Xantrex Truecharge2 Owner's Manual
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Xantrex Truecharge2 Owner's Manual

Xantrex truecharge2 series battery chargers owner's guide
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TC2 204060 Series BattChg Owners Guide.book Page i Friday, July 8, 2011 11:44 AM
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  • Page 1 TC2 204060 Series BattChg Owners Guide.book Page i Friday, July 8, 2011 11:44 AM Owner’s Guide Series Battery Charger...
  • Page 2 TC2 204060 Series BattChg Owners Guide.book Page ii Friday, July 8, 2011 11:44 AM...
  • Page 3 Xantrex Technology USA Inc., 541 Roske Drive, Suite A, Elkhart, Electrotechnical Commission for "plugs, socket-outlets and cou- Indiana USA 46516. Xantrex Technology USA Inc. reserves the right to revise this plers for industrial purposes". IEC models have an AC input recep- tacle that connects with an IEC cable (not provided).

  • Page 4: About This Guide

    Audience The Guide is intended for users and operators of the Truecharge2 Series STATEMENT OF HAZARD Battery Charger. The Installation section is primarily intended for qualified Contains statements of avoidance or strict compliance.
  • Page 5 Related Information You can find more information about Xantrex Technology USA Inc. as well as its products and services at www.xantrex.com. The product marking on the left when found imprinted on electrical and electronic units and appliances means that you are to refer to this guide for cautions and warnings.

  • Page 6: Important Safety Instructions

    UIDE FOR FUTURE REFERENCE ELECTRICAL SHOCK HAZARD • Do not expose the Truecharge2 Battery Charger to rain, snow, spray, This chapter contains important safety and installation instructions for the or bilge water. Truecharge2 Series Battery Chargers. Each time, before using the •...
  • Page 7 TC2 204060 Series BattChg Owners Guide.book Page v Friday, July 8, 2011 11:44 AM FIRE AND BURN HAZARD PERSONAL INJURY HAZARD Do not cover or obstruct the air intake vent openings and/or install in a This battery charger is not intended for use by persons (including zero-clearance compartment.

  • Page 8: Precautions When Working With Batteries

    Failure to follow these instructions can result in death or serious injury. NOTES: Locate the Truecharge2 Series Battery Charger unit away from batteries in a well ventilated compartment. Always have someone within range of your voice or close enough to come to your aid when you work near a lead-acid battery.
  • Page 9 • Make sure the voltage of the batteries matches the output voltage of • Never place the Truecharge2 Series Battery Charger unit directly the battery charger. • Be careful to keep corrosion from coming into contact with your eyes above batteries;...
  • Page 10 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. Unauthorized changes or modifications to the equipment could void the user’s authority to operate the equipment. viii Truecharge2 Series Battery Charger Owner’s Guide...

  • Page 11: Table Of Contents

    Configuring the Truecharge2 Battery Charger........
  • Page 12 TC2 204060 Series BattChg Owners Guide.book Page ii Friday, July 8, 2011 11:44 AM...

  • Page 13: Introduction

    TC2 204060 Series BattChg Owners Guide.book Page 1 Friday, July 8, 2011 11:44 AM Introduction This chapter describes the standard features of a Truecharge2 Battery Standard and Protection Features Charger, as well as its protection features. It also provides information on the different parts of the Truecharge2 Battery Charger.
  • Page 14 AC power is connected, • ability to display individual battery bank levels, and • ability to operate two Truecharge2 Battery Chargers in parallel for increased output current capacity. 1.In two specific installation orientations–see “Mounting Orientations (Deck and Horizontal)” on page 11.

  • Page 15: Truecharge 2 Battery Charger Features

    TC2 204060 Series BattChg Owners Guide.book Page 3 Friday, July 8, 2011 11:44 AM Truecharge 2 Battery Charger Features This section describes the different parts of the Truecharge2 Battery Charger. Item Description Onboard control and status display panel or simply Front Panel onboard display (see “Onboard Control and Status Display...

  • Page 16: Rear Panel

    Battery positive (+) for bank 1 (6 mm stud) Rear Panel Battery negative (–), common for all three banks (6 mm stud) This section describes the parts of the rear panel of the Truecharge2 Battery Air vents - located inside is the fan assembly Charger. AC wiring compartment...

