Xantrex Truecharge2 TC2012, Truecharge2 TC1512, Truecharge2 TC4012, Truecharge2 TC5012, Truecharge2 TC6012 Installation Manual

Series Battery Charger

Installation Guide

TC1012
TC1512
TC2012
TC3012
TC4012
TC5012
TC6012

TC1524
TC2024
TC3024
TC5024

10A–12V
15A–12V
20A–12V
30A–12V
40A–12V
50A–12V
60A–12V

15A–24V
20A–24V
30A–24V
50A–24V

This guide for use by qualified installers only

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Truecharge

™

2
Series Battery
Chargers

Installation Guide

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About Xantrex

Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and
controls with products ranging from small mobile units to utility-scale systems for wind,
solar, batteries, fuel cells, microturbines, and backup power applications in both grid­connected and stand-alone systems. Xantrex products inclu de inverters, battery chargers,
programmable power supplies, and variable speed drives that convert, supply, control,
clean, and distribute electrical power.

Trademarks

Truecharge™ 2 Series Battery Char ger is a tr ademark of Xantrex I nternational. 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.

Notice of Copyright

Truecharge™ 2 Series Battery Charger Installation Guide © September 2008 Xantrex
International. No part of this document may be reproduced in any form or disclosed to
third parties without the express written consent of:

Xantrex International
Suite #3, Stafford House, The Garrison,
St. Michael, Barbados

Xantrex International reserves the right to revise this document and to periodically make
changes to the content hereof without obligation or organizatio n of such revisions or
changes unless required to do so by prior arrangement.

Exclusion for Documentation

UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX™”)
(

A) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL

OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.

(

B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES,
WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF
THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE
USER’S RISK; AND

(C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH

STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY
CANNOT BE GUARANTEED. APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH
LANGUAGE VERSION WHICH IS POSTED AT WWW.XANTREX.COM.

Date and Revision Document Part Number

September 2008 Rev B 975-0402-01-01

Product Numbers

804-1210, 804-1215, 804-1220, 804-1230, 804-1240, 804-1250, 804-1260, 804-2415,
804-2420, 804-2430, 804-2450

Contact Information

Telephone: [phone] (toll free North America)

1 408 987 6030 (direct)
[phone] (Europe)

Fax: [phone] (toll free North America)

[phone] (Europe)
Email: [e-mail]
Web: www.xantrex.com

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About This Guide

Purpose

The purpose of this Installation Guide is to provide
explanations and procedures for installing and configuring
the Truecharge™ 2 Series Battery Charger.

Scope

The Guide provides safety guidelines, procedures for
installing the battery charger, as well as information on
configuring the battery charger. It does not provide details
about particular brands of batteries. You need to consult
individual battery manufacturers for this information.

Refer to Truecharge™ 2 Battery Charger Owner’s Guide
(doc. part number: 975-0401-01-01) for operational
instructions.

Audience

The Guide is intended for qualified installers who need to
install and configure any unit model of the Truecharge™ 2
Series Battery Charger. The installer should be a qualified
technician or electrician with knowledge and experience in
installing electrical equipment, knowledge of the applicable
installation codes, and awareness of the hazards involved in
performing electrical work and how to reduce those hazards.

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Organization

This Guide is organized into two chapters and one appendix.
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
Truechar ge™ 2 Battery Char ger including information on the
optional remote panel.

Chapter 2 provides procedures for installing, testing and
configuring the Truecharge™ 2 Battery Charger.

Appendix A contains physical, electrical performance, and
regulatory approval specifications for the Truecharge™ 2
Battery Charger.

Conventions Used

The following conventions are used in this guide.

This Guide contains information for 11 product models of the
Truecharge™ 2 Series Battery Charger.

The 12 Vdc models are: TC1012, TC1512, TC2012, TC3012,
TC4012, TC5012, and TC6012. When being refe rred to
individually, the product will be referred to by its model
name.

