Xantrex TC2 204060 - Manuals

975-0526-01-02 v NOTE: Follow these instructions and those published by the battery manufacturer and the manufacturer of any equipment you intend to use in the vicinity of the battery. Review cautionary markings on these products and on the engine. FIRE AND BURN HAZARD Do not cover or obstruct the a...

vi Truecharge2 Series Battery Charger Owner’s Guide Precautions When Working With Batteries NOTES: 1. Locate the Truecharge2 Series Battery Charger unit away from batteries in a well ventilated compartment. 2. Always have someone within range of your voice or close enough to come to your aid when yo...

975-0526-01-02 vii Precautions When Preparing to Charge NOTES: 1. 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. 2. For flooded n...

viii Truecharge2 Series Battery Charger Owner’s Guide 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 interfer...

Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

975-0526-01-02 1 Introduction This chapter describes the standard features of a Truecharge2 Battery Charger, as well as its protection features. It also provides information on the different parts of the Truecharge2 Battery Charger. Truecharge2 Battery Charger The Truecharge2 Battery Charger ships w...

2 Truecharge2 Series Battery Charger Owner’s Guide Introduction • electronic current limiting provides protection against short circuit conditions on the charger’s output, • ignition-protected rating, enabling installation in engine spaces, • isolated design, • short circuit protection for the BTS a...

975-0526-01-02 3 Truecharge 2 Battery Charger Features This section describes the different parts of the Truecharge2 Battery Charger. Front Panel Figure 1 Truecharge2 Battery Charger Front Panel 1 2 6 4 3 5 Item Description 1 Onboard control and status display panel or simply onboard display (see “O...

4 Truecharge2 Series Battery Charger Owner’s Guide Truecharge 2 Battery Charger Features Rear Panel This section describes the parts of the rear panel of the Truecharge2 Battery Charger. Item Description 5 AC wiring compartment cover provides the installer with easy access to the AC wiring compartme...

975-0526-01-02 5 Truecharge 2 Battery Charger Features Onboard Control and Status Display Panel This section describes the parts of the onboard control and status display panel of the Truecharge2 Battery Charger. See “Reading Onboard Display LEDs” on page 41 for more information. To reduce current d...

975-0526-01-02 7 Truecharge 2 Battery Charger Features 6 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. If an optional BTS is connected, the indicator LEDs represent real-time battery temperature...

8 Truecharge2 Series Battery Charger Owner’s Guide Preparing For Installation NOTE: The Truecharge2 Battery Charger is designed to be permanently mounted. Figure 4 shows a typical installation with three batteries, a battery temperature sensor (BTS) and a remote panel (both optional). It also shows ...

975-0526-01-02 9 Preparing For Installation Tools and Materials To mount and connect the Truecharge2 Battery Charger you need the following tools: • 10 mm socket wrench and extension for the DC terminals and ground stud, • Phillips screwdriver for removing and re-securing the AC and DC wiring compar...

10 Truecharge2 Series Battery Charger Owner’s Guide Preparing For Installation Location Install the Truecharge2 Battery Charger in a location that meets the following requirements: NOTES: When planning to install the Truecharge2 Battery Charger, be sure that you consider the location and orientation...

975-0526-01-02 11 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 (...

12 Truecharge2 Series Battery Charger Owner’s Guide Preparing For Installation Wiring Requirements NOTES: • Wiring and fuse sizes are governed by electrical codes and standards. Different requirements apply in different countries and to different types of installations, for example, boat, home or RV...

975-0526-01-02 13 Preparing For Installation DC Wiring The following tables show some typical wire sizes for various cable length runs, based on 3% voltage drop on DC cables, 75 °C (167 °F) rated wire with wiring being inside the engine compartment – assumed ambient of 50 °C (122 °F). NOTE : In the ...

14 Truecharge2 Series Battery Charger Owner’s Guide Preparing For Installation current and be rated to withstand the short circuit current available from the connected battery bank. Do not substitute devices rated only for AC voltage; they may not operate properly. The current rating of the DC fuses...

975-0526-01-02 15 Preparing For Installation Note that every jurisdiction will have different requirements as will each application, so research the regulations for your local jurisdiction to determine which wire size and type is correct based on the maximum AC input current marked on the chargers a...

16 Truecharge2 Series Battery Charger Owner’s Guide Installing the Truecharge 2 Battery Charger 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...

975-0526-01-02 17 Installing the Truecharge 2 Battery Charger Step 2: Connecting the DC Chassis Ground (Earth) NOTE: Have an electrician install a properly grounded circuit if one is not available. The Truecharge2 Battery Charger must be connected to a grounded, metal, permanent wiring system, or an...

