Xantrex XC1524, XC2524, XC5012 Owner's Manual

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XC_Cha rger_Owner .book Page 1 Friday, August 12, 2005 3:23 PM

Xantrex XC3012, XC5012, XC1524 and XC2524

Battery Charger

Owner’s Guide

12 V / 30 A 12 V / 50 A 24 V / 15 A 24 V / 25 A

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Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Charger

Owner’s Guide

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About Xantrex

Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobi le units to one MW util ity -sca le syste ms for wind, sol ar, batteries, fuel cells, microturbin es, a nd backup power applic ations in bot h grid- conn ecte d and stand-a lone syst ems. Xantrex products include inverters, battery chargers, programmable power supplie s, and variable speed drives that convert, supply, control, clean, and dis tribute electrical power.

Trademarks

Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Charger is a trademark of Xa ntrex International. Xantrex is a registe r ed trademark of Xantrex Inter national.

Other trademarks, regist ered trademarks, and product names are the prope rty of their respective owners and are us ed herein for identification purposes only.

Notice of Copyright

Disclaimer

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 LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMAT ION WILL BE ENTIRELY AT THE USER’S RISK.

Date and Revision

August 2005 Revision B

Part Number

975-0187-01-01

Contact Information

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: customerservice@xantrex.com (North America)

support.europe@xantrex. com (Europe) customerservice@xantrex.com (rest of world)

W eb: www.xantrex.com

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About This Guide

Purpose

The purpose of this Owner’ s Guide is to provide explanations and procedures for installi ng, ope rating, maintaining, and troubleshooting the Xantrex XC3012, XC5012, XC1524 a nd XC2524 Battery Charger.

Scope

The Guide provides safety guidelines, detailed planning and setup information, procedures for installing the charger, as well as infor mation about operating and troubleshooting the unit. It does not provide details about particular brands of batteries. Consult individual battery manufacturers for this information.

Audience

The Guide is intended for anyone who needs to install and operate the Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Charger. Installers should be certified te chn i cian s or elect ri cians.

Organization

This Guide is organized into 4 chapters and 1 appendix: Chapter 1, “Introduction”: Chapter 1 describes the XC Series standard features. It

also provides infor mation to prepare for installation of the XC Series. Chapter 2, “Installation”: Chapter 2 provides procedures for installing, testing and

configuring the XC Series. Chapter 3, “Operation”: Chapter 3 describes the opera ting states and provides

procedures for charging a battery and perfor ming an equalization. Chapter 4, “Troubleshooting”: Chapter 4 contains informa tion on error codes and

procedures for troubleshooting your XC Series charger. Appendix A, “Specifications”: Appendix A details the specifications for the

XC Series.

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About This Guide

Conventions U sed

The following conventions are used in this guide.

WARNING

Warnings identify conditions or practices that co uld result in personal injury or loss of life

CAUT ION

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

Important:

serious as a caution or warning.

This Guide contains informati on for four versions of the XC Series. The Xantrex XC3012 Battery Charge r (12 V, 30 A) will be referred to as the

XC3012 when it is being reference d individually. The Xantrex XC5012 Battery Charge r (12 V, 50 A) will be referred to as the

XC5012 when it is being reference d individually. The Xantrex XC1524 Battery Charge r (24 V, 15 A) will be referred to as the

XC1524 when it is being reference d individually. The Xantrex XC2524 Battery Charge r (24 V, 25 A) will be referred to as the

XC2524 when it is being reference d individually. When the Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Chargers are

being refere n ced toget h er, they will be referred to as the XC Series.

These notes describe things which are im portant for you to know, but not as

Relat ed Informatio n

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

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Important Safety Instructions

WARNING

This chapter contains important safety and operating instructions as prescribed by safety standards for chargers used in RV and marine applications. Read an d keep this Owner’s Guide for future reference.

1. Before installing or using the Xantrex XC3012, XC5012, XC1524 or XC2524 Battery Char ger (XC Series), read all instr uctions and cautionary markings on the XC Series, the batteries, and all appropr iate sections of this guide.

2. Do not expos e the XC Series to rain, snow, spray, or bilge wate r. To reduce risk of fire hazard, do not cover or obst ruct the ventilation openings. Do not install the XC Series in a zero -c le ara n ce comp a rt me nt. Overheating ma y resul t.

3. Use only attachments rec ommended or sold by Xantrex. Doing otherwise may result in a risk of fire, electric shock, or injury to persons.

4. The XC Series is designed to be permanently connected to the AC and DC electric al systems. Xantrex recommends that all wiring be done by a certified technician or electrician to ensure compliance with the local and national electrical codes relevant to your installation. I t is the responsibility of the installer to ensure that the installation of the XC Ser ies complies with all relevant el ectri ca l cod es.

5. To avoid a risk of fire and electric shock, make sure that existing wiring is in good condition and that wire is not undersiz ed. Do not operate the XC Series with damaged or substandard wiring.

6. Do not disassemble the XC Serie s. I t contains no user-serviceable parts. Attempt ing t o serv ice t he X C Series your self may res u lt in a risk of elec tric al shock or fire. NOTE: Disassembling the XC Series will void your warranty.

7. To reduce the risk of electrical shock, disconne ct both AC and DC power from the XC Series before attempting any maintenance or cleaning or bef ore working on any circuits connected to the XC Series. Turning the XC Series off using the remote displ ay will not reduce this risk.

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Safety

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 applicat ions in the United States, external connections to the charger shall comply with the United States Coast Guard Electrical Regulations (33CFR183, Sub part 1).

Explosive Gas and Battery Prec autions

W ARNING: Explosion or fire ha zard

1. Read this guide and follow the instructions exactly before installing or using your XC Series.

2. Follow all instru ctions published by the battery manufacturer and the manufacturer of the equipment in which the battery is instal led.

3. Working in the vicinity of lead-acid batteries is dangerous. Batte ries generate explosive gases dur ing normal operation.

4. The XC Series has been approved as Ignition Protected. It may be installed in areas containing ga soline tanks and fittings which require Ignition Prote cted equipment. Xantrex recommends, nevertheless, that it is safest not to install electrica l equi p me nt in the s e area s.

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

6. Never smoke or allow a spark or flame near the engine or batteries.

7. Use caution to reduce the risk of dropping a metal tool on the battery. It could spark or short circu it the battery or other electric al parts and could cause an explosion.

8. Remove all metal items, like rings, bracelets, and watc hes when working with lead-acid batteries. Lead-acid batteries produce a short circuit current high enough to weld metal, causing a severe skin burn.

9. Have someone within range of your voic e or clos e enough to come to your aid when you work near a lead-acid battery.

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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 w ork i ng near batt eri es.

12. If battery acid c ontac ts skin or clothin g, wash immedia tely wit h soap a nd water.

If acid enters your eye, immediate ly flood it with running col d water for at least twenty minutes and get m edical attention immediately.

13. If you need to remove a battery, always remove the ground terminal from the

battery firs t. Make sure al l accessories are off to reduce the possibility of causing a spark.

Safety

FCC Information

This equipment has been tested and found to comply with the limits for a Class B digital device, pursua nt to part 15 of the FCC Rules. These limits a re designed to provide reasonable protection again st harmful interference in a residential installati on. Thi s equipment g enerat es, uses, and can radi ate radio f requenc y ener gy and, if not installed and used in accordance with the instructions, may cause harmful interf erence to radio communications .

However , there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful int erference to radio or television reception, which can be determ ined 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 conne cted.

• Consult the deal er or an experienced radio/TV techni cian for help.

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Contents

Important Safety Instructions

Explosive Gas and Battery Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi FCC Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vii

Introduction

Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Charger Features - - - - - -1–2 XC Series Appearance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Information Centers of the XC Series- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Remote Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Onboard Status Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6 Rear Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7 Preparing for Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8

Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9

Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10

Wiring Requirement s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–12

DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–12 AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13

Battery Bank Size Require ments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14

Installation

Installing the XC Series - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

Installation Sequence - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

Pre-Installing DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3

Pre-Installing AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4

Mounting the Remote Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7

Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8

Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9

Final Connection s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10

Final DC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11 Final AC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12

Powering Up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12

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Contents

Installing Optional Accessories- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13

Battery Temperat ure Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13 Drip Protectio n Rubber Boots - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14

Configuring the XC Series- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–15

Operation

About Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

Multiplex 3-Sta ge Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2 Sequential 2-Stage Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3 Charging Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3

Charging Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6 Equalizing Flooded Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8 Transitioning the XC Series to On, Disabled or Off - - - - - - - - - - - - - - - - - - - - - - 3–10 Accessing Charger I nformation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11

Reading Remote Display and Onboard Status Indicator Lights - - - - - - - - - - - 3–11 Reporting While Chargi ng or Equalizing - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13 Reporting While Batte ry Monitoring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–14 Reporting While Disab led - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–14 Using A Generator As Source Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–15

Troubleshooting

Care and Maintenance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 Indicator Light Flashing Sequences- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3 Error Messages on Remote Display- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4 Problem Solving - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7

Specifications

Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2 Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2 AC Input Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3 Temperature Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4 Protection Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4 Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–5

Warranty and Product Information

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- - - - - - - - - - - - - - - - - - - - - - - - - - WA–1

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Introduction

Chapter 1 describes the XC Series standard features. It also provides information to prepare for installation of the XC Ser i es.

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Introduction

Xantrex XC3012, XC5012, XC1524 and XC 2524 Battery Charger Fe atures

The XC Series provides the following standard features:

• three full current rated, independently controlled outputs which enable it to charge thr ee dif ferent ba tter ies or batter y banks. Each bank can be of a diffe rent battery type, stage of charging, and temperature compensation

• one battery temperature sensor (BTS) is included. Optional BTSs may be purchased for the other two outputs, to pr ovide complete optimal battery charging to each battery or bank

• battery moni toring functions while in float mode or rest mode

• correct c harging voltage for your batt eries when connec ted to almost any single phase AC power outlet in the world

• invertable remote display panel which can also be removed from the char ger and mounted up to 20 m (65 ft) away for remote contr ol and monitoring

The XC Series provides the following protection features:

• true “fusele ss” reverse polarity protection to guard against continuous reverse battery polar ity without charger damage

• AC over voltage protection shutdown

• over temperature prote ction shutdown

• electr onic current limiting for prote ction against short circuit on the unit’s output

• built-in pr otection against accidental connection to a higher battery voltage, up to 24 VDC

• battery te mperature compensation to 0 °C (32 °F) (with BTS installed)

• igniti on protected rating, enabl ing installation in engine spaces

• isolated design to reduce shock hazard

• automatic charge resumption afte r AC power interruption

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XC Series Appearance

This section describes the parts of the XC Series. Figure 1-2 shows the XC Series.

