Xantrex TC20+ - Manual

Contents vii Maintenance Guidelines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2 Preparation for Cleaning Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3 Clothing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...

ix Important Safety Instructions 1. Before using the charger, read all instructions and cautionary markings on the charger, the batteries, and all appropriate sections of this guide. 2. Do not expose the charger to rain, snow, spray, or bilge water. To reduce risk of fire hazard, do not cover or obs...

Important Safety Information x 7. Do not disassemble the charger. See Appendix D, “Product and System Information” for instructions on obtaining service. Attempting to service the unit yourself may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is di...

Important Safety Information xi 3. Wear complete eye protection and clothing protection. Avoid touching your eyes while working near batteries. 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 fo...

1 Introduction Chapter 1, “Introduction” introduces and describes features of the Truecharge + multistage battery chargers.

Introduction 1–2 Truecharge + Features Truecharge + is an advanced battery charger designed specifically for high performance, deep-cycle lead-acid batteries. It is smaller and lighter than many other chargers and can be installed or stored in small compartments. It has AC to DC isolation, a surge p...

Truecharge + Features 1–3 Selector Switches Truecharge + has selector switches for charge mode, battery type, and battery temperature setting. Charge mode The charge-mode switch allows you to select three-step charge, two-step charge or 13.5 volt fixed output modes. Refer to Appendix B, “Battery Cha...

Introduction 1–4 Fixed Voltage Mode The fixed voltage mode setting is meant to be used as a power supply or battery eliminator. It is not meant for charging batteries. The battery type, battery temperature, and equalize switches are all ignored in fixed voltage mode. The remote battery temperature s...

Indicator Lights and Settings on the Front Panel 1–5 The indicator lights are also used to indicate error codes. See Chapter 4, “Maintenance and Troubleshooting” Table 1-1 Truecharge + front panel Panel Item Description 1 Status indicator lights which indicate that batteries are charged and ready fo...

Introduction 1–6 How Truecharge + Works Truecharge + changes the alternating current (AC) supply from the utility to the controlled low-voltage, direct current (DC) required to charge the battery by using high-frequency, switched-mode power conversion circuits. The high-frequency power conversion me...

2 Installing Truecharge + Chapter 2, “Installing Truecharge +” lists the materials you receive, provides site recommendations for installing Truecharge +, and provides the materials and procedures for its installation. The chapter also makes reference to the installation codes that may be applicable...

Installing Truecharge + 2–2 Materials List Contents The unit is packed with the following materials: • Owner’s Guide • Wiring cover with 2 blunt-tip screws and two lock washers • AC cable clamp • Three twist-on wire nuts • Three crimp-on butt-splices Recording information After unpacking the unit, r...

Preparing for Installation 2–3 Location Install Truecharge + in a location that meets the requirements set out in Table 2-1 . Circuits Truecharge + is designed to operate from a 15 amp, 120 VAC (nominal) branch circuit. The circuit must be protected by a 15 amp circuit breaker. Any switch in the cir...

Preparing for Installation 2–5 Wiring Requirements Figure 2-2 depicts a typical configuration system for the Truecharge + showing the AC and DC wiring and protection devices required for a successful installation. DC Wiring The DC wiring must meet the following requirements: • Length and size Use th...

Installing Truecharge + 2–6 AC Wiring Be sure that your AC wiring meets the following requirements before you install the Truecharge +: • Input wiring The AC input wiring for Truecharge + should be three-conductor cable, providing a line, neutral, and ground conductor in an outer jacket. The conduct...

Preparing for Installation 2–7 Tools To mount and connect Truecharge + you need: p a slot screwdriver with a maximum 3/16 in wide blade for the DC terminals p a No. 1 Phillips screwdriver for securing the AC wiring compartment cover p a wire stripper p the manufacturer's recommended crimp tool for a...

Installing Truecharge + 2–8 Installing Truecharge + Installation steps Truecharge + is installed in three steps. The unit is 1. mounted ( page 2–8 ) 2. connected to the batteries ( page 2–9 ) 3. connected to its AC power source ( page 2–11 ) Mounting Mount the Truecharge + on a vertical surface such...

Installing Truecharge + 2–9 Connecting DC Wiring For A Single Battery Or Multiple Batteries The procedure for installing the DC wiring applies to a single battery or multiple batteries or battery banks. Figure 2-3 shows the connection order. Figure 2-3 DC wiring connection order WARNING Truecharge +...

Installing Truecharge + 2–10 To install the DC wiring: 1. Plan the route the DC wires will follow trying to make it as short as possible. Measure the required wire length, and cut the cables. Allow some extra length for connections and to provide slack in the wires. It is possible that the connectio...