  • Page 17: Onboard Control And Status Display Panel

    This section describes the parts of the onboard control and status display off and the buttons are disabled. panel of the Truecharge2 Battery Charger. See “Reading Onboard Display However, to temporarily check the status of the connected battery when AC LEDs”...
  • Page 18 Flooded - Lead-acid battery; default setting • GEL - Gel-type lead-acid battery • Lead Calc. - Lead-calcium battery • Custom - Only available if a custom algorithm has been programmed by Xantrex or a designated OEM. Truecharge2 Series Battery Charger Owner’s Guide...
  • Page 19 TC2 204060 Series BattChg Owners Guide.book Page 7 Friday, July 8, 2011 11:44 AM Truecharge 2 Battery Charger Features Item Description Item Description Battery Temp. Select button • Cold - for battery temperature below 5 °C (41 °F); raises • Press and hold the button for three seconds to select one of the charging voltage to compensate continued...

  • Page 20: Preparing For Installation

    Failure to follow these instructions can damage the unit and/or damage other equipment. NOTE: In some jurisdictions a NOTE: The Truecharge2 Battery Charger is designed to be permanently double-pole breaker may be mounted. Figure 4 shows a typical installation with three batteries, a battery required.

  • Page 21: Tools And Materials

    6 mm (1/4 in.) studs at the charger end (Marine grade hardware is recommended), To mount and connect the Truecharge2 Battery Charger you need the • DC fused disconnect or properly rated circuit breaker for each battery...
  • Page 22 ) is ignition- NOTES: protected equipment, so it can be installed in areas When planning to install the Truecharge2 Battery Charger, be sure that you containing gasoline tanks or fittings which require consider the location and orientation carefully. The Truecharge2 Battery ignition-protected equipment.
  • Page 23 TC2 204060 Series BattChg Owners Guide.book Page 11 Friday, July 8, 2011 11:44 AM Preparing For Installation panel covers are attached and secured. This rating means that it meets standards to prevent dripping water from entering the enclosure, and causing shock hazard and damage to equipment. The other possible mounting orientations [shown in Figure 6 (c) and (d)] Deck Mount - this orientation will not prevent the entry of dripping water, and are not suitable for marine...

  • Page 24: Wiring Requirements

    10 cm. sized. Maximum continuous DC current available from the charger (4 in.) may be an additional 6–10% above the nominal current rating of the charger. 6 cm. (2.5 in.) Figure 7 Ventilation Clearance Truecharge2 Series Battery Charger Owner’s Guide...
  • Page 25 TC2 204060 Series BattChg Owners Guide.book Page 13 Friday, July 8, 2011 11:44 AM Preparing For Installation DC Wiring Table 2 DC Wiring Examples for 24 V chargers The following tables show some typical wire sizes for various cable length Wire Length Wire Size (AWG and mm runs, based on 3% voltage drop on DC cables, 75 °C (167 °F) rated wire...
  • Page 26 30 A application. Some basic examples are given below. 50 A 80 A The AC input wiring for the Truecharge2 Battery Charger should be three- 100 A conductor cable, providing a line, neutral, and ground conductor (or L, N, 125 A...

  • Page 27: Battery Bank Size Requirements

    AC The Truecharge2 Battery Charger is designed to work with a minimum input current marked on the chargers and given in “AC Input battery bank size.

  • Page 28: Installing The Truecharge 2 Battery Charger

    The installer is responsible for ensuring compliance with the installation codes for your particular Mount the Truecharge2 Battery Charger using all four mounting slots and application. See CAUTION statement under “Preparing For Installation” on holes which are provided. Mounting orientations a) and b) in Figure 5 meet page 8.
  • Page 29 Xantrex recommends that you install a DC chassis ground (earth) wire from the ground stud on the Truecharge2 Battery Charger to the engine bus or DC ground bus. The DC chassis ground (earth) wire should be sized correctly with the power conductors, and both must be sized for the battery fuses that are used to protect the DC wiring.
  • Page 30 ABYC standard E-11 requires no more than 7 inches (17.8 cm). Be sure the breaker or fused disconnect is open. Route the wiring to the batteries and to the Truecharge2 Battery Charger. Avoid routing wiring through an electrical distribution panel, ACCIDENTAL SHORT OR SPARK HAZARD battery isolator, or other device that will add voltage drops.
  • Page 31 ◆ Connect the negative cable from the negative terminal on the negative ground bar or bus to the negative DC terminal on the Truecharge2 Battery Charger. Use a flat washer, a lock washer and a nut (five of each included in the installation kit) to secure the connection.
  • Page 32 16. If available, route the optional battery temperature sensor (BTS) from the battery (one which is located in the warmest ambient temperature) to the charger location. 17. Proceed to “Step 4: Installing AC Wiring”. Truecharge2 Series Battery Charger Owner’s Guide...
  • Page 33 Unscrew the wiring compartment cover from the left rear of the by a breaker switch of the correct size and type, to comply with the Truecharge2 Battery Charger to expose the AC wiring access hole and electrical code for your location and application. The current rating of the charger’s AC pigtail leads.
  • Page 34 25 mm (1 in.) from the end of the jacket. manufacturer, and follow all crimping instructions. Connect the AC supply wires to the Truecharge2 Battery Charger Failure to follow these instructions will result in death or serious pigtail wires.
  • Page 35 TC2 204060 Series BattChg Owners Guide.book Page 23 Friday, July 8, 2011 11:44 AM Installing the Truecharge 2 Battery Charger Insert one wire into one end of the butt-splice, until the insulation screw to secure the hits the internal metal crimp section, insert the butt-splice into the wiring compartment crimper , and crimp firmly.
  • Page 36 Installing the Truecharge 2 Battery Charger Step 5: Powering Up Make one last check that all connections are correct and secure. The Truecharge2 Battery Charger charger may now be powered up. Close the DC disconnect switch or breaker. EXPLOSION AND/OR FIRE HAZARD The final connection of the DC battery circuit will generate an arc.