XC Series Appearance

Figure 1-1

Item Description

1 Remote display for all programming f unctions and monitoring of the XC Series. 2 Onboard status panel for monitoring charger status and charging current at the

3 Mounting flanges

XC Series

XC Ser ies when the remote display is mounted remotely from the charger.

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Introduction

Infor m ation Centers of the XC Serie s

Remote Display

This section descr ibes the parts of the remote display of the XC Series. The remote display ca n be rotated 180°, or it c an be removed and r emotely mounted up to 20 m (65 ft) from the XC Serie s for convenience. Figure 1-2 shows the remote display.

A “press and hold” action on the remote display means that the button must be held down for more than 2 seconds in order to send the instruction. A “press” action on the remote display means that the button must be pressed and released before 2 seconds have elapse d.

2 3 4 5

Figure 1-2

Item Description

2 Battery bank indicator lights

ON/STANDBY push button

• Press to turn on or dis able the charger while AC power is connected

• Press and hold to ap ply s election when in setup or equalization mode

• Press to show battery bank voltages when AC is disconnected

• Illuminate to show which bank has been sele cted for setup or status display

• Illuminate during a fault or warning to show which bank has the fault or warning, or illuminate all three if th e charger itself has the faul t or war n ing

XC Series Remote Display

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Item Description

3 Alpha-numeric display shows

• Configuration

• Fault or warning mess ages (see Table 4-2 on page 4–4)

• Battery bank volt age and current

• Type of charging (2 stage or 3 stage)

• Sta te of charge

4 Units indi cator lights

• Illuminate to show unit of measure for the numeric read-out on the alpha -numeric display

Information Centers of the XC Series

BANK selection pus h button

• Press to select a bank during setup

• Press at the same time as

TYPE selection push button

MODE to enter o r exit equalization mod e.

• Press to selec t flooded (lead acid), gel, AGM, or lead calcium batteries.

MODE selection pus h button

• Pre ss to sele ct c harg i n g st at e du r i ng s et u p : 2 st ag e o r 3 stag e.

• Press at the same time as

BANK to enter or exit equalization mode.

• Press and hold to enter setup.

The indicator li ghts and dis pla y are also use d to indicate error codes. See Chapter 4, “Troubleshooting” for a list of faults and how to clear them.

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Introduction

Onboard Status Panel

This section describes the parts of the onboard status panel of the XC Series. Figure 1-3 shows the panel.

2 3

Figure 1-3

Item Description

1 Charge Current

• Displays the output charge c urrent in % of charger m aximum for the bank being charged

• 100% indicator light flashes to indicate batte r y temperature too high (> 50 °C, 122 °F)

• 10% indicator light flashes to indic ate battery temperature too low (< 0 °C, 32 °F)

• 25% indicator light flashes to indicate that a bat tery has been disqualified (see page 3–4)

Charger Status -

• Ready indicator light illuminated indicates all batteries are fully c harged, and are now in float or rest

Charger Status -

• Charging indicator ligh t illuminated indicates unit is performing a normal cha rge cycle

• Charging indi cator lig ht flash ing indi cates that the unit is perform ing an equali zati on cycle

Charger Status -

• Fault indica tor light continuously illum inated indicates any fault condition that prevents the XC S eries from charging one or more batterie s, but is not a charger fai lure - remote display shows details of fault

• Fault indicator light flashing indicates the XC Series has experienced a charger failure remote display shows

XC Series Onboard Stat us Panel

READY

CHARGING

FAULT

err

followed by

CHf

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Rear Panel

This section de scribe s the pa rts of the rear panel of the XC S eries. Figure 1-4 shows the rear panel.

Rear Panel

Bank3Bank

Figure 1-4

XC Series Rear Panel

Item Description

1 Remote display communication connector 2 BTS1 (battery temperature sens or for bank 1) connector

2 3

4 1

3 BTS2 (battery temperature sens or for bank 2) connector 4 BTS3 (battery temperature sens or for bank 3) connector 5 Battery negative, common for all 3 banks (6 mm stud) 6 Battery posi tive for bank 1 (6 mm stu d) 7 Battery posi tive for bank 2 (6 mm stu d) 8 Battery posi tive for bank 3 (6 mm stu d) 9 Fan ass e mb l y 10 Chassis ground (ear th) for DC wiring 11 AC wiring access panel

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Introduction

Preparing for Installation

The XC Series is designed to be permanently mounted. Figure 1-1 shows a typical installation with three batteri es, a BTS and a remote display. It also shows the AC and DC wiring and protection device s required for a successful installation.

L N G

Figure 1-5

XC Series System

1 AC mains source with correct size and type of circuit break er 2 AC input wiring compartment 3 DC negative cable 4 DC positive cables 5 DC circuit bre aker or DC fuse and disconnect 6 Battery or ba ttery bank 7 Engine ground bus or DC negative bus 8 Remote display pa nel 9 Battery temperature sensor (#1 is standard equipment. #2 a nd #3 are optional) 10 DC chassis ground (ea rth)

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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 fo r pilot holes for mounting screws

• wire stripper

• manufacturer's recommended crimp tool for any crimp terminals that are being used

You need the foll ow in g mate ri als:

• 3 conductor AC input wiring Use the inf ormation in “AC Wiring” on page 1–13 and your local electr ical codes to determine the corr ect wire and breaker or fuse.

Preparing for Installation

• AC cable strain relief (if the one inc luded is not sufficient for your local electrical code requirements)

• appropri atel y sized D C ca bles for each b atte ry, with suitable connectors at the battery end

• appropria tely sized DC chassis ground (earth) with suitable connectors

• ring termin als to fit 6 mm (1/4 in.) studs at the charger end

• DC fuse and disconnect or circuit breaker for each battery bank

• mounting hardware, 3 mm (#6) corrosion resistant 6 pieces.

• other means to route and secure AC and DC wiring

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Introduction

Location

Install the XC Series in a location that meets the foll owing requirements:

Condition Requirement

Dry The XC Series must be installed in a dry location not subject to rain, spray or splashing

bilge water.

Clean The XC Series should not be exposed to metal filings or any other form of conductive

contamination.

Cool The ambient air temper ature should be between 0 °C - 50 °C (32 °F - 122 °F) for best

performance.

Ven t il at ed Ther e mus t be at le as t 76 mm (3 in . ) o f clearance on each en d o f the XC Series f or ai r

flow. Ventilation openings on the unit must not be obstructe d. If mounting in a tight fitt i ng co mp artm en t, th e co m p a rt m e n t m u st be v en tilat ed w it h cut -outs to prevent overheating.

Safe This battery charger is ignition protected, so it can be installed in areas containing

gasoline tanks or fittings which usually require ignition protected equipment. Xantrex recommends, however, that it is safe st not to install electrical equipment in these areas.

Close to batteries

The XC Series should be ins talled as close as possible to the batteries, but not in the same compartment to prevent excess corrosion. Avoid exces sive cable leng ths and use the recommended wire sizes . Xant rex recommends <3% wire voltage drop (r ound circuit) on battery cables under ful l load.

When planning where and how to mount the XC Series, be sure the installati on allows the char ger to be mounted in one of the permitted vertica l or horiz ontal orientations. For marine install ations, only the mounting configur ations with a check mark in Figure 1-6 meet the North American an d European marine requirements. Marine products are requi red to meet drip tests, to ensure safety in the presenc e of condensatio n. I f you are cert ain your installation is not subject to moisture, configuration d) in Figure 1-6 may be used.

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a) b)

Preparing for Installation

Vertical

c) d)

Horizontal

Figure 1-6

XC Series Mounting Orientations

Vertical - this c onfig uration i s uns afe and should not be used

Vertical - this configuration may be used in an envi ronment wh ich i s dry and cl ean only (non-marine)

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Introduction

Wiring Requirements

WARNING

W i r e and fuse sizes are dictated b y electrical standards. Diffe rent standards apply in different countries and differ ent types of installations, for ex ample, boat, home or RV. It is the responsibility of the installer to ensure that the installation complies with al l applicable standards.

CAUT ION

Ensure that both wires and fuses are cor rec tly sized. Maximum conti nuous curre nt ava ilabl e fro m the char ger may be an additi ona l 6–10% a bov e the nominal current rating of the charger. Output current may also vary depending on ambient temperature conditions.

DC Wiring

The following two tables show some typic al wire sizes, based on 3% voltage drop (round circui t), 75 °C (167 °F) rated wire and wiring being inside the engine compartment – assumed ambient of 50 °C (122 °F).

Table 1-1

Wire Len g th (

maximum length one way) Wire Size (AWG and mm

feet meters XC3012 XC5012 XC2524 XC1524

51.5No. 10

7.5 2.25 No. 8

20 6 No. 6

DC Wiring Requirements

5mm

8mm

13 mm

No. 6 13 mm

No. 4 19 mm

)

No. 10

5mm

No. 10

5mm

No. 10

5mm

No. 12 3mm

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Over-current protection disconnect

The DC circuit from the battery to the char ger must be equipped with a disconnect and over-c urrent protection device. The device usually consists of a DC-rated circuit breake r, a “fused disconnect”, or a separate fuse and disconnect. These devices must be rated for DC voltage and current. Do not substitute devic es rated only for AC voltage; they may not operat e properly.

The current ratin g of the DC fuses must be matched to the size of the DC wiring used, in accor d ance w ith t he appli cab le co des .

