Xantrex Truecharge TC1512, Truecharge TC5012, Truecharge TC2012, Truecharge TC3012, Truecharge TC6012 Installation Manual

TC1012

10A–12V
TC1512
TC2012
TC3012
TC4012
TC5012
TC6012

TC1524
TC2024
TC3024
TC5024

15A–12V

20A–12V

30A–12V

40A–12V

50A–12V

60A–12V

15A–24V

20A–24V

30A–24V

50A–24V

Installation Guide

Series Battery Charger

This guide for use by qualified installers only

™

Truecharge

2
Series Battery
Chargers

Installation Guide

This guide for use by qualified installers only

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 © June 2008 Xantrex
International. All rights reserved.

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

June 2008 Rev A

Part Number

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

This guide for use by qualified installers only

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 model unit of the Truecharge™ 2
Series Battery Charger. The installer should be a qualified
technician or electrician.

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.

This guide for use by qualified installers only

iii

About This Guide

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.

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:

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

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

The 12V 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.

The 24V 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.

These notes describe things which are important

Related Information

You can find more information about Xantrex Technology
Inc. as well as its products and services at www.xantrex.com

iv 975-0402-01-01

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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.

CAUTION: 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.

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.

This guide for use by qualified installers only

v

Safety

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

5. The use of any attachments not recommended or sold by
Xantrex, may result in risk of fire, electric shock, or
injury to persons.

6. Do not operate the Truecharge™ 2 Battery Charger if it
has received a sharp blow, been dropped, has cracks or
openings in the enclosure (especially when the fuse cover
has been damaged and will not close), or otherwise
damaged in any other way. If the Truecharge™ 2 Battery
Charger is damaged, see the Warranty section.

7. Do not disassemble the Truecharge™ 2 Battery
Charger—there are hazardous voltages within. It contains
no user-serviceable parts. See Warranty 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 your
warranty. Internal capacitors remain charged after all
power is disconnected.

8. 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.

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

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WARNING: Explosion hazard

10. 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 each time before servicing the charger in the vicinity
of the battery, that you read this manual and follow the
instructions exactly.

11. To reduce the risk of battery explosion, follow these
instructions and those published by the battery
manufacturer and the manufacturer of any unit yo u
intend to use in the vicinity of the battery. Review
cautionary markings on these products and on the engine

Safety

Personal Precautions When Working With
Batteries

WARNING: B

LECTRICAL SHOCK

E

IRCUIT CURRENT

C

ENTED GASES

V

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.

ATTERIES PRESENT RISK OF

, B

URN FROM HIGH SHORT

, F

IRE OR EXPLOSION FROM

. O

BSERVE PROPER PRECAUTIONS

-

.

975-0402-01-01 vii

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Safety

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 metal
to skin, causing a severe burn.

8. If you need to remove a battery, always remove the
ground terminal from the battery first. Make sure 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.

14. 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.

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BATTERY CHARGER LOCATION

15. Locate the Truecharge™ 2 Battery Charger unit away
from batteries as practical 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).

Safety

975-0402-01-01 ix

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Safety

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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Contents

Important Safety Instructions
1

Introduction

Truecharge™ 2 Battery Charger - - - - - - - - - - - - - - - - - - - - - 1–1
Standard and Protection Features - - - - - - - - - - - - - - - - - - - - 1–2
Truecharge™ 2 Battery Charger - - - - - - - - - - - - - - - - - - - - - 1–4
Rear Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Onboard Control and Status Display Panel - - - - - - - - - - - - - - 1–8
Remote Panel (Sold Separately) - - - - - - - - - - - - - - - - - - - - -1–15

2

Installation

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

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

- - - - - - - - - - - - - - - - - - - - v

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

Battery Bank Size Requirements - - - - - - - - - - - - - - - - -2–11

Installing the Truecharge™ 2 Battery Charger - - - - - - - - - - -2–12

Installation Sequence - - - - - - - - - - - - - - - - - - - - - - - - -2–12
Planning DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - -2–13
Planning AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - -2–15
Mounting the Truecharge™ 2 Battery Charger - - - - - - - -2–18
Make the Final Connections - - - - - - - - - - - - - - - - - - - -2–19

Installing the Drip Protection Rubber Boots - - - - - - -2–20
Final DC Connections - - - - - - - - - - - - - - - - - - - - - -2–20
Final AC Connections - - - - - - - - - - - - - - - - - - - - - -2–22
Grounding Instructions - - - - - - - - - - - - - - - - - - - - -2–23

Powering Up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–23

This guide for use by qualified installers only

xi

Contents

Installing Optional Accessories- - - - - - - - - - - - - - - - - - - - - -2–24

Mounting the Optional Remote Panel - - - - - - - - - - - - - -2–24
Installing the Optional Battery Temperature Sensor (BTS) 2–25

Configuring the Truecharge™ 2 Battery Charger- - - - - - - - - -2–26

Configuring the Charger Mode - - - - - - - - - - - - - - - - - - -2–27
Configuring the Battery Bank Type - - - - - - - - - - - - - - -2–29
Configuring the Battery Temperature without the BTS - -2–30
Configuring the Maximum Output Current Percentage - - -2–31

Installing Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–32

A

Specifications

Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - A–3
AC Input Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - A–5
DC Output Specifications - - - - - - - - - - - - - - - - - - - - - - - - - A–6
Temperature Specifications - - - - - - - - - - - - - - - - - - - - - - - - A–6
Protection Features- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–7
Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–8

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1

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
including information on the optional remote panel.