18 Truecharge2 Series Battery Charger Owner’s Guide Installing the Truecharge 2 Battery Charger Step 3: Installing DC Wiring The procedure for installing the DC wiring applies to a single battery, as well as multiple batteries or battery banks. 1. Remove the DC compartment cover. See “Front Panel” o...

975-0526-01-02 19 Installing the Truecharge 2 Battery Charger 7. Install crimp lugs on the charger end of the DC battery cables using the crimp manufacturer’s instructions and tool. NOTE: Make sure the positive terminals of the Truecharge2 Battery Charger will be connected to the correct terminals o...

20 Truecharge2 Series Battery Charger Owner’s Guide Installing the Truecharge 2 Battery Charger NOTE: If you are using more than one battery, you will need to connect the negative cable from each of the batteries to the negative ground bar or bus. The negative ground bar or bus will then have a sing...

975-0526-01-02 21 Installing the Truecharge 2 Battery Charger Step 4: Installing AC Wiring Before connecting AC wiring, make sure the AC source circuit is protected by a breaker switch of the correct size and type, to comply with the electrical code for your location and application. The current rat...

22 Truecharge2 Series Battery Charger Owner’s Guide Installing the Truecharge 2 Battery Charger 7. Feed the AC supply wiring through the wider end of strain relief and out the tapered end. 8. Slide the strain relief on the jacket of the wiring (not on the individual conductors) approximately 25 mm (...

975-0526-01-02 23 Installing the Truecharge 2 Battery Charger c) 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 crimper 1 , and crimp firmly. The proper location for the crimp is approximately 1.6 mm (1/16 ...

24 Truecharge2 Series Battery Charger Owner’s Guide 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. 1. Close the DC disconnect switch or breaker. 2. Switch t...

975-0526-01-02 25 Installing a Parallel Configuration A parallel configuration is when two Truecharge2 Battery Chargers are coupled together to increase the output capacity. For example, a 40-amp Truecharge2 Battery Charger can be connected with another 40-amp Truecharge2 Battery Charger for a combi...

26 Truecharge2 Series Battery Charger Owner’s Guide Installing a Parallel Configuration Powering up after installing a parallel configuration: 1. Follow the procedures in “Step 5: Powering Up” on page 24. 2. Observe that the Parallel LED on the remote panel lights up to indicate that two chargers ar...

975-0526-01-02 27 Installing Batteries Battery installation should always be treated like a brand new installation. This means, that all safety and precautionary guidelines that were followed prior and during the installation of the battery charger, must again be followed in order to avoid risks of ...

28 Truecharge2 Series Battery Charger Owner’s Guide Installing Batteries Multi-Stage Charging Most Truecharge2 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 toler...

975-0526-01-02 29 Installing Batteries 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 ...

30 Truecharge2 Series Battery Charger Owner’s Guide Installing Batteries 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 ...

975-0526-01-02 31 Installing Batteries Charging Voltage Setpoints The Truecharge2 Battery Charger charging process is designed to make the battery or battery banks reach the following voltage setpoints. Battery Qualification The Truecharge2 Battery Charger will perform a battery qualification on eac...

32 Truecharge2 Series Battery Charger Owner’s Guide Installing Batteries Setting the Battery Temperature without a BTS NOTE: Always be aware of the temperature setting, observe the battery’s actual temperature and adjust the Battery Temperature setting accordingly. For varying conditions, use the Wa...

975-0526-01-02 33 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™ 2 Battery Charger will not harm any load connected to it as long as the load can withstand t...

34 Truecharge2 Series Battery Charger Owner’s Guide Configuring the Truecharge2 Battery Charger Once the charger is connected to at least one battery bank and to AC, it is live and it may be configured. The indicator LEDs on the onboard display will illuminate for a second (power on test) before rep...

975-0526-01-02 35 Charging Batteries Before you start to charge batteries read the “Important Safety Instructions” on page iv and follow all safety precautions when working with batteries. To charge your batteries: 1. If possible, disconnect any heavy loads on the batteries being charged, by opening...

36 Truecharge2 Series Battery Charger Owner’s Guide 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. If you selected...

975-0526-01-02 37 Equalizing Flooded Batteries The Truecharge2 Battery Charger cannot automatically determine when to stop the equalization of a battery. 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 manu...

38 Truecharge2 Series Battery Charger Owner’s Guide Equalizing Flooded Batteries Performing An Equalization NOTE: 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-volt chargers and 32 V for 24-volt chargers within ...

975-0526-01-02 39 Equalizing Flooded Batteries 3. 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. When the charger is performing the equalization, the Equalize LED illuminate...

40 Truecharge2 Series Battery Charger Owner’s Guide Transitioning the Charger to ON, Standby, or Disabled There are two ways to turn ON the Truecharge2 Battery Charger: • Connect the batteries to the charger (i.e., charger is on standby) then connect AC power at the source. If the batteries are not ...

