 mm stud) See Important note below. 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...
  • Page 21 Rear Panel Item Description Air intake vent - located inside is the fan assembly 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.

  • Page 22: Onboard Control And Status Display Panel

    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.
  • Page 23 Onboard Control and Status Display Panel Item Description Charging Output (%) LEDs • The LEDs illuminate like a progress bar displaying the present total output charge current as a percentage of the set maximum charge current. The numbers below the LEDs represent the percentage values.
  • Page 24 Introduction Item Description 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 •...
  • Page 25 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. Type of fault and warning Charging Output (%) LEDs Charging Output (%) <5...
  • Page 26 Introduction Table 1-1 Fault and Warning Indicators Temp Battery Fuse Charger Remote Fault Fault or Warning Condition Low Battery Temp fault (< -25°C) See Figure 1-6. AC input out of range Warning (<104V and >90V) or (<264V and >255V) See Figure 1-5. AC input out of range fault (<90V or >265V)
  • Page 27 Onboard Control and Status Display Panel Table 1-1 Fault and Warning Indicators Temp Battery Fuse Charger Remote Fault Fault or Warning Condition Reverse Polarity Fuse fault Internal fault Flashing LED Solid LED Fault LED blinks if current is derated in this region. Imax 0.8 Imax Input...
  • Page 28 Introduction Charger Charger ALARM set FAULT set Charger Charger ALARM reset FAULT reset -25 -20 -15 -10 -5 65 70 °C Ambient Temperature derating to 80% Imax. Figure 1-6 Battery and Charger Temperature Thresholds 1–14 975-0401-01-01...

  • Page 29: Remote Panel (Sold Separately)

    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™...
  • Page 30 Introduction • 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 • Set the charger to or on STANDBY • Set or cancel an equalization cycle •...
  • Page 31 Remote Panel (Sold Separately) Item Description Charger Status LEDs Displays the present status of the charger. • Ready - a solid light indicates that all batteries are fully charged and in rest stage. • Ready and Charging - solid lights indicate that batteries are fully charged and in float stage.
  • Page 32 1–18...

  • Page 33: Operation

    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.

  • Page 34: About Truecharge™ 2 Battery Charger

    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 charging (Bulk and Absorption).

  • Page 35: Three-Stage Charging

    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.

  • Page 36: Two-Stage Charging

    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...

  • Page 37: Charging Voltage Setpoints

    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)

  • Page 38: Charging Overview

    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.
  • Page 39 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.

  • Page 40: 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 disconnect switches or by switching the loads off.
  • Page 41 Charging Batteries The batteries can be in one of eight 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)

  • Page 42: Equalizing Flooded Batteries

    • 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.

  • Page 43: Performing An Equalization

    Equalizing Flooded Batteries Performing An Equalization 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.
  • Page 44 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™...

  • Page 45: Transitioning The Truecharge™ 2 Battery Charger To On, Standby, Or Disabled

    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: • Connect the batteries to the charger (i.e., charger is on standby) then connect AC power at the source (charging begins) or •...

  • Page 46: Accessing Charger Information

    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.

  • Page 47: Reporting Without Ac Power Or While On Standby

    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.
  • Page 48 2–16...

  • Page 49: Troubleshooting

    Troubleshooting Chapter 3 contains information and procedures for troubleshooting your Truecharge™ 2 Battery Charger.

  • Page 50: Care And Maintenance

    Troubleshooting Care and Maintenance 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.
  • Page 51 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.

  • Page 52: Indicator Leds On The Onboard Display Panel And Optional Remote Panel

    Troubleshooting Indicator LEDs on the Onboard Display Panel and Optional Remote Panel All indicator LEDs on 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™...
  • Page 53 Indicator LEDs on the Onboard Display Panel and Optional Remote Panel Table 3-1 Interpreting Fault and Warning Indicators Fault or Warning Solution Temp Battery Fuse Charger Remote Fault Condition High Battery Temp • Check the batteries. Do not charge a battery that is rated other than 12 V nominal for all 12 V chargers or warning (>50°C) 24 V nominal for all 24 V chargers.
  • Page 54 Troubleshooting Table 3-1 Interpreting Fault and Warning Indicators Fault or Warning Solution Temp Battery Fuse Charger Remote Fault Condition High Battery Temp • Check the batteries. Do not charge a battery that is rated other than 12 V nominal for all 12 V chargers or fault (>70°C) 24 V nominal for all 24 V chargers.
  • Page 55 Indicator LEDs on the Onboard Display Panel and Optional Remote Panel Table 3-1 Interpreting Fault and Warning Indicators Fault or Warning Solution Temp Battery Fuse Charger Remote Fault Condition Low Battery Temp • Check the batteries. Do not charge a frozen battery. Charging a frozen battery may present a risk of fault (<...
  • Page 56 Troubleshooting Table 3-1 Interpreting Fault and Warning Indicators Fault or Warning Solution Temp Battery Fuse Charger Remote Fault Condition High Battery voltage • Discontinue or disconnect AC power source from supplying power to the charger. fault (>16.6V) • Disconnect voltage sensitive DC loads from DC supply to prevent damage.
  • Page 57 • 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 Solid LED 975-0401-01-01 3–9...
  • Page 58 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. Ready and Charging LEDs illuminate The charger is in float mode of three- solid stage charging.