Introduction

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

• ring terminals, nuts, and washers

• strain relief clamp for AC input cables

This guide for use by qualified installers only

Introduction

Standard and Protection Features

The T ruecharge™ 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 your batteries when
connected to almost any single phase AC power outlet in
the world

• low electromagnetic interference (EMI)

• automatic charge resumption after AC power interruption

• programmable custom charge sequence

• fully discharged battery charging

3

2

• an optional remote panel4 which can be mounted up to
15 m (50 ft) away for remote control and monitoring.

• an optional battery temperature sensor

5

(BTS) provides
battery temperature voltage compensation from -25 to
70 °C (-13 to 158 °F)

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.

4.Part number: 808-8040-00

5.Part number: 808-0232-01

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Standard and Protection Features

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

• reverse polarity protection via an output fuse to guard
against reverse battery polarity

• AC input out-of-range protection shutdown

• ambient over temperature protection 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

• over temperature and short circuit protection for the BTS
and communication connector ports

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

• IP-32 drip protection rating

1

• fan lockout protection

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

• battery under temperature charging protectio n preventing
battery charging at -20 °C or below

• charging current compensation for different battery
temperatures

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

975-0402-01-01 1–3

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Introduction

Truecharge™ 2 Battery Charger

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

1

3

2

5

Figure 1-1

Item Description

1 Onboard control and status display panel or simply

2 Mounting flanges are used to permanently install the

Truecharge™ 2 Battery Charger

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.

product.

4

6

3 DC wiring compartment cover protects the DC

1–4 975-0402-01-01

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

Truecharge™ 2 Battery Charger

Item Description

4 Fuse access panel cover provides access to the DC fuse

in the event of an accidental reverse polarity installation.

5 AC wiring compartment cover provides the installer

with easy access to the AC wiring compartment, to
allow for a trouble free installation. Remove and replace
when installing the product.

6 DC ground stud for connecting the char ger’s chassis to

ground.

975-0402-01-01 1–5

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Introduction

Rear Panel

This section describes the parts of the rear panel of the
Truecharge™ 2 Battery Charger.

7

8

5

6

40 A model (TC4012) shown. Other models may vary.

Figure 1-2

Item Description

1 BTS port- battery temperature sensor port

Truecharge™ 2 Battery Charger Rear Panel

4

3

2

1

2 Communication port - remote panel port
3 Battery positive (+) for bank 3 (6 mm stud)
4 Battery positive (+) for bank 2 (6 mm stud)
5 Battery positive (+) for bank 1 (6 mm stud)

6 Battery negative (–), common for all three banks

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See Important note below.

(6 mm stud)
(common for both banks in model TC1512)
(model TC1012 has a single bank only–one positive
terminal and one negative terminal)

Rear Panel

Item Description

7 Air intake vent - located inside is the fan assembly
8 AC wiring - line, neutral, and ground input wires

Important:

When installing only a single bank (or one
battery) for Truecharge™ 2 Battery Chargers that have
multiple outputs, positive bank 1 must be utilized. Bypassing
bank 1 and using any of the other banks (bank 2 or bank 3)
may render the charger to function improperly.

975-0402-01-01 1–7

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Introduction

Onboard Control and Status Display Panel

This section describes the parts of the onboard control and
status display panel of the Truecharge™ 2 Battery Charger.

Important:

means that the button must be held down for more than three
seconds then released in order to send the instruction. A “press”
action on any panel button means that the button must be pressed
and released before two seconds have elapsed.

1
3

4

5

6

A “press and hold” action on any panel button

2

Figure 1-3

Onboard Control and Status Display Panel

To reduce current draw from the connected battery when AC
power is not present, the panel’s LED control and status
lights are automatically turned off and the buttons are
disabled.

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Onboard Control and Status Display Panel

Item Description

1 Charging Output (%) LEDs

• The LEDs illuminate like a progress bar displaying the present
total output charge current as a percentage of the set maximum
charge current. The numbers below the LEDs represent the
percentage values. See Figure 1-4 on page 1–11.

• A single LED may flash intermittently in combination with a solid
Fault LED (indicating a fault) or with a flashing Fault LED
(indicating a warning). The icons above the LEDs represent the
various types of fault and warning conditions. See Figure 1-4 on
page 1–1 1.

2 Fault LED

The LED may illuminate a solid light (indicating a fault) or fl ash
intermittently (indicating a warning) in combination with flashing
Charging Output (%) LEDs. See Table 1-1, “Fault and Warning
Indicators” on page 1–11 for details.

3 Charger Status LEDs

Displays the current status of the charger.

• Ready - a solid light indicates batteries are fully charged and in
rest stage.

• Ready and Charging - solid lights indicate batteries are fully
charged and in float stage.

• Charging - a solid light indicates charger is performing a normal
charge cycle.

• Equalize - a solid light indicates that the charger is performing an

equalization cycle.

- a flashing light indicates that the equalization cycle
will begin after the absorption stage is done.

4 Charger Mode Select button

• Press and hold the button for three seconds to select either of two
settings. An indicator LED corresponds to each setting. Each
setting optimizes the charging sequence differently in charging the
batteries by stages.

•Three-stage - Bulk, Absorption, and Float; default setting

•Two-stage - Bulk and Absorption only

• When setting or cancelling an Equalization program: Press and
hold both the Battery Temp. Select and Charger Mode Select
buttons.

975-0402-01-01 1–9

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