975-0526-01-02 41 Accessing Charger Information The Truecharge2 Battery Charger provides a lot of information about the status of the charger and the batteries. Reading Onboard Display LEDs The Fault LED works in conjunction with the Charging Current (%) LEDs. The icons at the top row above the Char...

42 Truecharge2 Series Battery Charger Owner’s Guide 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 Truecharge2 Battery Charger on Standby mode, the onboard display (and the opti...

975-0526-01-02 43 Accessing Charger Information Table 9 Interpreting Fault and Warning Indicators Fault or Warning Condition Temp Fan AC Battery Fuse Charger Remote Fault Solution AC input out of range fault (<85 V or >265 V) • Check AC connections. Change to a more stable AC power source and ...

44 Truecharge2 Series Battery Charger Owner’s Guide Accessing Charger Information Low Battery Temp fault (< -25°C) • 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 actua...

975-0526-01-02 45 Accessing Charger Information 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(s) on the cha...

46 Truecharge2 Series Battery Charger Owner’s Guide 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” on page 54 for AC input current draw to determine ...

975-0526-01-02 47 Maintaining the Charger 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. For obtaining service other than replacin...

48 Truecharge2 Series Battery Charger Owner’s Guide Replacing the DC Output Fuse To replace the DC Output Fuse: 1. Locate the fuse cover on the charger’s top panel (see “Front Panel” on page 3). 2. Loosen the screw on the fuse cover using a Phillips screwdriver. NOTE: The screw will not separate fro...

975-0526-01-02 49 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. Mode...

50 Truecharge2 Series Battery Charger Owner’s Guide 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. Symptom Indicator LEDs do not illuminate when charge...

975-0526-01-02 51 Troubleshooting Symptom Fault indicator LED illuminates. Temp and Battery indicator LEDs flash. Symptom Truecharge2 Battery Charger completes a charging cycle, but the battery voltage seems too low. EXPLOSION HAZARD Never charge a frozen battery. Failure to follow these instruction...

52 Truecharge2 Series Battery Charger Owner’s Guide Troubleshooting Symptom The Truecharge2 Battery Charger appears to be taking too long to charge battery. Ready indicator LED does not illuminate after 24 hours of charging. Symptom The Truecharge2 Battery Charger appears to have quickly charged the...

975-0526-01-02 53 Troubleshooting Symptom The Truecharge2 Battery Charger will not perform equalization. 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...

54 Truecharge2 Series Battery Charger Owner’s Guide Specifications NOTE: Specifications are subject to change without prior notice. Physical Specifications Base Unit Dimensions: L × W × H TC2012, TC4012 250×170×70 mm (9.84×6.70×2.76 in.) TC1024, TC2024 250×170×70 mm (9.84×6.70×2.76 in.) TC6012, TC30...

975-0526-01-02 55 Specifications DC Output Specifications Number of isolated battery bank outputs 3 separated outputs DC output voltage range including dead battery charging voltage 12-volt units:24-volt units: 0 – 16 Vdc0 – 32 Vdc Maximum equalization voltage 12-volt units:24-volt units: 16 Vdc32 V...

56 Truecharge2 Series Battery Charger Owner’s Guide Specifications Float voltage: FloodedGEL AGM Lead-calcium 12-volt units 24-volt units 25 °C (77 °F) 25 °C (77 °F) 13.5 ±0.1 27.0 ±0.2 13.8 ±0.1 27.6 ±0.2 13.4 ±0.1 26.8 ±0.2 13.5 ±0.1 27.0 ±0.2 Equalize mode current 50% rated output ±6% Equalize mo...

975-0526-01-02 57 Specifications Protection Features Battery reverse polarity Protected by replaceable DC output fuses Over-voltage limits The Truecharge2 Battery Charger will 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. Output current l...

58 Truecharge2 Series Battery Charger Owner’s Guide Warranty and Return Information Warranty What does this warranty cover and how long does it last? This Limited Warranty is provided by Xantrex Technology USA Inc. (“Xantrex”) and covers defects in workmanship and materials in your Truecharge2 Serie...

975-0526-01-02 59 Warranty and Return Information 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 ...

60 Truecharge2 Series Battery Charger Owner’s Guide Warranty and Return Information Disclaimer Product T HIS 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 ...

975-0526-01-02 61 Warranty and Return Information 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 co...

62 Truecharge2 Series Battery Charger Owner’s Guide Warranty and Return Information Information About Your System As soon as you open your Truecharge2 Series Battery Charger package, record the following information and be sure to keep your proof of purchase. If you need to contact Customer Service,...

Xantrex Technology USA Inc. 1 800 670 0707 Tel1 800 994 7828 Faxwww.xantrex.com 975-0526-01-02 Printed in China. TC2 204060 Series BattChg Owners Guide.book Page ii Friday, July 8, 2011 11:44 AM