  • Page 37: Installing A Parallel Configuration

    TC2 204060 Series BattChg Owners Guide.book Page 25 Friday, July 8, 2011 11:44 AM Installing a Parallel Configuration A parallel configuration is when two Truecharge2 Battery Chargers are Installing a parallel configuration: coupled together to increase the output capacity. For example, a 40-amp...
  • Page 38 Remote panel’s Fault/Warning LED only clears when fault or warning conditions at both chargers are cleared. The remote panel will resume The two Truecharge2 Battery Chargers’ output currents are synchronized synchronizing the two chargers’ settings at this point. during most of the charging cycle. When a battery is approaching a fully charged state, it is normal to see one charger’s output current drop down...

  • Page 39: Installing Batteries

    When AC input is within the lower range between 90–108 Vac, the Turn off the AC source by disconnecting the AC line and/or opening Truecharge2 Battery Charger derates to 80% of maximum current. the AC source disconnect. However, when AC input increases above 108 Vac up to 265 Vac, maximum current returns to 100% capacity.
  • Page 40 Remote panel NOTE: Not to scale. For illustration purposes only. (optional) Most Truecharge2 Battery Charger models have three outputs that share the full rated current enabling it to charge three different batteries or battery AC source banks that either have the same chemistry or can tolerate the same charge sequence and thresholds.
  • Page 41 TC2 204060 Series BattChg Owners Guide.book Page 29 Friday, July 8, 2011 11:44 AM Installing Batteries Three-Stage Charging The three-stage charging mode employs the following sequence: Bulk, Vbat = Vabs lout < 10% lrating for 1 minute for 1 minute Absorption, and Float.
  • Page 42 (Standby) Time ABS CV timeout max 5 hrs REST (Standby) Start of timeout max 7 days charging cycle Total ABS timeout max 8 hrs Figure 10 Two-Stage Charging Process Truecharge2 Series Battery Charger Owner’s Guide...

  • Page 43: Temperature Considerations

    15.5 13.5 16.0 The Truecharge2 Battery Charger charges all banks at the same time but the bank in most need of charging is the one that receives the most charge. For Table 6 Charging Maximum Voltages for 24-volt chargers example, if Bank 1 and Bank 2 are both charged, but Bank 1 has a load and...
  • Page 44 30 °C Flooded/PbCa/ -0.27 (86 °F) Select the appropriate battery temperature setting. The LEDs will indicate which of the three types is being selected: -0.21 Warm, Hot, or Cold. Truecharge2 Series Battery Charger Owner’s Guide...
  • Page 45 TC2 204060 Series BattChg Owners Guide.book Page 33 Friday, July 8, 2011 11:44 AM Installing Batteries Operating DC Loads When the Truecharge™ 2 Battery Charger is operating, DC loads such as fans and lights may vary in speed or intensity. This is normal. The Truecharge™...

  • Page 46: Configuring The Truecharge2 Battery Charger

    Flooded (default), GEL, Lead Calc., AGM, and Custom. The Custom setting is indicated when all four battery type LEDs are illuminated. This setting should only be used if a custom algorithm has been programmed by Xantrex or a designated OEM. Truecharge2 Series Battery Charger Owner’s Guide...

