Xantrex XC2524 - Manual

v Important Safety Instructions 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. 2. Do not expose the XC Series to rain, s...

Safety vi 975-0187-01-01 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...

Safety 975-0187-01-01 vii 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 immedia...

975-0187-01-01 ix Important Safety Instructions Explosive Gas and Battery Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi FCC Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vii 1 Introduction Xantrex XC3012, XC...

Contents x 975-0187-01-01 Installing Optional Accessories- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13 Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13Drip Protection Rubber Boots - - - - - - - - - - - - - - - - - - - ...

1 Introduction Chapter 1 describes the XC Series standard features. It also provides information to prepare for installation of the XC Series. XC_Charger_Owner.book Page 1 Friday, August 12, 2005 3:23 PM

Introduction 1–2 975-0187-01-01 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 ...

XC Series Appearance 975-0187-01-01 1–3 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 1 Remote display for all programming functions and monitoring of the XC Series. 2 Onboard status panel for monitoring ...

Introduction 1–4 975-0187-01-01 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. Figure...

Introduction 1–6 975-0187-01-01 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 1 Charge Current• Displays the output charge current in % of charger maximum for ...

Rear Panel 975-0187-01-01 1–7 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 1 Remote display communication connector 2 BTS1 (battery temperature sensor for bank 1) connector 3 BTS2 (ba...

Introduction 1–8 975-0187-01-01 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. ...

Preparing for Installation 975-0187-01-01 1–9 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 • drill bit for pilot hol...

Introduction 1–10 975-0187-01-01 Location Install the XC Series in a location that meets the following requirements: When planning where and how to mount the XC Series, be sure the installation allows the charger to be mounted in one of the permitted vertical or horizontal orientations. For marine i...

Introduction 1–12 975-0187-01-01 Wiring Requirements DC Wiring The following two tables show some typical wire sizes, based on 3% voltage drop (round circuit), 75 °C (167 °F) rated wire and wiring being inside the engine compartment – assumed ambient of 50 °C (122 °F). WARNING Wire and fuse sizes ar...

Preparing for Installation 975-0187-01-01 1–13 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 ...

Introduction 1–14 975-0187-01-01 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 XC 1524 XC 2524 XC 3012 XC 5012 Minimum Battery Bank Size (Ah...

2 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 • One battery temperature sensor (BTS) • Five #6 ...

Installation 2–2 975-0187-01-01 Installing the XC Series Installation Sequence To make charger installation quick and easy, Xantrex recommends that the installation tasks be performed in the following sequence: 1. Select charger mounting position and plan AC and DC cable routing (page 1–8) 2. Instal...

Installing the XC Series 975-0187-01-01 2–3 Pre-Installing DC Wiring The procedure for installing the DC wiring applies to a single battery or multiple batteries or battery banks. To install DC wiring: 1. Identify the battery or bank that most frequently becomes deeply discharged. This bank will oft...

Installation 2–4 975-0187-01-01 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 u...

Installing the XC Series 975-0187-01-01 2–7 Mounting the Remote Display To accommodate the charger mounting orientation, the remote display can be removed and turned 180 ° for readability. If you intend to mount the display remotely, up to 20 m (65 ft), remove the display before mounting the charger...

Installation 2–8 975-0187-01-01 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. A standard North Americ...

Installing the XC Series 975-0187-01-01 2–9 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 ...

Installation 2–10 975-0187-01-01 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 5 2 6 3 7 4 8 9 10 12 13 14 1 11 15 XC_Charger_Owner.book Page 10 Friday, Aug...

Installing the XC Series 975-0187-01-01 2–11 Final DC Connections 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), ...

Installation 2–12 975-0187-01-01 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 ...

Installing Optional Accessories 975-0187-01-01 2–13 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 (BT...

Installation 2–14 975-0187-01-01 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 e...

Configuring the XC Series 975-0187-01-01 2–15 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 tim...

Installation 2–16 975-0187-01-01 To configure the charging type: 1. Press and hold MODE until set (setup) is displayed. 2. Press MODE to select 2-stage ( 2st ) or 3-stage ( 3st ) charging. When you have selected a charging type that is different from the present configuration, the bank indicator lig...

Operation 3–2 975-0187-01-01 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...

About Charging 975-0187-01-01 3–3 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 minut...

Operation 3–4 975-0187-01-01 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 charg...

About Charging 975-0187-01-01 3–5 Things to be aware of When the XC Series is operating, fans and lights (DC loads) may vary in speed or intensity. This is normal. The XC Series will not harm any load connected to it as long as there is a battery present on that bank. When you initially turn the XC ...