  • Page 59: Replacing The Dc Output Fuse

    Replacing the DC Output Fuse Replacing the DC Output Fuse To replace the DC Output Fuse: 1. Disconnect all AC and DC sources to the charger. 2. Locate the fuse cover on the charger’s top panel (see Figure 1-1, “Truecharge™ 2 Battery Charger” on page 1–4).

  • Page 60: Troubleshooting

    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.
  • Page 61 Troubleshooting Symptom Fault indicator LED illuminates. Temp and Battery 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.
  • Page 62 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 Battery capacity is too high for Use a higher capacity charger. the Truecharge™...
  • Page 63 Troubleshooting Symptom The Truecharge™ 2 Battery Charger will not transition to equalization mode. Possible Cause Solution Battery is the wrong type, or set Determine if the battery type is set to GEL or to the wrong type to equalize. AGM. These battery types cannot be equalized.
  • Page 64 3–16...

  • Page 65: Specifications

    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.

  • Page 66: Physical Specifications

    Specifications Physical Specifications Base Unit TC1012, TC1512: Dimensions: 200 × 170 × 70mm (7.87 × 6.70 × 2.76 in.) L × W × H TC2012, TC3012, TC4012: 250 × 170 × 70mm (9.84 × 6.70 × 2.76 in.) TC5012, TC6012: 350 ×...

  • Page 67: Electrical Specifications

    24 V units: 0 – 32 Vdc Nominal operating AC 110 – 250 Vac input voltage Maximum DC output TC1012: 10 ±10% A current (total) TC1512: 15 ±10% A TC2012: 20 ±10% A TC3012: 30 ±10% A TC4012: 40 ±10% A TC5012: 50 ±10% A...
  • Page 68 Specifications Float voltage: 12 V units 24 V units ±0.1 V for 12 V units 25 °C (77 °F) 25 °C (77 °F) ±0.2 V for 24 V units Flooded 13.5 27.0 13.8 27.6 13.4 26.8 Lead-calcium 13.5 27.0 Equalize mode current 50% rated output ±6% Equalize mode—...

  • Page 69: Ac Input Specifications

    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: 2.5 A TC1012: 1.5 A TC1512: 3.5 A TC1512: 2.0 A TC2012: 4.5 A TC2012: 2.5 A TC3012: 7.0 A...

  • Page 70: Dc Output Specifications

    Specifications DC Output Specifications DC output voltage range including 12 V units: 0 – 15.5 Vdc dead battery charging voltage 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 Vdc @ 25 °C (77 °F)

  • Page 71: Protection Features

    Protected by a replaceable DC output fuse polarity Over-voltage limits The Truecharge™ 2 Battery Charger will stop charging any bank if the output voltage is above 16.6 ±0.5 Vdc. Output current limit TC1012: 10 ±10% A TC1512: 15 ±10% A TC2012: 20 ±10% A TC3012: 30 ±10% A...

  • Page 72: Approvals

    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 E11 - Alternating Current and Direct Current Electrical Systems on Boats ABYC A31 - Battery Chargers and Inverters...

  • Page 73: Warranty And Return Information

    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.
  • Page 74 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?
  • Page 75 Xantrex or its authorized service centers (hereafter "ASCs"); d) the product if it is used as a component part of a product expressly warranted by another manufacturer;...

  • Page 76: Return Material Authorization Policy

    Return Material Authorization Policy For those 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"...

  • Page 77: Out Of Warranty Service

    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"...

  • Page 78: Information About Your System

    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. ❐ Serial Number _________________________________ ❐ Product 804-1210, 804-1215, 804-1220, 804-1230,...
  • Page 80 Xantrex Technology Inc. 1 800 670 0707 Tel toll free NA 1 408 987 6030 Tel direct +34 93 470 5330 Europe 1 800 994 7828 Fax toll free NA +34 93 473 6093 Europe customerservice@xantrex.com www.xantrex.com 975-0401-01-01 Printed in China...

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