WARNING

Warnings identify conditions or practices that could result in
personal injury or loss of life.

CAUTION

Cautions identify conditions or practices that could result in
damage to the unit or other equipment.

Important:

These notes describe things which are important

for you to know, but not as serious as a caution or warning.

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The 24 Vdc models are: TC1524, TC2024, TC3024, and
TC5024. When being referred to individually, the product
will be referred to by its model name.

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

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Important Safety Instructions

READ AND SAVE THIS INSTALLATION GUIDE FOR FUTURE

REFERENCE.

This chapter contains important safety, installation, and
operating instructions for the 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.

2. Do not expose the Truecharge™ 2 Battery Charger to
rain, snow, spray, or bilge water. To reduce risk of fire
hazard, do not cover or obstruct the air intake vent
openings. Do not install the Truecharge™ 2 Battery
Charger in a zero-clearance compartment. Overheating
may result.

3. This appliance is not intended for use by persons
(including children) with reduced physical, sensory, or
mental capabilities or lack of experience and knowledge,
unless they have been given supervision or instruction
concerning use of the appliance by a person responsible
for their safety. Children should be supervised to ensure
that they do not play with the appliance.

WARNING: Risk of injury

T o reduce the risk of injury, charge only properly rated (such as
12 V and 24 V) lead-acid (GEL, AGM, Flooded, or lead­calcium) rechargeable batteries. Other battery types may burst,
causing personal injury and damage.

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4. To avoid a risk of fire and electric shock, make sure that
all wiring is in good condition and is not undersized. Do
not operate the Truecharge™ 2 Battery Charger with
damaged or substandard wiring.

5. Do not operate the Truecharge™ 2 Battery Charger if it
has received a sharp blow, been dropped, has cracks or
openings in the enclosure including if the fuse cover has
been lost, damaged, or will not close, or otherwise
damaged in any other way. If the Truecharge™ 2 Battery
Charger is damaged, see the Warranty section under
Truecharge™ 2 Battery Charger Owner’s Guide (doc.
part number: 975-0401-01-01).

6. Do not disassemble the Truecharge™ 2 Battery
Charger—there are hazardous voltages within. It contains
no user-serviceable parts. See the Warranty section under
Truecharge™ 2 Battery Charger Owner’s Guide (doc.
part number: 975-0401-01-01) for instructions on
obtaining service. Attempting to service the
Truecharge™ 2 Battery Charger yourself may result in a
risk of electrical shock or fire and will void the warranty.
Internal capacitors remain charged after all power is
disconnected.

7. To reduce the risk of electrical shock, disconnect both
AC and DC power from the Truecharge™ 2 Battery
Charger before attempting any maintenance or cleaning
or working on any circuits connected to the T ruecharge™
2 Battery Charger. Turning off using the on/standby
button on the remote panel will not reduce this risk.

8. The Truecharge™ 2 Battery Charger must be provided
with equipment-grounding conductors connected to the
AC input ground and to the DC chassis ground.

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9. Working in the vicinity of lead-acid batteries is
dangerous. Batteries generate explosive gase s during
normal operation. Therefore, it is of utmost importance
that you read this manual and follow the instructions
exactly each time you use the charger .

10. To reduce the risk of battery explosion, 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.

Personal Precautions When Working With
Batteries

1. Have someone within range of your voice or close
enough to come to your aid when you work near a lead ­acid battery.

2. Have plenty of fresh water and soap nearby in case
battery acid contacts skin, clothing, or eyes.

3. Wear proper, non-absorbent gloves, complete eye
protection, and clothing protection. Avoid touching your
eyes and wiping your forehead while working near
batteries.

WARNING: Explosion hazard

WARNI NG: B

ATTERIES PRESENT RISK OF

E

LECTRICAL SHOCK

, B

URN FROM HIGH SHORT

-

C

IRCUIT CURRENT

, F

IRE OR EXPLOSION FROM

V

ENTED GASES

. O

BSERVE PROPER PRECAUTIONS

.