The DC chassis ground (earth ) should not be more than one size smaller than the DC wiring size selected (s ee Table 1-1). Refer to your local electrical codes for verification.

Preparing for Installation

AC Wiring

The AC wiring must meet the following requi rements before you install the XC Series:

The AC input wiring for the XC Series should be three-conductor cable, providing a line, neutral, and ground conductor (or L1, N,

GND) in an outer jacket.

For example, in North America for 120 VAC use a 14 AWG wire with a 15 A breaker; or typic ally in Europe for 230 VAC use either a 2.5mm

wire with a 16 A, double pole br eaker or fuse o r use 1.5 mm2 wire with a 1 0 A, double pole breaker or fuse. Note that every jurisdiction will have different requirements, so see the regulation s for your local jurisdiction to determine which wire size and type is correct. A sec o nd example:

• for marine applic ations the United States ABYC requires stranded wire, which

is more robust than solid wire when exposed to vibration

• for RV applications, the United States NEC allows solid wire in multi-

conductor cable, but stranded wire will withstand vibration better.

The circuit supplying the XC Series must be protected by the correct size and type of breaker to meet the code for your local jurisdiction and application. If a fuse is used, a discon nect swi tch is ne eded ahead o f the fus e.

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Introduction

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

Models XC 1524 XC 2524 XC 3012 XC 5012 Minimum Battery

Bank Size (Ah)

Minimum Battery Bank Size

30 50 60 100

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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 lockwas hers

• Five #6 flatwashers

• Five #6 nuts After unpacking the unit, record the serial number and

other purchase information on page WA–4 of this guide.

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Installation

Installing the XC Series

W AR NING: Shock and En ergy Hazards

Be sure to read the safety guidelines and pay attenti on to all cautions and warnings throughout the installat ion procedure. The ins taller is resp ons ible for ensuring compl iance with the insta llation codes for your pa rticular application. Disconnect all sources of AC and DC power before proceeding.

Installation Sequence

To make charger installation quic k and easy, Xantrex recommends tha t the installation tasks be performed in the following sequence:

1. Select charger mounting position and p lan AC and DC cable routing (page 1–8)

2. Install DC cable runs and fuses or breakers (page 2–3)

3. Make the AC connections at the charger (page 2–4)

4. Mount the remote display and charger in position (page 2–7)

5. Make the final DC and then AC cable connections (including earth grounds) (page 2–10)

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Pre-Installing DC Wiring

The procedure for installing the DC wiring applies to a single battery or multiple batteries or battery banks.

W ARNING: Shock or arc burn hazard

To help prevent accidental shorts or sparks, leave the DC disconnects or breake rs in the Off position or fuses removed from their fuse holders until installation is com plete.

Installing t he XC Series

Important:

terminals to provide drip protection and incre ased protection from short circuit s. You need to install the boots before doing any othe r DC wiring. See “To install rubber boots:” on page 2–14.

Xantrex recommends that you in stall t he r ubber boot s over the XC Series DC

To install DC wiring:

1. Identify the bat tery or bank that most frequently becomes deeply discharged.

This bank will ofte n be a deep cycle battery referr ed to as the House Bank on a boat, as opposed to an engine Start Battery. This high priority bank should be connected to bank 1 on the XC Series, which is the default bank.

2. Plan the route that the DC wires will follow, keeping it as short as possible.

Measure and cut the requir ed wire length. Allow some extra length for connections and to provide slack in the wires. Note: The con nection to the battery negative circuit may not be at a battery, but may be at an engine negative bus or a DC negative bus. If in doubt, consult the boat schematics.

3. Identify the positive wires, by using color-coded wire or by marking both ends

of the wire with c olored ta pe or simi lar k ind of marking. Repeat with a dif f erent color for the negat ive. Most install at ion codes recommend col oring the positive red and the negative black.

Important:

bank it is connected to. F or example, bank 1 (–), ba nk 1 (+), bank 2 (–).

Yo u m ay fi n d it he lp f u l to labe l each ca bl e, asso ci a ting it wi t h th e batter y

4. Install a DC circuit breaker or fuse/disconnect in each positive cable close to

each batte ry. For your appli cations a nd juri sdiction , consu lt you r loc al electr ical codes regarding the distance betwe en th e battery and the disconnect device. Be sure the breaker is open or fuse is not inserted at this time.

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Installation

5. Route the wiring to the batteries and to the XC Series, but don’t connect it yet. A void routing wir ing through an electri cal distributio n panel, battery isolator , or other device that will a dd voltage drops.

6. Install crimp lugs on each end of the battery cables using the crimp manufacturer’s instructions and tool.

7. Install rubber boots over the charger end of the DC cables. Xantrex recommends that you install rubber boots over the XC Series DC terminals to provide drip protection. Follow the procedure on page 2–14 to install rubbe r boots.

8. Route the battery temperature sensor from each battery to the charger location.

9. Proceed to “Pre-Installing AC Wiring”.

Pre-Installing AC Wiring

Before connecting AC wiring, make sure the AC source circuit is protecte d by a breaker switch of the correct size and type, to comply with the electrical code for your location and appl ication.

To install AC wiring:

1. Disconnect the AC source by turning off the breaker feeding the circuit, unplugging from sho repower and disconnecting any other power sources (s uch as a generator).

2. Plan the route that the AC wiring will follow from the source (usually an AC distribut ion panel) to the XC Series. Measure and cut the required length of three-condu ctor cable. For example, in North America for 120 VAC use a 14 AWG wire with a 15 A breaker; or typic ally in Europe for 230 VAC use either a 2.5mm 16 A, double pole breaker or fuse or use 1.5 mm breaker or f use. Note that e very jur isdi ction wil l have dif ferent r equir ements, so see the regulations for your local jurisdiction to determine which wire size and type is correct. Allow some extra length for connections and to provide slack.

wire with a

wire with a 10 A, double pole

3. Make the AC connections to the back of the charger when it is sitting on a table or other convenient wor k surface. Route the AC cables to the source after the charger is mounted in position.

4. Unscrew the wiring compart ment cover from the left rear of the XC Series to expose the AC wiring access hole.

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5. Insta ll the cab le strai n rel ie f on the XC Series end o f the source AC cable.

6. Carefully re move 50 – 75 mm (2 – 3 in.) of the outer j acket, being care ful not to

cut or nick the insulat ion on the individual conductors.

7. Pull the XC Series pigtail wires out through the access hole.

8. Thread the source AC cable through the knockout beneath the wiring

compartment cover and then pull it out thr ough the access hole.

Installing t he XC Series

9. Connect the AC wiring to the XC Series pigtail wires, being sur e to connect the

line conductor to the line, the neutral to the neutral, and the ground to the ground. The pigtail wires are color coded as follows:

Conductor Color code

Line Black or brown Neutral White or blue Ground Green with yellow strip e

10. Make the connections with twist-on or crimp-on connectors or with other

approved connector s suitable for your installation. For example, the ABYC Standards and Recommended Practices for Small Craft prohibit twist-on connectors for AC connections on a boat. For non-marine installa tions in locations not subject to vibration, either type of c onnector may be used. For marine installations, follow the procedure for insta lling butt splice connectors.

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Installation

To connect AC wires with the crimp-on butt-splice connector:

Important:

You must exercise care when crimping butt-splice connectors. Use the

crimp tool recommended by the manufacturer for the connector us ed.

a) Using a wire stripper, carefully strip 8 mm (5/16 in.) from the ends of the

two wires be ing connected.

b) Insert one wire into one end of the butt-splice, until the insulation hits the

internal metal crim p section, insert the butt-splice into the crimping tool, and crimp firmly. The proper location for the crimp is approximately

1.6 mm (1/16 in.) past where the butt-splice insulation tapers down as shown.

1/16 “

STRIP 5/16”

CRIMP TOOL

c) Repeat Step b for the ot he r end of the butt-s p li ce.

11. Push the AC cable stra in relie f into t he el ectrica l jun ction box hole unti l it snaps into place.

12. When all connections are completed, push the wiring and connectors inside the wiring compartment. Install the wiring compartment cover and fasten with t he supplied blunt-tip screws and lockwashers.

13. Proceed to “Mounting the Remote Display” .

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Mounting the Remote Display

WARNING: Shock hazard

Even if you int end to leave the remote display in the shipped orientation in the XC Series, you must remove the remote display and secure it in place by removing the non-stick backing on th e rea r and pre ssing the remote display flange s in place. If you do not use the non-stick backing, the XC Series will not be drip protected.

To accommodate the charger mounting orientation, the r emote 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 and secure the blank plat e to cover the display socket on the unit.

Installing t he XC Series

CAUT ION

Ensure you are plac ing the display in the correct orientation before removing the ad hesive backing. The adhesive tape for attaching the remote is extremely strong and you may be unable to remov e it without damaging the display or other equipment.

To remove the display:

1. Unplug the display cable from the telephone-type connect or on the back of the

unit.

2. Release the display cable from the retaining clips on the underside of the unit.

3. Remove the remote display from the c harger and read and then remove the

warning label that is attached to it.

To secure the display or blank plate on the unit:

1. Choose the display orie ntation that is appropriate f or the charger orientation.

2. Remove the adhesive backing on the back of the display or blank plate .

3. Line up the display or blank plate with the display socket, making sure it is in

the chosen orientation.

4. Firmly press the flange s in place. Do not press in the middle of the display.

5. Route the display’s North American style telephone-type cable under the unit

and plug the cable into the bottom connec tor on the rear panel of the unit.

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Installation

To remot ely mo un t the display:

1. Remove the display as describe d 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 installa tion. A standard North American style , 4 conductor (RJ-1 1) telephone cabl e exten der is adequate.

4. Use the enclosed mounting template to cut a hole for the display in the c hosen mounting surface. Take care that there is nothing behind the surface for you to damage.

5. Feed the remote display extension cable through the hole and route it to the charger. Be careful not to damage the telephone conne ctor locking tab when routing the cable . You can use some tape to protect the locking tab from catching on something and breaking off when routing the cable.