  • Page 47: Charging Batteries

    Review the charging instructions supplied by the manufacturer of your batteries and follow all safety precautions and the required steps. Equalize (in progress) Equalize (solid light) Apply AC power to the Truecharge2 Battery Charger by: Equalize Equalize (flashing) • closing the AC breaker or (waiting for absorption to end) •...
  • Page 48 TC2 204060 Series BattChg Owners Guide.book Page 36 Friday, July 8, 2011 11:44 AM Charging Batteries After charging is complete, the Truecharge2 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.

  • Page 49: Equalizing Flooded Batteries

    TC2 204060 Series BattChg Owners Guide.book Page 37 Friday, July 8, 2011 11:44 AM Equalizing Flooded Batteries In the following conditions the Truecharge2 Battery Charger will not enter equalization mode: • the battery type is set to GEL or AGM RISK OF BATTERY DAMAGE •...

  • Page 50: Performing An Equalization

    Always wear proper, non-absorbent gloves, complete eye protection, and clothing protection. Avoid touching your eyes and wiping your forehead while working near batteries. See following note. Failure to follow these instructions can result in death or serious injury. Truecharge2 Series Battery Charger Owner’s Guide...
  • Page 51 Equalizing Flooded Batteries Press and hold for five seconds the Charger Mode Select button and Battery Temp Select button at the same time to put the Truecharge2 Battery Charger into equalization mode. IMPORTANT: The onboard display and remote panel buttons will not allow selection of equalization for AGM and GEL batteries.

  • Page 52: Transitioning The Charger To On, Standby, Or Disabled

    AC power are both connected to the charger (from Standby). injury. The charger begins to charge the batteries from Standby. There is only ONE way to safely turn the Truecharge2 Battery Charger off (Disable): There are two ways to put the Truecharge2 Battery Charger in ◆...

  • Page 53: Accessing Charger Information

    TC2 204060 Series BattChg Owners Guide.book Page 41 Friday, July 8, 2011 11:44 AM Accessing Charger Information The Truecharge2 Battery Charger provides a lot of information about the status of the charger and the batteries. Type of fault and warning...
  • Page 54 AC or DC power is illuminates solid mode supplied to the Truecharge2 Battery Charger or when the charger is turned Equalize LED flashes The charger will perform an equalization cycle on using the button on the remote panel.
  • Page 55 TC2 204060 Series BattChg Owners Guide.book Page 43 Friday, July 8, 2011 11:44 AM Accessing Charger Information Table 9 Interpreting Fault and Warning Indicators Fault or Warning Solution Temp Battery Fuse Charger Remote Fault Condition AC input out of range •...
  • Page 56 High Charger Temp • Allow the Truecharge2 Battery Charger to cool while the AC is connected so the fan stays on. fault • Improve ventilation or install the charger in a cooler location.
  • Page 57 TC2 204060 Series BattChg Owners Guide.book Page 45 Friday, July 8, 2011 11:44 AM Accessing Charger Information Table 9 Interpreting Fault and Warning Indicators Fault or Warning Solution Temp Battery Fuse Charger Remote Fault Condition Reverse Polarity Fuse • Check for reverse battery polarity (negative fault connected to negative, positive connected to positive is correct) at battery and charger output terminals.

  • Page 58: Using A Generator As Source Power

    TC2 204060 Series BattChg Owners Guide.book Page 46 Friday, July 8, 2011 11:44 AM Using A Generator As Source Power The Truecharge2 Battery Charger can be run from a regular AC power source or from an alternate power source such as a generator. Refer to “AC Input Specifications”...

  • Page 59: Maintaining The Charger

    To clean battery terminals, follow the recommendations and procedures of the battery manufacturer. NOTE: The Truecharge2 Series Battery Charger contains no user- serviceable parts with the exception of the DC output fuse(s) which are user-replaceable. See “Replacing the DC Output Fuse” on page 48 for instructions.

  • Page 60: Replacing The Dc Output Fuse

    Locate the fuse cover on the charger’s top panel (see “Front Panel” on page 3). Loosen the screw on the fuse cover using a Phillips screwdriver. NOTE: The screw will not separate from the cover. Truecharge2 Series Battery Charger Owner’s Guide...
  • Page 61 TC2 204060 Series BattChg Owners Guide.book Page 49 Friday, July 8, 2011 11:44 AM Replacing the DC Output Fuse Fuse Replacement Ratings RISK OF EQUIPMENT DAMAGE ® For continued protection, replace only with Littelfuse type 257 (or equivalent) with ratings as shown below. Failure to follow these instructions can damage the unit and/or damage other equipment.