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4. If battery acid contacts skin or clothing, wash
immediately with soap and water. If acid enters yo ur 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.

6. Use extra caution to reduce the risk or dropping a metal
tool on the battery. It could spark or short circuit the
battery or other electrical parts and could cause an
explosion.

7. Remove all personal metal items, like rings, bracelets,
and watches when working with batteries. Batteries can
produce a short circuit current high enough to weld a ring
or metal bracelet or the like to the battery terminal,
causing a severe burn.

8. If you need to remove a battery, always remove the
negative terminal from the battery first for systems with
grounded negative. If it is grounded positive, remove the
positive terminal first. Make sure all loads connected to
the battery and all accessories are off so you don’t cause
an arc.

9. Never charge a frozen battery.

PREPARING TO CHARGE

10. Make sure the area around the battery is well ventilated.

11. Make sure the voltage of the batteries matches the output
voltage of the battery charger.

12. Clean battery terminals. Be careful to keep corrosion
from coming into contact with your eyes and skin.

13. 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.

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14. For flooded non-sealed batteries, add distilled water in
each cell until battery acid reaches the level specified by
the battery manufacturer. This helps to purge excessive
gas from cells. Do not overfill. For a battery without
removable cell caps, carefully follow manufacturer's
instructions.

BATTERY CHARGER LOCATION

15. Locate the Truecharge™ 2 Battery Charger unit away
from batteries 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. Never allow battery acid to drip on the charger when
reading gravity, or filling battery.

18. Do not operate the charger in a closed in area, or restrict
the ventilation in any way.

19. Do not place a battery on top of the charger.

20. For North American marine installations, external
connections to the charger shall comply with the United
States Coast Guard Electrical Regulations (33CFR183,
Sub Part I).

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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. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in
accordance with the instructions, may cause harmful
interference to radio communications.

However, there is no guarantee that interference will not
occur in a particular installation. If this equipment does cause
harmful interference to radio or television reception, which
can be determined by turning the equipment off and on, the
user is encouraged to try to correct the interference by one or
more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and
receiver.

• 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.

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Important Safety Instructions

- - - - - - - - - - - - - - - - - - - vii

1

Introduction

Truecharge™ 2 Battery Charger - - - - - - - - - - - - - - - - - - - - - 1–1
Standard and Protection Features - - - - - - - - - - - - - - - - - - - - 1–2
Truecharge™ 2 Battery Charger - - - - - - - - - - - - - - - - - - - - - 1–4
Rear Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6

2

Installation

Preparing for Installation - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
Wiring Requirements - - - - - - - - - - - - - - - - - - - - - - - - - 2–8

DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–10

Battery Bank Size Requirements - - - - - - - - - - - - - - - - -2–12

Installing the Truecharge™ 2 Battery Charger - - - - - - - - - - -2–13

Installation Sequence - - - - - - - - - - - - - - - - - - - - - - - - -2–13
Mounting the Truecharge™ 2 Battery Charger - - - - - - - -2–14
Connecting the DC Chassis Ground (Earth) - - - - - - - - - -2–15
Installing DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - -2–16
Installing AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - -2–20
Powering Up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–24

Installing Optional Accessories- - - - - - - - - - - - - - - - - - - - - -2–25

Installing the Optional Battery Temperature Sensor (BTS) 2–25
Mounting the Optional Remote Panel - - - - - - - - - - - - - -2–26

Contents

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Configuring the Truecharge™ 2 Battery Charger- - - - - - - - - -2–27

Configuring the Charger Mode - - - - - - - - - - - - - - - - - - -2–27
Configuring the Battery Bank Type - - - - - - - - - - - - - - -2–29
Configuring the Maximum Output Current

Percentage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–30

Installing Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–31

A

Specifications

Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - A–3

AC Input Specifications - - - - - - - - - - - - - - - - - - - - - - - A–3

DC Output Specifications - - - - - - - - - - - - - - - - - - - - - - A–4
Environmental Specifications- - - - - - - - - - - - - - - - - - - - - - - A–5
Protection Features- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–6
Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–7

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1

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.