6. Remove the adhesive backing on the back of the display.

7. Line up the display with the mounti ng hole.

8. Firmly press the flange s in place. Do not press in the middle of the display.

9. Once the XC Series is mounted, plug the cable i nto th e bottom connec tor on th e

10. Proceed to “M ounting”.

Mounting

Mount the XC Series using the mounting slots provided. For marine install ations, only the mounting configur ations with a check mark in

Figure 1-6 on page 1–11 meet the North American and European requirements. This is to ensure that a ny moisture that may be present will not enter the XC Series.

Important:

before drilling the pilot holes for mounting the XC Series.

To mount the XC Series:

rear panel of the XC Series.

Be sure to measure you r AC and DC cable s and plan th e routing of the c ables

1. Keep the carton and pa cking material in c ase you need to return the XC Series for servici ng.

2. Ensure that you have selected a mounting surface that is clear, flat and allows for a minimum of 76 mm (3 in.) of clearance on each end for fan circulation.

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3. Secure the enclosed mounting template to the m ounting surface with tape.

4. Drill the six pilot holes for the mounting screws, taking care that there is

nothing behind the sur face that can be damaged by the drill.

5. Mount the XC Series using corrosion resistant, #6 (3 mm) round, pan head (or

similar) sc rews . The top two keyhole-style moun ting holes can be used to hold the XC Series in place while f astening the bottom four screws. For secur e, permanent mounting, use all six mounting slot s.

Grounding

WARNING: Electric shock hazard

Installing t he XC Series

Do not make an ungrounded installation. Have an electri cian install a properly grounded circuit if one is not available. Im proper connection can result in risk of an electric shock.

The XC Series Battery Charger must be grounded to reduce the risk of electrical shock. The AC input ground wire of the charger must be properly connect ed to ground in accordance with the applicable electrical codes, this is usually a ground terminal in the AC distri bution panel where the branch circui t originates.

Xantrex recommends that you install a DC chassis ground (earth ) from the ground stud on the XC Series to the engine negat ive bus or DC ground bus. The DC chassis ground (ear th) should not be more than one size smaller than the power c onductors, and must be rat ed for the battery f uses that are used to protect the DC wiring. Refer to your local electrical codes to verify if this is requir ed in your jurisdiction or in your application.

Proceed to “F inal Co nn ecti o ns ”.

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Installation

Final Connections

Once the DC cable s , AC cab les and XC Series are al l in pl ace the fina l con nect i on may be made.

Figure 2-1 shows the connection order.

263

Figure 2-1

DC Wiring Connection Order

9 11 13

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Final DC Connections

WARNING: Shock hazard

Make sure that the DC fuse or ci rcuit breaker is still open.

To make the last DC connections:

1. Connect t he 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), to the negative DC terminal on the XC Series (Figure 2-1). Use a flatwasher, a lockwasher and a nut (5 included in the installa tion kit) to secure the connection. Tighten the nuts to 3 N-m (30 lb-in.) torque and test that the wire is secure.

Installing t he XC Series

2. Connect each positive cable to the correct positive DC terminal on the XC Series (Figure 2-1). Use a flatwasher, a lockwasher and a nut (5 included in the installa tion kit) to secure the connection. Tighten the nuts to 3 N-m (30 lb-in.) torque and test that the wire is secure.

3. Connect the free end of each positive cable to the correct positive terminal of the battery, using sufficient torque as recommended by your battery manufacturer.

4. Connect the free end of the negative cable to the negative terminal on the battery, using sufficient torque as recommended by your battery manufacturer. Note: If you are using more than one batte ry, you will need to connect the negative ca ble from each of t he batteries to the negative ground bar or bus. The negative ground ba r or bus will then have a single negative cable connecting to the negative charger terminal.

5. Before proc eeding, carefully check the wiring polarity – make sure the positive terminals of the XC Series are connected to the correct terminals of the battery (fuses or br eakers) and from there to the positive terminals of the battery. Make sure the negat ive terminal of the XC Series is connect ed to the battery negative terminal (or engine negative bus/DC negative bus). Do not reverse the connections.

6. Install the DC chassis gr ound (earth) from the ground stud on the XC Series to the engine negativ e bus or DC ground bus.

7. Connect the BTS cable and the remote display cable to the rear of the charger.

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Installation

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 connections:

1. Complete the installation by routing the AC cable to the AC source.

2. Connect the AC cable to the AC disconnect bre aker and ground in accordance with the color codes on pa ge 2–5.

3. Secure cables in place using tie-wraps, P-clamps or cable straps according to electrical codes.

Powering Up

Make one last check that all connections and connectors are secure . The XC Series charger may now be powered up. Switch the AC powe r on at the

source breaker. It is normal to see a 7-10 second de lay while the unit powers up. During this time, the indicator lights on the onboard status panel and the remote display will not disp lay any information.

At very low AC source volta ges (for example, less than 105 VAC) the start up time will increase proportionally up to as much as 40 seconds.

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Installing Optiona l Ac c essories

The XC Series ships with a battery temperature sensor (BTS) and drip prote ction rubber boots for the DC cables.

Battery Temperature Sensor

Xantrex strongly r ecommends that you install a Battery Temperature Sensor (BTS) to protect your batte ry and improve charging accuracy. It is best to use a separate BTS with each individual bat tery bank, to provide optimal char ging and protection of each bank. If no BTS is connected, the charger defaults to the charging conditions for 40 °C (104 °F). At this tem perature the charging voltage is lower to keep batteries f rom overc harging; charging will be slower and the batter ies will be slightly unde rcharged.

Installing Optional Accessories

One BTS is provided with with your XC Series and additional battery temperature sensors may be purchased separately.

To install a BTS:

1. Switch off al l devices operating from the battery.

2. Connect the ri ng terminal on the sensor directly on to the negative batte ry stud,

or affix the double-sided adhesive backing (included) to the sensor back and attach the sensor to the side of the battery to be monitored.

3. Route the s ensor cable to the char ger and plug it i nto t he bank 1 ( default if usi ng

only one BTS), bank 2 or bank 3 connector on the rear panel.

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Installation

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 connectio ns to the char ger, feed the rubber boot over the charger end of the DC cables.

2. Perform all other DC connect ions as described in “To install DC wiring:” on page 2–3.

3. After the DC cables are connected to the charger, slide the boot up the cables and over the DC terminals. If you are only usi ng one battery, slide the spare boots over the unused DC terminals.

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Configuring the XC Series

Once the charge r 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 r eporting. The remot e display will use this time to query the char ger for the current operating conditions.

Configuring the XC Series

If AC was already applied, ensure that the char ger is in on by pres sing

ON/STANDBY

if necessary.

To configure the battery bank type:

1. Press and hold

2. Press

TYPE to select the battery type configuration programming mode.

MODE until

set

(setup) is displayed.

The XC Series will default to Bank 1 and will show the present battery type setting.

3. Press

BANK repeatedly to select which bank you are setting up. The bank

indicator li ght will illuminate to show which bank has been selected.

4. Press

TYPE repeatedly to select the battery type for each bank. When you have

selected a batte ry type that is different from th e present configuration, the bank indicator li ght flashes. Set th e

If y o ur batte ry is then select

Flooded Lead Acid (has remov able caps intended for refilling)

TYPE a ccording to the table below:

FLa

GEL (any sealed type exc ept AGM) Absorbed Glass Mat (AGM) Lead Calcium Custom (i f p re-configured at factory)

5. Press and hold

ON/STANDBY until

yes

is displayed to store the selec ted battery

GEL AGM LdC CUS

type. If no is displayed, verify that you are set ting the correct battery type and try again.

6. Repeat steps 1 th rough 4 for all ba nks attac hed to the XC Series. Each time

yes

is displayed for a newly prog rammed batte ry type, the charg er exits the programming mode.

7. At any time during setup, you can pr ess

ON/STANDBY once to cancel the current

change and return to charging or battery monitor ing.

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Installation

To configure the charging type:

1. Press and hold

2. Press

MODE to select 2-stage (

MODE until

set

(setup) is displayed.

2st

) or 3-stage (

3st

) charging. When you have selected a charging type that is different from the present configuration, the bank indicator light flashes. See “About Charging” on page 3–2.

3. Press and hold ON/STANDBY until

4. At any time during setup, you can pr ess

yes

is displayed to store the selected mode.

ON/STANDBY once to cancel the current

change and return to charging or battery monitor ing.

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Operation

Chapter 3 describes the operating states and provides procedures for charging a ba tte ry and performing an equalization.

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Operation

About Charging

The XC Series has three full current r ated, independently controlled outputs which enable it to charge three different batteries or battery banks. Each output c an accommodate any one of the four allowable battery types, regardless of what battery types are connected to the other outputs. Each output can be in a different stage of charge, ralative to the other banks; for exampe, Ba nk 1 in float, Bank 2 in absorption and Bank 3 in bulk. Each bank can accommoda te a separate battery temperature sensor. The XC Series can also perform either multiplex (3 stage) charging, or sequential (2 stage) charging.

Important:

common negative .

The battery banks are not galvanically isolated from each other. They share a

Multiplex 3-Stage Charging

In multiple x charging mode the charger will check all qualified battery banks every 15 seconds to determine which bank is most in need of char ging. That bank will then be char ged for the ne xt 15 seconds. Every 15 minutes the char ger wi ll quer y all outputs and detect whic h battery banks are present and healthy.

The multiplex charging mode employs the 3-stage char ging algorithm: Bulk, Absorption, and Float. During the Bulk stage the battery is accepting high c urrent. In the Absorpti on stage the batte ry volt age is held c onstant and the current de cline s. A battery will also "gas" (produce hydr ogen and oxygen) during this stage. Finall y, in the Float stage, the charger continues to provide voltage at a lower level to maintain t he battery in a fully charged state. If there is no load on the battery, it will typically dr aw very li ttl e current . The char ger, however, is able to pr ovi de curren t to its full ra ting to power DC loads on the battery. In float, if batteries are very new or a battery is on the low end of the size range and if it is fully charged to the point where it will n ot acc ept any mo re curr ent , then t he cha rger will ent er an ad ap tive float/no flo at behaviour where it will alternate between float charging ( resting the battery (

rdy

flo

) and

The charger will restart the charging cycle in the Bulk stage if the battery voltage drops below 12.5 V (12 V units) or 25 V (24 V units) for 15 minutes. Afte r 21 days, the charge r will automatically rest art charging in order to refresh the batteries.