Installing Truecharge + 2–11 8. Before proceeding, carefully check the wiring polarity – make sure the positive on the charger is going to the positive on the batteries (fuse or breaker) and make sure the negative on the charger is going to the battery negative terminal (or engine negative bus or DC...

Installing Truecharge + 2–12 3. Route the wiring without connecting it to the AC source or to the charger yet. 4. Install the supplied cable clamp in the knock-out of your choice on the AC wiring compartment on the top end of the charger and tighten the locknut. Run the AC wiring through the cable c...

Installing Truecharge + 2–13 To connect AC wires with the crimp-on butt-splice connector: 1. Using a wire stripper, carefully strip 5/16” (8mm) from the ends of the two wires being connected. 2. Insert one wire into one end of the butt-splice, insert the butt-splice into the crimping tool, and crimp...

Installing Truecharge + 2–14 Grounding Truecharge + must be grounded to reduce the risk of electrical shock. The AC input ground wire must be properly connected to ground in accordance with all applicable electrical codes. Meeting electrical codes is achieved by connecting the ground conductor of th...

Installing Optional Accessories 2–15 Effect on charging With the BTS, the charging setpoints are temperature-compensated up to 140 °F (60 °C). If the battery temperature exceeds 140 °F the charger stops charging. The BTS also provides more accurate compensation over a wider range of temperatures tha...

3 Operation Chapter 3, “Operation” provides background information for charging batteries with Truecharge + and procedures for charging and for equalizing batteries. Chapter 3 also explains how to calculate charging times, how generators affect Truecharge + and explains how the front panel indicator...

Operation 3–2 About Charging This section provides information about • calculating the charging time • effect of battery temperature on charging • indicator light activity during the charging process • using a generator to run Truecharge + Charging Time Formula Charging time will depend on the capac...

About Charging 3–3 Battery Temperature Temperature switch Selecting the correct temperature setting selects the appropriate charging voltage to compensate for battery temperature. Effect of temperature Cold battery temperature If you choose the Cold setting, Truecharge + delivers, for example, 14.8 ...

Operation 3–4 Using A Generator As Source Power The Truecharge + can be run from a regular power source or from an alternate power source such as a generator. Refer to Appendix A, “Specifications” for AC input draw to determine the size of generator you need. Many generators provide output voltage t...

Charging batteries 3–5 Charging batteries Before you start Before you start to charge batteries read the “Important Safety Instructions” on page ix and take all safety precautions when working with batteries. To charge your batteries: 1. If possible, disconnect all loads from the battery, by removin...

Operation 3–6 2. Set the Battery Type selector switch according to the table below. 3. Set the Battery Temperature selector switch for the temperature of your battery as follows: If temperatures fluctuate near the batteries, set this switch each time you charge the batteries. If your batteries are i...

Equalizing Flooded Batteries 3–7 light on Truecharge 40 +) will light for most of the charging cycle. Near the end of the cycle, the charging current decreases and the other indicator lights illuminate in sequence. The charger pauses every 15 minutes for approximately 10 seconds to measure the batte...

Operation 3–8 Battery type Truecharge + equalizes only flooded lead-acid batteries. It does not equalize sealed lead-acid batteries since they can be damaged by this process. If the battery type selector is set for Gel or AGM, and you try to equalize them, the indicator lights on the front panel fla...

Equalizing Flooded Batteries 3–9 Important Turn off or disconnect all loads on the battery during equalization. The voltage applied to the battery during equalization may be above the safe levels for some loads. Be sure to check battery electrolyte before and after equalization. Fill only with disti...

4 Maintenance and Troubleshooting Chapter 4, “Maintenance and Troubleshooting” provides information for maintaining and troubleshooting Truecharge +.

Maintenance and Troubleshooting 4–2 Care and Maintenance Cleaning Truecharge + contains solid-state electronic components that require no maintenance. The best care you can give the unit is to protect it from contact with liquids, spray, or fumes which may cause corrosion. Disconnect all AC and DC p...

Maintenance and Troubleshooting 4–4 Typical Problems This section lists typical problems you may have with the Truecharge +, suggests their causes, then offers possible solutions to the problems. Symptom Indicator lights do not turn on, or remain on, when charger is connected to an AC receptacle. Sy...

A Specifications Appendix A “Specifications” contains the Truecharge + physical, electrical, AC input, and protection feature specifications.

Specifications A–2 Physical Specifications Electrical Specifications Dimensions 15 1/8 in x 6 3/4 in x 2 3/4 in 385 mm x 172 mm x 70 mm Weight Truecharge 20 + 6.9 lbs (3.1 kg)Truecharge 40 + 7.4 lbs (3.3 kg) AC input connections Three color-coded No. 16 AWG wires (L, N, G) minimum 6 inches long in a...