Operation 3–6 975-0187-01-01 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 disconn...

Charging Batteries 975-0187-01-01 3–7 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...

Operation 3–8 975-0187-01-01 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 no ...

Equalizing Flooded Batteries 975-0187-01-01 3–9 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 elec...

Operation 3–10 975-0187-01-01 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 ON / STANDBY on the remote display if AC is still connected. There are two ways to disable the XC Series: • disconnect AC power at th...

Accessing Charger Information 975-0187-01-01 3–11 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 happe...

Accessing Charger Information 975-0187-01-01 3–13 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 c...

Operation 3–14 975-0187-01-01 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 M...

Accessing Charger Information 975-0187-01-01 3–15 ◆ Press ON / STANDBY on the optional remote display to initialize another 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 p...

4 Troubleshooting Chapter 4 contains information on error codes and procedures for troubleshooting your XC Series charger. XC_Charger_Owner.book Page 1 Friday, August 12, 2005 3:23 PM

Troubleshooting 4–2 975-0187-01-01 Care and Maintenance The XC Series 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 power and ...

Indicator Light Flashing Sequences 975-0187-01-01 4–3 Indicator Light Flashing Sequences Table 4-1 Indicator Light Sequences on the XC Series Activity Charger status Charging indicator light illuminates The unit is charging in bulk or absorption mode Charging indicator light flashes The unit is perf...

Troubleshooting 4–4 975-0187-01-01 Error Messages on Remote Display Table 4-2 Error Messages Display Onboard Status Panel Indicator lights Fault Solution ERR Red fault indicator light flashing or illuminated Fault A fault has been detected. The fault code will be shown immediately after Err. ACL AC ...

Problem Solving 975-0187-01-01 4–7 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 pr...

A Specifications Appendix A details the specifications for the XC Series. XC_Charger_Owner.book Page 1 Friday, August 12, 2005 3:23 PM

Specifications A–2 975-0187-01-01 Physical Specifications Electrical Specifications Dimensions Base unit: 367 mm x 240 mm x 106 mm14.45 in. x 9.45 in. x 4.17 in. Remote Display: 118 mm x 41 mm x 32 mm 4.65 in. x 1.6 in. x 1.26 in. Weight 5.7 kg (12.6 lbs) AC input connections Two color-coded No. 16 ...

AC Input Specifications 975-0187-01-01 A–3 AC Input Specifications Float voltage (in VDC for XC3012 and XC5012)(Multiply VDC by 2 to get the float voltage for XC1524 and XC2524) 50 °C (122 °F) 25 °C (77 °F) < 0 °C (32 °F) Flooded 12.8 13.5 14.2 Gel 13.1 13.8 14.5 AGM 12.9 13.4 13.9 Lead-calcium 1...

Specifications A–4 975-0187-01-01 Temperature Specifications Protection Features Nominal ambient 25 °C (77 °F) Operating range 0 – 50 °C (32 – 122 °F) Current de-rating approx. 2% (Imax) / °C (50 – 65 °C) (122 – 149 °F) Storage -40 – 80 °C (-40 – 176 °F) Humidity 5 – 95%, RH non-condensing Battery r...

Approvals 975-0187-01-01 A–5 Approvals Safety CSA/NRTL approved to CSA107.2 and UL1236, including the marine supplement, ignition protection, and UL1564EN60335-1, EN60335-2-29 Battery ChargersISO 8846: Ignition Protection for Small CraftABYC E11 - Alternating Current and Direct Current Electrical Sy...

975-0187-01-01 WA–1 Warranty and Product Information Limited Warranty for: Xantrex XC3012 Battery Charger Xantrex XC5012 Battery ChargerXantrex XC1524 Battery ChargerXantrex XC2524 Battery Charger "XC Series" What does this warranty cover and how long does it last? This Limited Warranty is p...

Warranty and Product Information WA–2 975-0187-01-01 What does this warranty not cover? This Limited Warranty does not cover normal wear and tear of the product or costs related to the removal, installation, or troubleshooting of the customer's electrical systems. This warranty does not apply to and...

975-0187-01-01 WA–3 WARNING: LIMITATIONS ON USE Please refer to your product user manual for limitations on uses of the product. Specifically, please note that the Xantrex Battery Charger is not intended for use in connection with life support systems and Xantrex makes no warranty or representation ...

Warranty and Product Information WA–4 975-0187-01-01 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. If you need to contact Customer Service, please r...

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: [email protected] (North America)s...