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Sequential 2-Stage Charging

In sequential charging mode the charger will check all battery banks ever y 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 char ged for the next 15 minutes.

The sequential charging mode employs the 2-stage charging algorithm. It is the same as the 3-stage algorithm except that there is no float stage; after the absorption stage the charge r stops providing voltage and current to the battery and enters a "rest stage". Like the 3-stage algorithm, the charger will restart the charging cycle in the Bulk stage if the battery voltage drops below 12.5V (12 V units) or 25 V (24 V units) for 15 minute s. After 21 days, the charger will automatically restar t charging in order to refresh the batteries.

About Charging

Charging Overview

The XC Series will perform a battery detec tion sequence every 15 minutes, or on reapplicat ion of AC, to determine which battery banks are present a nd healthy.

If you connect a battery when AC is disconnected, the remote will not recognize it until the unit has perf ormed a battery detection with AC applied.

To force a battery detection sequence,

1. Turn off AC.

2. Wait approximately 20 seconds or until all l ights on the charger or remote have

gone out .

3. Turn on AC.

The charger will then perform a battery detection when AC is reapplied

The charge r does not charge the ba nks in a pre-determined sequence . The bank most in need of charging is the one that receives the charge. For example, if B ank 1 and Bank 2 are both charged, but Bank 1 has a load and Bank 2 does not, then the charger may rar ely cha rge Bank 2 .

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Operation

Disqualified Batteries

The XC S eri es can ide n tify wh en a batt ery will not accep t a charge (bat t ery is damaged) or whe n it is fully charged (healthy) and does not require further charge. Batteries that will not accept a charge will be removed (disqualified) from the chargi ng sequenc e until a ll ba nks ar e checked aga in (eve ry 15 mi nutes). A da maged battery will continue to be disqualified eac h cycle and the charger will not waste energy trying to charge it. Under some conditions it is also possible that a healthy battery that is ful ly charged but unable to accept current (for example, at the moment it tra nsitions from Absorpti on to Float or Rest ) will be deemed un able to be charged and tempra rily removed from the charging se quence. The charger will enter an adaptive float /no fl o at behaviour wh ere it will alte rn ate be t ween fl oat charg ing

flo

) and resting the battery (

( the onboard status pan el will flash. The battery will be eval uated every 15 minutes and added back to the charging sequence when it is later able to accept charge.

rdy

) and the 25% Charge Current indi cator light on

If disqualification occurs during Bulk or Absorption, the battery is damaged or there is another charging source present other than the charger itself. The remote display will show

dis

and the 25% Charge Current indicator light on the onboard

status panel will flash.

Measuring Battery Voltage

Use a voltmeter that has a state d accura cy of 0.5% or better on DC voltage. Place the probes of the meter directly on the studs or plates of the charger terminals. Do not probe on the wire lugs or other places in the battery wir ing system as this will introduce error into the measurement: the char ger monitors battery volta ge as measured at the ch arge r termi nal s .

Tem per a ture Con s ider at ion s

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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 tur n the XC Series on and configure it, it is possi ble that some banks may be disqualified. Because the charger is able to detect unhealthy batterie s and disqualify them, bat teries that may have appeared healthy be fore will now be correctl y iden tified as need i ng att entio n .

Perform these disqualification checks in the order shown:

1. Wait 15 minutes for the next battery detecti on cycle . The warning may be

temporary.

2. Verify that the battery meets the minimum AmpHour rating (XC1524: 30 Ah,

XC2524: 50 Ah, XC3012: 60 Ah, XC5012: 100 Ah)

About Charging

3. Try adding a sm all DC load.

4. Replace the battery.

975-0187-01-01 3–5

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Operation

Chargin g B atteries

Before you start to c harge 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 batter y, by opening a disconnect switch, or by switching the loads off.

2. Ventilate the are a aro und the battery thoroughly. Review the charging instructions supplied by the manufacturer of your batteries and take any steps required.

3. Apply AC power to the XC Series by closing the AC breaker and/or applying shorepower or turning the gener ator on. The indicator ligh ts will blink as an initiali zation sequence runs, lasting typically 10 seconds. After initial ization the charging indicator light illum inates. During charging, the charging current indicator lights show the total current being delivere d to the sele cted battery bank as well as any DC load applied.

4. Re-connect all loads to the battery, by closing a disconnect switch, or by switching the loads on.

The batteries can be in one of six different stages:

Mode Remote Display

Bulk mode Absorption mode Rest mode (2-stage charging) Float mode (3-stage c harging) Equalize mode Battery fault

bUL AbS rdy FLo EqU err

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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 a nd ready for use. If you sele cted the 3-sta ge chargi ng mode, the XC Series is in float mode and will maintain the ba tteries’ charge.

Rest mode If you selected the 2-stage char ging mode, the ready indicator light shows the charge r is now in rest mode and is checking battery voltage and elapsed time since the last ch arge cyc le .

With either char ging mode, the XC Series will begin a charging cycle 21 days after the last cycle, or when battery voltage drops to below 12.5 V (12 V units) or 25 V (24 V units) for 15 minutes.

Charging Batteries

975-0187-01-01 3–7

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Operation

Equalizi ng Fl oode d Ba tteries

About Equaliz ing

The XC Series equalizes only flooded lead-acid or le ad-calcium batterie s. It does not equalize sealed le ad-acid batteries since they can be damaged by this process.

In the following conditions the remote display will show not enter equalization mode:

• the batter y type is set for Gel or AGM

• any bat tery is not fully charge d (all three battery banks must be charged to float or rest stage before equaliz ation can be activated on any bank)

• there is an active fault on the battery you are trying to charge

and the XC Seri es wil l

Xantrex recommen ds that you run a normal cha rg e cycle on the ba tterie s before you equalize the m.

W ARNING: Explosion hazard

During equalization, the battery generates explosive gases. Follow all the battery safety precautions listed in this guide. Ventilate the area around the battery thoro ughly and ensure that t h ere are no sources of flame or spar k s in the vicini ty

CAUTION: Risk of battery damage

The XC Series cannot automatic ally determine when to stop the equalization of a battery. You must monitor the battery speci fic gravity thr oughout equalization to determine the end of the equaliz e cyc le. 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 manually, but may not be sufficiently short to prevent battery damage.

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Performing An Equalizati on

Turn off or disconnect all DC loads on the batter y during equalization. The volta ge applied to the batte ry during equalization may be above the safe le vels for some loads.

To equalize your batteries:

1. Check the batter y elec trolyte level. If necessary, refill with distill ed water only.

All the cells should have similar electrolyte leve ls. If the levels are widely diffe rent, it will influence the relative concentration of acid, thereby affecting the specific gravity measurements.

2. Verify that all banks are in either float or rest mode.

Equalizin g Flooded Batteries

3. Press

4. Press

MODE and BANK at the same time. BANK to select which bank you wish to equalize. The bank indicator light

will flash to show which bank has been sele cted.

5. Press and hold

ON/STANDBY to put the XC Series into equaliza tion mode.

You can cancel the equalizat ion reque st by pressing ON/STANDBY once. If the battery cannot be equalized, the display will show no. Check that the battery is f looded and in float mode.

EQU

6. When the charger is in equalize mode, the display w ill show

7. Monitor the sp ecific gravity of each cell of the ba ttery during equalization with

a battery hydrometer. The equalize cycle will terminate in one hour. Check the specific gravity of each cell and repeat the equaliz ation cycle until they all meet the battery manufacturer’s specifications for specific gravity or until the specific gravity stabilizes rela tive to each other for an hour.

8. The charger au tomatically exits equaliz ation to float mode or rest mode after 1

hour. To manually exit equalization mode early, press

MODE and BANK at the

same time and then press and hold ON/STANDBY. You can cancel the manual exit request by pressing ON/STANDBY once.

9. When equalization has finished, check the battery electrolyte level. If

necessary, refill with distille d water only.

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Operation

Transitioning the XC Series to On, Disabled or Off

There are two ways to turn the XC Series on:

• connect AC power at the sourc e

• press

ON/STANDBY on the remote displa y if AC is still connected.

There are two ways to disable the XC Series:

WARNING: Shock hazard

The XC Series still has li ve volta ge while disabl ed. Even when AC power is removed, if th e XC Series is connecte d to a bat tery on bank 1, the uni t will take powe r from the battery. The only time th e XC Series is de-energized compl etely is when both AC and DC are disconnected.

• disconnect AC power at the source

• press

The XC Series continues to monitor the batteries, but will not charge them.

There is only one w ay to safel y turn th e X C Series off:

• disconnect the AC power at the source and disconnect all DC batterie s.

This is the only state where the XC Series is completely discharged. When the XC Series is disabled or off, the remote display is inactive.

ON/STANDBY on the remote display.

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Accessing Charger Information

The XC Series can give you a lot of information about the status of the charger and the batterie s.

Reading Remote Display and Onboard Status Indicator Lights

The remote display and onboar d status panel show what is happening during the chargi ng process and are also helpful in trouble s hooting. Refer to Chapter 4, “T roubleshooting” for more information about interpreting the remot e display and onboard status ind icator lights.

The remote display is designed to report on the active status of the charger. While the unit is charging, the remote display reports only on the battery be ing charged at that moment. It does not report the status of other batteries.

Accessing Charger Information

The Ready light on the onboard status indicator panel only illum inates when all connected banks have reached float (

) of 3-stage charging or rest (

rdy

) of 2-

flo

stage charging. If one of the three batteries has been disqualified before it reaches float/rest stage, while the others have reache d float ( (

rdy

) of 2-stage charging , the Ready light on the onboar d status indic ator panel will

flo

) of 3-stage charging or rest

not illuminate.