Specifications A–4 AC Input Specifications Protection Features Truecharge 20 + Truecharge 40 + AC input voltage range 90 – 135 VAC, 50/60 Hz Maximum AC input current at 90 VAC 6.5 A rms 12 A rms Typical AC input current at 120 VAC 4.6 A rms 8.5 A rms No-load AC power draw (without remote panel) less...

Approvals A–5 Approvals Over-temperature Internal charger temperature is measured. Unit shuts down and restarts as follows: • Over-temperature shutdown at 62 °C • Over-temperature restart at 61 °C Current derating in ambient temperatures—automatic output Truecharge 20+ 20 A at 30 °C to 10 A at 50 °C...

B Battery Charging Appendix B “Battery Charging” describes the Truecharge + multistage charging algorithm.

Battery Charging B–2 Charging Algorithms Battery Type Truecharge + charges lead-acid flooded, gel, and AGM (absorbed glass mat) batteries. Flooded “Flooded” batteries have removable battery caps for refilling with distilled water and testing the electrolyte. Gel The sealed gel battery has its electr...

Charging Algorithms B–3 Bulk Charge In the first stage, known as the bulk charge, Truecharge + delivers its full- rated output current.This constant current is delivered to the batteries until the battery voltage approaches its absorption voltage—typically around 14.4 volts for 12 volt batteries. Th...

Battery Charging B–4 Figure B-1 Three-stage charging profile Equalization Charge The equalization charge must be manually initiated because it is not required each time the battery is recharged. Equalization is a deliberate overcharge designed to return each cell to optimum condition by reducing sul...

C Battery Maintenance Appendix C “Battery Maintenance” contains procedures for maintaining the battery enclosure, battery terminals and lugs, and battery cables. It also provides a list of the clothing, tools, equipment, and supplies you should have before you begin battery maintenance.

Battery Maintenance C–2 Maintenance Guidelines Electrolyte At a minimum, check the level of the electrolyte in each battery cell once a month (for flooded batteries). It should be above the top of the plates, but not completely full. Most batteries have a plastic cup that just touches the electrolyt...

Preparation for Cleaning Batteries C–3 Preparation for Cleaning Batteries The appropriate clothing, tools, equipment, and supplies are listed below. Gather what you need before beginning. Clothing Appropriate clothing could include old clothes, rubber boots, or old shoes. Battery acid is highly corr...

Battery Maintenance C–4 Maintaining and Cleaning Follow these procedures to maintain the • battery enclosure • battery terminal and lugs • cables Battery Enclosure and Batteries Mix four ounces of baking soda with a gallon of fresh water and fill a spray bottle. Spray the solution on all exposed sur...

Maintaining and Cleaning C–5 Reconnect the battery cable terminals to the battery lugs and tighten to approximately 10–15 foot-pounds using the torque wrench. If you do not have a torque wrench, use an appropriate tool to tighten the bolts reasonably snug. Do not over-tighten. After tightening the c...

D Product and System Information Appendix D “Product and System Information” contains the Xantrex warranty for your product and return instructions. It also contains a place for you to record the serial number and date of purchase and other details of your battery charger.

Product and System Information D–2 Warranty What does this warranty cover? This Limited Warranty is provided by Xantrex Technology, Inc. ("Xantrex") and covers defects in workmanship and materials in your Xantrex Truecharge 20+ and Truecharge 40+. This warranty lasts for a Warranty Period of...

Warranty D–3 Direct returns may be performed according to the Xantrex Return Material Authorization Policy described in your product manual. For some products, Xantrex maintains a network of regional Authorized Service Centers. Call Xantrex or check our website to see if your product can be repaired...

Product and System Information D–4 DISCLAIMER Product THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS, WHERE PERMITTED BY LAW, IN LIEU OF ALL OTHER WARRANTIES, CONDITIONS, GUARANTEES, REPRESENTATIONS, OBLIGATIONS AND LIABILI...

Return Material Authorization Policy D–5 Return Material Authorization Policy Before returning a product directly to Xantrex you must obtain a Return Material Authorization (RMA) number and the correct factory "Ship To" address. Products must also be shipped prepaid. Product shipments will b...

Product and System Information D–6 If you are returning a product to a Xantrex Authorized Service Center (ASC) A Xantrex return material authorization (RMA) number is not required. However, you must contact the ASC prior to returning the product or presenting the unit to verify any return procedures...

Information about your Truecharge + D–7 Information about your Truecharge + Please record the following information when you unpack your Truecharge +unit. : If you need to contact Customer Service, please gather the following information before calling.The information will assist the service represe...

A absorption charge, battery activity during B–3 AC input specifications A–4 AC wiring requirements 2–6 AGM (absorbed glass mat) batteries B–2 AGM batteries, selector switch for 1–3 anti-corrosion grease C–2 B baking soda C–3 batteries AGM (absorbed glass mat) B–2 first aid when working with 1–x mai...