  • Page 62: Troubleshooting

    TC2 204060 Series BattChg Owners Guide.book Page 50 Friday, July 8, 2011 11:44 AM Troubleshooting In the event that you have a problem with your Truecharge2 Battery Charger, the following tables will help you to identify the problem and offer possible solutions to the problem.
  • Page 63 Troubleshooting Symptom Symptom Fault indicator LED illuminates. Temp and Battery indicator Truecharge2 Battery Charger completes a charging cycle, but the battery LEDs flash. voltage seems too low. Possible Cause Solution Battery has a shorted cell. Disconnect AC to the charger and...
  • Page 64 Troubleshooting Symptom Symptom The Truecharge2 Battery Charger appears to be taking too long to charge The Truecharge2 Battery Charger appears to have quickly charged the battery. Ready indicator LED does not illuminate after 24 hours of battery. Ready indicator LED illuminates sooner than expected.
  • Page 65 TC2 204060 Series BattChg Owners Guide.book Page 53 Friday, July 8, 2011 11:44 AM Troubleshooting Symptom The Truecharge2 Battery Charger will not perform equalization. Possible Cause Solution Battery is the wrong type, or set Determine if the battery type is set to to the wrong type to equalize.

  • Page 66: Specifications

    12/24-volt units: 80% @ 120 Vac connections negative) for battery cable ring terminals and 12/24-volt units: 84% @ 230 Vac one M6 mm DC equipment ground Surge protection Line-to-neutral surge protector rated at 275 Vac Truecharge2 Series Battery Charger Owner’s Guide...
  • Page 67 TC2 204060 Series BattChg Owners Guide.book Page 55 Friday, July 8, 2011 11:44 AM Specifications DC Output Specifications DC Output Specifications Number of isolated battery 3 separated outputs Normal operating output bank outputs range 12-volt units: 0 – 16 Vdc DC output voltage range 24-volt units: 0 –...
  • Page 68 50% current derating above 50 °C (122 °F) Off-state current draw (without remote installed) <35 mA dc Storage –40 to 80 °C (–40 to 176 °F) Humidity 5 – 95%, RH non-condensing Truecharge2 Series Battery Charger Owner’s Guide...
  • Page 69 –25 °C (–13 °F) is sensed by the battery temperature Over-voltage limits The Truecharge2 Battery Charger will sensor (BTS). stop charging if the output voltage is above 16.6 ±0.5 Vdc for 12 Vdc units, 33.2 ±0.1 Vdc for 24 Vdc units.

  • Page 70: Warranty And Return Information

    Limited Warranty is provided by Xantrex Technology USA Inc. from excluded areas. (“Xantrex”) and covers defects in workmanship and materials in your Truecharge2 Series Battery Charger. This warranty period lasts for 24 How do you get service? If your product requires troubleshooting or months from the date of purchase at the point of sale to you, the original end warranty service, contact your merchant.
  • Page 71 TC2_204060_Chapters.fm Page 59 Thursday, August 4, 2011 1:12 PM Warranty and Return Information What proof of purchase is required? by Xantrex at your direction for incorporation into the product; In any warranty claim, dated proof of purchase must accompany the product and the product must not the product if its original identification (trade-mark, serial number) have been disassembled or modified without prior written authorization by markings have been defaced, altered, or removed;...
  • Page 72 ARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS OPERATION OF THE PRODUCT BY PERSONS NOT AUTHORIZED BY XANTREX OU MAY HAVE OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE PROVINCE TO PROVINCE OR JURISDICTION TO JURISDICTION Truecharge2 Series Battery Charger Owner’s Guide...

  • Page 73: Return Material Authorization Policy

    Include the following: Customer Service once your unit has been received. • The RMA number supplied by Xantrex Technology USA 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 74: Information About Your System

    Information About Your System before calling. This information will help our representatives give you better service. As soon as you open your Truecharge2 Series Battery Charger package, record the following information and be sure to keep your proof of ❐...
  • Page 75 TC2 204060 Series BattChg Owners Guide.book Page i Friday, July 8, 2011 11:44 AM...
  • Page 76 TC2 204060 Series BattChg Owners Guide.book Page ii Friday, July 8, 2011 11:44 AM Xantrex Technology USA Inc. 1 800 670 0707 Tel 1 800 994 7828 Fax www.xantrex.com 975-0526-01-02 Printed in China.

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