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Operation

Table 3-1

Reading XC Series Status

Charger Status

Charging in bulk or absorptio n mode . Remote display shows scrolling display of charging state, battery voltage in volts and charging current in amps. Indicator lights indicate the charging current in % of full ch ar ge . A t tr a n sit io n po i n ts wh en th e cu r r en t is changing, two indicator lights may flash alternate ly, then settle into the new charging current reading.

Equalizing. Charging indicator light flashes once every four seconds if b ank 1 is being e quali zed, t wic e ever y four seconds if bank 2 is being equalized, and three times every four seconds if ban k 3 is being equalized.

Float mode of three stage charging or rest mode of two stage charging. All batteries have been fully charged.

Remote Display Onboard S tatus Indicator Lights

BUL

Charging indicator light illuminates

ABS

EQU

FLo

Charging indicator light flashes

Ready indicator lig ht illuminates

Rdy

A battery has been disqualif ied while in float mode of three stage char ging or rest mode of two stage charging.

A battery has been disqualified while in bulk or absorption mode.

Non-charger fault condition. Any fault condition that prevents the charger from charging one or more banks, but is not a charger failure. Remote display shows details of fault.

3–12 975-0187-01-01

FLo or rdy

dis

ERR BAT PoL

(example)

25% current indicator light flashes

Fault indicator ligh t illuminates

XC_Cha rger_Owner .book Page 13 Friday, August 12, 2005 3:23 PM

Accessing Charger Information

Table 3-1

Charger Status

Battery too hot fault

Battery too cold fault

Charger fault condition. The charger is damaged, contact service.

Reading XC Series Status

Remote Display Onboard Status Indicator Ligh ts

ERR HoT

ERR CLD

ERR CHF

Reporting While Charging or Equalizing

After configura tion, 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 bei ng charged:

• Charging Stage

Fault indicator ligh t illuminated 100% current indicator light flas hes

Fault indicator ligh t illuminated 10% current indicator light flashes

Fault indicator ligh t f lashes

• Battery Voltage

• Charger Cur rent If there is a fault or warning related to one of the banks, the fault or warning

information will display in the scrolling display before the charging sta te for the bank presently being charged. Charging for banks not in fault will continue (see “Error Messages on Remote Display” on page 4–4). Charging for the bank in fault will resume once the fault condition is cleared.

975-0187-01-01 3–13

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Operation

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 (aff ecting all banks), all charging will be suspended until the charger fault is resolved (see “Error Messages on Remote Display” on page 4–4).

The remote will display al l of the fol lowing, in order:

• Highest level c harger fault or warning (if present)

• Bank 1 Highest level bank fault or warning (if present)

• Bank 1 Charging S tage

• Bank 1 Battery Voltage

• Bank 1 Charger Curr ent

• Bank 2 Highest level bank fault or warning (if present)

• Bank 2 Charging S tage

• Bank 2 Battery Voltage

• Bank 2 Charger Curr ent

• Bank 3 Highest level bank fault or warning (if present)

• Bank 3 Charging S tage

• Bank 3 Battery Voltage

• Bank 3 Charger Curr ent

Reporting While Disabled

If AC power has been disconnected or if you have used the remote display to disable the XC Series the unit is considered to be disabled. The remote display is also disabled at this tim e.

While the XC Series is disa bled, you may wish to see the present status of the banks.

To view the present status of the banks:

◆ Press

ON/STANDBY.

If AC power is disconnected, the remote display will show one cycle (similar to the battery monitor cycle) for each bank that was qualified as present and healthy during the last batte ry detection cycle. The remote display will turn itself off after one complete cycle.

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◆ Press ON/STANDBY on the option al remote display to initialize another cycle.

If AC power is co nn ected , the X C S eri e s wi ll turn on, ch eck which battery banks are present and healthy, and begin charging.

While the XC Series is off, and a fault is present, the remote display will turn itself on approximately once per minute to show the fault and th en turn itse l f o ff.

Using A Generator As Source Power

The XC S eri e s can b e run from a regular pow er sou rce or fro m an alte rnat e power source such a s a generat or. Refer to Appendix A, “Specif icati ons” for AC input dra w to de termine the size of gene rator you nee d. Many g enerat ors provide output voltage that is modified sine wave or m odified square wave (MSW) rather than the true sine wave (TSW) that your utility provides.

Accessing Charger Information

The XC Series may be used with MSW generators but the lifetime may be reduced somewhat depen ding on the severity of any peak voltage overshoots, and the severity of waveshape risetimes.

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3–16

XC_Cha rger_Owner .book Page 1 Friday, August 12, 2005 3:23 PM

Troubleshooting

Chapter 4 contains information on error codes and procedures for troubleshooting your XC Series charger.

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Troubleshooting

Care and Mai n ten ance

WARNING: Risk of electric shock

The XC Series contains no user serviceable components. Attempti ng any kind of service will void your warr anty. Contact your de aler or the manufacturer for service information.

The XC Series contains solid-sta te electronic components tha t 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 clean the outside of the case and wiring with a damp cloth if you suspect it has come in contact with batte ry fluid, salt water, gasoline or oil, or other corrosive mate rial. Periodic ally, check all DC a nd AC wiring co nnecti ons to be s ure they have not loosened or deteriorated. Also check all cable clamps to ensure they are tightly fas tened.

Loose battery te rminals and lugs e xposed to open ai r corr ode rapidly. The corrosion appears as a white powde r or granular foam on the terminals and any nearby exposed metal parts . If it contacts your skin, it will cause burns unless you rinse it off immediately. Most textiles that a re exposed to this corrosive eventually dissolve.

To clean battery terminals:

1. Disconnect all loa ds and charging sources.

2. Using the appropria te tool, remove the negati ve battery cable first and re-insta ll it la s t.

3. To remove any stubborn residue, sprinkle baking soda directly on the area, scrub with a wet toothbru sh (or other soft-bristle brush), add water as required, and then rinse.

CAUT ION

Take care not to allow any washing solution to enter the battery filling c aps in the ca se of a flooded battery, as any contamination into a cell will chemically damage it.

4. Reconnect the batt ery cable terminals to the battery lugs and tighten.

5. After tightening the cables, evenly coat all the expo sed metal surfaces of the battery termina ls and lugs with liquid neoprene. If liquid neoprene is not available, use a light coati ng of a nti-cor rosion grease or o ther sealant . Do not le t anything come between the mating sur faces of the lugs and terminals.

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Indicator Light Flashing Sequences

Table 4-1

Activity Charger status

Charging indicator light illuminates The unit is charging in bulk or abso rption mode Charging indicator light flashes The unit is performing the equalization charge.

Ready indicator light illum inates The unit is ei ther in float mode of three stage

Fault indicator light illuminates Any fault conditi on that prevents the charger from

Fault indicator light flashes Charge r fault condition - remote display shows

Indicator Light Sequences on the XC Series

(Charging indicator light flashes onc e every four seconds if bank 1 is being equalized, twice ever y four seconds if bank 2 is being equalized, and three time s ev ery four seconds if bank 3 is being equalized)

charging or rest mode of two stage charging. All batteri es have been fully charged.

charging one or more banks, but is not a charger fault cond ition - remote display shows details of fault. Example: polarity detected)

err

followed by

contact service.

Err BAT PoL

CHf

(battery reverse

. The charger is damaged,

Charging cu rrent indicator l ights illuminate

Charging cu rrent indicator l ights flash

Charging cu rrent indicator l ights flash, Fault indica tor light illuminated

975-0187-01-01 4–3

These lights indicate the charging current. At transiti on poi nts whe n the cur rent is cha nging, two indica tor lights may flash alternately, then settle into the new charging current reading.

100% indicator light flas hes to indicate battery temperat ure too high warning (> 50 °C, 122 °F) 10% indicator light flashes to indicate battery temperature too low warning (< 0 °C, 32 °F) 25% indicator light flashes to indicate that a battery has been disqualified (see page 3–4)

100% indicator light flas hes to indicate battery temperature too high fault (> 55 °C, 131 °F) 10% indicator light flashes to indicate battery temperature too low fault (< -20 °C, -4 °F)

XC_Cha rger_Owner .book Page 4 Friday, August 12, 2005 3:23 PM

Troubleshooting

Error Messages on Remote Display

Table 4-2

Display

ERR

ACL

Err bat PoL

Err CHf

CHg Hot

Error Messages

Onboard Statu s Panel Indicator lights Fault Solution

Red fault indicator light flashing or illuminated

Red fault indicator light illuminated

Red fault indicator light flashing

Fault A fault has been detected. The fault code

will be shown immediately after

AC Low Warning

Reverse Polarity

Charger Hardware Fault

Overtemperature Warning

Check AC connections, check AC availability at source.

Reverse Polari ty Battery connected. Check connections. Ensure correct polarity (negative connected to negative, positive connected to positive).

Call for service.

Allow t h e XC Series to co ol. Improve ventilation or install in cooler location. If the temperature increases, the XC Series will enter the faul t level and stop functioning.

Err

Err CHg Hot

CLd

4–4 975-0187-01-01

Red fault indicator light illuminated

Green 10% indicator light flashes Display green bank indicator light for affected ba ttery ban k illuminated

Overtemperature Shutdown

Battery Too Cold Warning

Allow t h e XC Series to co ol. Improve ventilation or install in cooler location.

Allow batteries to warm up before attemptin g to ch arg e ag ai n. Ch arg i n g a battery that has frozen is a potentia l explosion hazard. If the temperature drops, the XC Series will enter the fault level and stop charging the affected bank.

XC_Cha rger_Owner .book Page 5 Friday, August 12, 2005 3:23 PM

Error Messages on Remote Display

Table 4-2

Display

Err CLd

DIS

Error Messages

Onboard Statu s Panel Indicator lights Fault Solution

Red fault indicator light illuminated Green 10% indicator light flashes Display green bank indicator light for affected ba ttery ban k illuminated

25% current indic ator light flashes

Battery Too Cold Shutdown

Battery Disqualified Warning

Allow batteries to warm up before attemptin g to ch arg e ag ai n. Ch arg i n g a battery that has frozen is a potentia l explosion hazard.