Truecharge™ 2 Battery Charger

The Truech arge™ 2 Battery Char ger ships with the following
items.

• one Truecharge™ 2 Battery Charger unit

• installation and operation guides

• rubber boots for DC terminals

• nuts and washers

• strain relief clamp for AC input cables

• three crimp connectors for AC wiring

Note: Keep the carton and packing material in case you need to

return the Truecharge™ 2 Battery Charger for servicing.

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Introduction

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Standard and Protection Features

The Truecharge™ 2 Battery Charger provides the following
standard features:

•three

1

full current rated outputs

• battery monitoring functions while in float mode or rest
mode

• correct charging voltage for batteries when connected to
almost any single phase AC power outlet in the world

• low electromagnetic interference (EMI)

• automatic charge resumption, if required, after AC power
interruption

• programmable custom charge settings

2

• fully discharged battery charging

3

The Truecharge™ 2 Battery Charger provides the following
protection features:

• battery reverse polarity protection via a replaceable
output fuse

• AC input out-of-range derating and shutdown

• ambient over temperature derating and shutdown

• battery over-charging protection

• electronic current limiting provides protection against
short circuit conditions on the charger’s output

• ignition protected rating, enabling installation in engine
spaces

• isolated design

1.Model TC1012 has one output and model TC1512 has two outputs. All oth er models
have three outputs. Each output (for models with 2 or 3 outputs) can charge different bat­teries that either have the same chemistry or can tolerate the same charge sequence.

2.The charger can be programmed with custom charge setpoints using PC interface. This
programming can only be done using a special configuration tool operated by Xantrex or a
designated OEM.

3.The charger can initiate charging a non-damaged but zero voltage battery.

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Standard and Protection Features

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• short circuit protection for the BTS and communication
connector ports including protection from incorrectly
inserting the remote panel communication cable plug into
the BTS port and vice versa

• drip-proof rubber boots for DC terminals for added
moisture protection

• IP-32 drip protection rating

1

• locked fan2 protection

The Truecharge™ 2 Battery Charger provides the following optional
features:

• an optional remote panel

3

which can be mounted up to

15 m (50 ft) away for remote control and monitoring.

• an optional battery temperature sensor

4

(BTS) provides
battery temperature voltage compensation from 0 to
70 °C (-13 to 158 °F)

The optional Battery Temperature Sensor (BTS) provides these
protection features:

• battery under temperature charging protectio n preventing
battery charging at -25 °C or below

• battery over temperature charging protection preventing
battery charging at 70 °C or higher

• charging voltage compensati on ba sed on the temperature
of the battery the optional BTS is connected to

1.In two specific installation orientations–see Figure 2-2, “Truecharge™ 2 Battery Char­ger Mounting Orientations” on page 2–7.

2.A locked fan occurs when the fan’s blades are hindered from turning by objects such as
insects or accumulated debris that can obstruct the fan’s operation. The Truecharge™ 2
Battery Charger sounds an alarm if the fan suddenly stops turning. If the fan does not
resume turning after a minute, the charger reports a fault and immediately stops charging.

3.Part number: 808-8040-00

4.Part number: 808-0232-01

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Truecharge™ 2 Battery Charger

This section describes the different parts of the Truechar ge™
2 Battery Charger.

Figure 1-1

Truecharge™ 2 Battery Charger

Item Description

1 Onboard control and status display panel or simply

onboard display (see “Rear Panel” on page 1–6 for

more information) for controlling the Truecharge™ 2
Battery Charger settings and for monitoring charger
status and charging current.

2 Mounting flanges are used to permanently install the

product.

3 DC wiring compartment cover protects the DC

terminals, as well as the communication and BTS ports.
Remove and replace when installing cables.

1

2

6

4

3

5

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