Wait 15 minutes for the next battery detection cycle. The warning may be temporary. Verify that th e batt er y meets th e mini mu m AmpHour rating (XC1524: 30 Ah, XC2524: 50 Ah, XC3012: 60 Ah, XC5012: 100 Ah) Try adding a small DC load. Repl ac e th e batte ry.

Err HI

Display green bank indicator ligh t for th e affe cted batt ery bank illuminated

Red fault indicator light illuminated Display green bank indicator ligh t for th e affe cted batt ery bank illuminated

Over Voltage Shutdown Warning

Over Voltage Shutdown

Check battery. Do not charg e a battery rated at more than 12 volts nominal (XC3012, XC5012) or 24 volts nominal (XC1524, XC2524). Disconnect or turn off other charging sources such as the alternator or the charg er o n a genera to r wi t h el ectric s t ar t. If the w ar ning level escala tes wit ho u t being corrected, the XC Series enter the fault le v el and stop charging the affected bank.

975-0187-01-01 4–5

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Troubleshooting

Table 4-2

Display

Hot

Err Hot

Error Messages

Onboard Statu s Panel Indicator lights Fault Solution

Green 100% indicator light flashes Display green bank indicator ligh t for th e affe cted batt ery bank illuminated

Red fault indicator light illuminated Green 100% indicator light flashes Display green bank indicator light for affected ba ttery ban k illuminated

Battery too Hot Warning

Battery too Hot Shutdown

Cannot apply change

Allow battery t o c ool. Im prove ve ntila ti on or install in cooler location. It may indicate a shorted cell in the battery or excessive water loss. If the temperature increases, the XC Series will enter the fault level and stop cha rging the affected bank.

Allow battery t o c ool. Im prove ve ntila ti on or install in cooler location. It may indicate a shorted cell in the battery or excessive water loss.

The operation you have tried to execute cannot be completed.

Err no Bat

Red fault indicator light illuminated

No batteries detected

The charger did not detect a ny batteries.

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Problem Sol v in g

If the remote display is not fu nct ioning, troubleshoot your XC Series using the tables below. In the event that you have a problem with your XC Series, the following tables wil l he lp you to i dentif y t he proble m and of fe r poss ible s oluti ons t o the problem.

Symptom

Indicator lights do not illuminate when charger is connected to AC power.

Possible Cause Solution

Problem Solving

Symptom

No power at AC source and no battery connected on bank 1

Defective AC wiring

Charger level fault

Ensur e that po w er is available at the source and a batte ry or bank is connected on bank 1

Replace wiring

Call for service

Fault indicator light illuminates. XC Series stops functioning.

Poss ib l e Ca us e Solution

XC Series does not detect battery for one of following reasons:

• poor conne ction

• reverse polarity connection

• dama g ed w iri ng

XC Series int er n a l temper a tu r e too hot

Check quality of battery connection and wires. Ensure correct polarity (negative connected to negative, pos itive connected to positive).

Allow the XC Series to cool. Improve ve ntilation or install in cooler location.

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Troubleshooting

Symptom

Fault indicator light flashes. XC Series stops functioning.

Poss ib l e Ca us e Solution

XC Series hardware failure Call for service

Symptom

Fault indicator light illuminates. 100% indicator light flashes.

Possible Cause Solution

Symptom

Battery temperature is too hot for safe charging.

Allow battery to cool. Improve ventilation or install in cooler location. It may indicate a shorted cell in the battery or excessive water loss.

Fault indicator light illuminates. 10% indica tor light flashes.

Possible Cause Solution

Batt er y temper a tu r e is too co ld f or safe charging.

Allow batteries to warm up before attempting to charge again. Charging a battery that has frozen is a potential explosion hazard.

XC Series completes a charging cycle, but the batte ry voltage seems (about 2 volts) too low.

Poss ib l e Ca us e Solution

Battery has a shorted cell. Check the battery.

4–8 975-0187-01-01

V erify you are attempting to charge a battery correctly rated at 12 volts nomina l (XC3012, XC5012) or 24 volts nominal (XC1524, XC2524). Re-check the battery vol tage wit h all lo ads re moved and the batte ry is at rest for about an hour.

XC_Cha rger_Owner .book Page 9 Friday, August 12, 2005 3:23 PM

Symptom

The XC Series appears to be taking too long to charge battery . Ready indicator light does not illuminat e after 24 hours of charging.

Possible Cause Solution

Problem Solving

Symptom

Battery capacity is too high for the

Use a hi g h er capa city charge r.

XC Series model.

Load connected to battery is

Disconnect load or switch load off. draining charge current so that battery does not recharge.

Battery has a dama ged ce ll.

Repl ac e ba tt er y.

The XC Series will not tra nsition to equalization mode.

Possible Cause Solution

Battery is the wrong type, or set to the wrong type to e qualize.

Verify battery type is set to Gel or AGM. These

battery types cannot be equalized.

Not all batter ies are fully charged.

Wait for all batteries to be in float (

charging or rest (

rdy

) of 2-stage chargi ng before

flo

) of 3-stage

attempti ng to equaliz e (the ready indic ator light will

illuminate).

An active fault is present on the

Clear the active fault (see Table 4-2 on page 4–4) bank you are attempting to equalize.

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4–10

XC_Cha rger_Owner .book Page 1 Friday, August 12, 2005 3:23 PM

Specifications

Appendix A details the specifications for the XC Series.

XC_Cha rger_Owner .book Page 2 Friday, August 12, 2005 3:23 PM

Specifications

Physical Specif ication s

Dimensions Base unit: 367 mm x 240 mm x 106 mm

Remote Display: 118 mm x 41 mm x 32 mm

Weight 5.7 kg (12.6 lbs) AC input connections Two color-coded No. 16 AWG wires (L, N) and one

No. 18 AWG (G) minimum 152 mm (6 in.) long in a separate AC wiring enclosure with 21.3 mm (0.84 in.) hole provision for connection of a ½ inch North American "trade size" cable cla mp or conduit hub o r in ternat ional PG 13. 5 or PG16 o r M20 gla nd or cable strain relief fitting.

14.45 in. x

4.65 in. x 1.6 in. x 1.26 in.

9.45 in. x 4.17 in.

DC output connections Four right-angle M6 studs (3 positives and 1 common

negative) for battery cable ring terminals and one M6 m m DC equipment ground

Elect ric al Spec if ication s

Number of battery bank outputs 3 isolated, indepe ndently controlled outputs Nominal battery volta ge 12 V units: 12 VDC

Normal operating output range 12 V units: 0 – 16 VDC

Nominal operating AC voltage 110 – 240 VAC Rated DC output curren t (total) XC3012: 30 A (up to 15 V)

Absorption voltage (in VDC for XC3012 and XC5012) (Multiply VDC by 2 to get the absorption voltage for XC1524 and XC2524)

24 V units: 24 VDC

24 V units: 0 – 32 VDC

XC5012: 50 A (up to 15 V) XC1524: 15 A (up to 30 V) XC2524: 25 A (up to 30 V)

50 °C (122 °F) 25 °C (77 °F) <0°C (32°F)

Flooded 13.7 14.4 15.1 Gel 13.5 14.2 14.9 AGM 13.8 14.3 14.8 Lead-calcium 14.8 15.5 16.0

A–2 975-0187-01-01

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AC Input Specif ications

Float voltag e (in VDC for XC3012 and XC5012) (Multiply VDC by 2 to get the float volta ge for XC1524 and XC2524)

Equalize mode current 50% rated output Equalize mode —maximum out put

voltage

Off-state current draw (w ith remote insta lled)

AC Input Specifi c ations

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 12.8 13.5 14.2

XC3012: 16.0 VDC XC5012: 16.0 VDC XC1524: 32.0 VDC XC2524: 32.0 VDC

XC3012: <20 m A XC5012: <20 m A XC1524: <15 m A XC2524: <15 m A

AC input voltage range 100 – 260 VAC at full power

90 – 105 VAC at 80% restric ted load Note: Charger may not start with input voltage <100 VAC

Maximum AC input current at 100 VAC at 184 VAC

XC3012: 6 AAC XC3012: 4.3 AAC XC5012: 10 AAC XC5012: 5.7 AAC XC1524: 6 AAC XC1524: 4.3 AAC

XC2524: 10 AAC XC2524: 5.7 AAC Power factor at rated load ≥0.95 Frequency 47 – 63 Hz Efficiency – peak 12 V units: 80% @ 120 VAC, 83% @ 230 VAC

24 V units: 85% @ 120 VAC, 87% @ 230 VAC Surge prote ction Line-to-neutral surge protector rated at 275 VAC

975-0187-01-01 A–3

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Specifications

Temperature Specifications

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

Protection Features

Battery reverse polarit y No damage incurred by reverse polarity. Safe non-operating batte ry voltage 35 VDC maximum Over-volta ge limits The XC Series wil l stop char ging any bank t hat ha s a

voltage greate r than + 0.5 V over the temperature compensated absorption vol tage. It will restart when this voltage is + 0.2 V.

Output current limit XC3012: 30 – 33 ADC

XC5012: 50 – 55 ADC XC1524: 15 – 16.5 ADC XC2524: 25 – 27.5 ADC

Over-temperature Internal charger temperature is measured. Unit shuts

down and restarts as follows:

• Over-temperature shutdown at 75 °C (167 °F)

• Over-temperature restart at 70 °C (158 °F)

Current derating in ambient temperatures

Battery over-temperature protection

Rated current to 50 °C (122 °F) 2%/ °C derating above 50 °C (122 °F)

Battery tempe r ature, as sensed by the battery temperature sensor (if inst alled), results in the charger no longer charging the individual battery or bank at a battery temperature of 55 °C (132 °F).

A–4 975-0187-01-01

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Approvals

Safety CSA/NRTL approved to CSA107.2 and UL1236, including the marine

supplement, ignition protection, and UL1564 EN60335-1, EN60335-2-29 Battery Chargers ISO 8846: Ignition Protection for Small Cr aft ABYC E11 - Alterna ting Current and Direct Current Electrical Systems on Boats ABYC A20 - Battery Charging Devices NFPA70/1996 US NEC for home and RV installa tion requirements

EMC FCC Cl ass B

CE marked, meeting EMC Direct ive 89/336/EEC (referencing EN55014-1, EN55014-2, EN61000-3-2, EN61000-3-3, EN61000-4-2, EN61000-4-3, EN61000-4-4, EN61000-4-5, EN61000-4-6, EN 61000-4-11) CISPR25 (similar to S A E J1113-41) Class 1 on DC outputs

Approvals

Other KKK-A-1822 Rev D - Federal Specification for the Star-of-Life Ambulance

975-0187-01-01 A–5

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A–6

XC_Cha rger_Owner .book Page 1 Friday, August 12, 2005 3:23 PM

Warranty and Product Information

Limited Warranty for:

Xantrex XC3012 Battery Charger Xantrex XC5012 Battery Charger Xantrex XC1524 Battery Charger Xantrex XC2524 Battery Charger

"XC Series"

What does this warranty cover and how long does it last? This Limited Warranty is provided by

Xantrex Technology Inc. ( "Xantrex") and cover s defects in workman ship and materials in your Xantrex XC Series product. This warranty lasts for a Warranty Period of 24 months from the date of purchase at po int of sale to you, the original end user customer. This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the Warranty Period.

What will Xantrex do? Xantrex will , at its option, repair or replace the defective product free of charg e,

provided that you notify Xantrex of the product defect within the Warranty Period, and provided that Xantrex through inspection establishes the existence of such a defect and that it is covered by this Limited Warranty.

Xantrex will, at it s option, use new and/or reconditioned p arts in performing warranty repair and building replacement products. Xan trex reserves the right to use parts or products of original or improved design i n the repair or replacement. If Xantrex repairs or replaces a product, its warr anty continues for the remaining portion of the original Warranty Period or 90 days from the date of the return shipm ent to the customer, whichever is gr eater. All replaced products and all parts rem oved from repaired products become the property of Xantrex.

For United States and Canada returns, Xantrex covers both parts and labor necessary to repair the product, and return shipmen t to the customer via a Xantrex-selecte d non-expedited surface freight within the cont iguous United States and Canada. Alaska and H aw aii are excluded. Contact Xantrex Customer Service for details on our fr eight policy for return shipments outside of the contiguous Unite d States and Canada.

How do you get service ? If your produc t requires troubleshooting or warranty service, contact your dealer. If

you are unable to contact your dealer , or the dealer is unable to provide service, contact Xantrex di rectly at:

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 (tol l free Nort h America)

+34 93 473 6093 (Europe) 1 360 925 5143 (direct and rest of world)

Email: customerservice@xantrex.com (North America and rest of world)

support. europe@xantrex. com (Europe)

Direct returns m ay be performed according to the Xantrex Retu rn Material Authorization Policy described in your product manual. For some products, Xantrex maintains a networ k of regional Authori zed Servic e Centers. Call Xantrex or check ou r w ebsite to see if your product can be repaired at one of these facilities.

In any warranty claim, dated proof of purchase must accompany the product and the product must not have be en disassembled or modified without prior written authorization by X antrex.

Proof of purchase may be in any one of the following forms:

• The dated purchase receipt from the original purchase of the product at point of sale to the end user, or

• The dated dealer invoice or purchase receipt showing original equipment manufacturer (OEM) status, or

• The dated invoic e or purchase receipt showing the product exchanged under warranty

975-0187-01-01 WA–1

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Warranty and Product Information

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, installatio n , or troubleshooting of the custom er's electrical systems. This warranty does not apply to and Xantrex will not be responsible for any defect in or damage to :

a) the product if it has been misused, neglected, improper ly installed, physically damaged or altered, eit h er

internally or externally, or damaged from improper use or use in an unsu itable environment;

b) the product if it has been subjected to fire, water, excessive corrosion, biological infestation s, or input voltage

that cr eates operating conditions beyond the ma ximum or minim um limits listed in the Xantrex product specifications including high input voltage from generators and lightning strikes;

c) the product if repairs have been done to it other than by Xantrex or its authorized service centers (hereafter

"ASCs"); d) the product if it is used as a com ponent part of a product expressly warranted by another manufacturer; e) the prod uc t if its or iginal identi fi ca tion (trade-m ark, ser ia l nu m b er ) m a rk in g s ha v e be e n de fa ced, al te re d , or

removed.

DISCLAIMER OF WARRANTY

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 LIABILITIES, EXPRESS OR IMPLIED, STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT, HOWEVER ARISING (WHETHER BY CONTRACT , TORT, NEGLIGENCE, PRINCIPLES OF MANUFACTURER'S LIABILITY, OPERA TION OF LAW, CONDUCT, STATEMENT OR OTHERWISE), INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED WARRANTY.

IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, LOSSES, COSTS OR EXPENSES HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND, ANY LOSS OR DAMAGE TO PROPERTY, ANY PERSONAL INJURY, ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE, OR THE INCORRECT INSTALLATION, INTEGRATION OR OPERATION OF THE PRODUCT.

Exclusions If thi s product is a consumer pr oduct purchased in the United States, federal law does not allow an

exclusion of implied warranties. To the extent you are entitl ed to implied warranties under federal law, to the extent permi tted by applicable law they are limited to th e duration of this Lim ited Warranty. Some states do not allow limitations or exclusions on implied w arranties or on the du ration of an implied war ranty or on the limitation or exclusion of incidental or conseque ntial damages, so the above limitation(s ) or exclus ion(s) may not apply to you. This Li mited Warranty gives you specific legal rights. You may have other rights which may vary depending on the country, province, or state.

WITHOUT LIMITING THE GENERALITY OF THE FOREGOING, UNLESS SPECIFICALLY AGREED TO BY IT IN WRITING, XANTREX

(a) MAKES NO WA RRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY

TECHNICAL OR OTHER INFORMATION PROVIDED IN MANUALS OR OTHER DOCUMENTATION

PROVIDED BY IT IN CONNECTION WITH THE PRODUCT; AND (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.

WA–2 975-0187-01-01

XC_Cha rger_Owner .book Page 3 Friday, August 12, 2005 3:23 PM

WARNING: LIMITATIONS ON USE

Please refer to your product user manual for limitations on uses of the product. Sp ecifically, 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 in connection with any use of the product for such purposes.

Xantrex Technology, Inc. 8999 Nelson Way Burnaby, British Columbia Canada V5A 4B5

Retu rn Material Authorization Policy

If your product requires wa rranty service, pl ease contact your dealer first. If you are unable to contact y our dealer,

or your dealer is unable to pr ovide service, cont act Xantrex.

Before r etur ni ng a p roduct di rect ly to Xantre x you must obt ain a Ret urn Mate rial Aut horiz at ion (RM A) numbe r and

the correct factory "Ship To" address. Product shipments will be refused and returned at your expense if they are

unauthorized returned without an RMA number clearl y m arked on the outside of the shipping box, if they are

shipped collect, or if they are shipped to the wrong location.

When you contact Xantrex to obtain service, please have your instruction manual ready for reference and be

prepared to supply:

• The serial number of your product

• Information about the inst allation and use of the unit

• Information about the failure and/or reason for the re turn

• A copy of your dated proof of purchase

When you ship:

1. Package the unit saf ely, preferably using the original box and packing materials. Pleas e ensure that your produc t i s sh ipped fully insured in the original packaging or equivalent. This warranty will not apply where the product is damaged due to improper packaging.

2. Include the following:

• The RMA number s upplied by Xantrex Technology Inc clearly marked on the out s ide of the box.

• A return addr es s w her e the unit can be sh ipped. Post of fice boxes ar e not acceptabl e.

• A contact tel ephone number where you can be r eached during work hours

• A brief description of the problem

Please contact Xantrex for details of the freight policy for your country of purchase. For Un ited States and Canada returns, ship the unit prepaid to the address provided by your Xantrex customer service representative.

If you are returning a product to a Xantrex facility in North America from outside of the USA or Canada: In additi on to the above, you MUST include return freight funds and are fully responsible for all documents, duti es, tariffs, and deposits.

If you are returning a product to a Xantrex Authorized Service Center (ASC): A Xantre x return material authorization (RMA) num ber is not required . How ever, you must contact the ASC prior to ret urning the product or presenting the unit to verify any return procedures that may apply to that particular facility.

975-0187-01-01 WA–3

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Warranty and Product Information

Information About Your System

As soon as you open your Xantrex XC301 2, XC5012, XC1524 or XC2524 Battery Charger package, record the following info rm ation and be sure to keep your proof of purchase.

❐ Serial Number ❐ Purchas ed From ❐ Purchase Date

If you need to cont ac t C us to m e r Se r vice, please record the fo llowin g d et ails bef or e cal lin g . Th i s in fo rm a tion wil l help our representativ es give you better service.

❐ Type of installation ❐ Length of time charger has been installed ❐ Battery/battery bank size ❐ Battery type (e.g. flooded, sealed gel cell, AGM) ❐ DC wiring size and length ❐ Description of li ght indicators or remote display

readout

❐ Appliances operating when problem oc curred ❐ Description o f proble m

_________________________________________________________________________________________ _________________________________________________________________________________________

_________________________________ _________________________________ _________________________________

___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________ ___________________________________________

___________________________________________ ___________________________________________

___________________________________________

WA–4 975-0187-01-01

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XC_Cha rger_Owner .book Page 6 Friday, August 12, 2005 3:23 PM

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: customerse rvice@xan trex.com (North A merica)

support.europ e@xantrex.com (Europe) customerservice@xantrex.com (rest of world)

975-0187-01-01

Printed in Canada

Xantrex XC1524, XC2524, XC5012 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual