Xantrex Technology 10A12V, 15A12V, 15A24V, 20A12V, 20A24V user guide

...

TC1012 TC1512 TC2012 TC3012 TC4012 TC5012 TC6012

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

Series Battery Charger

TC1524 TC2024 TC3024 TC5024

15A–24V 20A–24V 30A–24V 50A–24V

Installation Guide

This guide for use by qualified installers only

Truecharge™ 2 Series Battery Chargers

Installation Guide

This guide for use by qualified installers only

About Xantrex

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

Trademarks

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

Other trademarks, registered trademarks, and product names are the property of their respective owners and are used herein for identification purposes only.

Notice of Copyright

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

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

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

Exclusion for Documentation

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

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

(

OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.

(

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

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

Date and Revision Document Part Number

September 2008 Rev B 975-0402-01-01

Product Numbers

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

Contact Information

Telephone: 1 800 670 0707 (toll free North America)

Fax: 1 800 994 7828 (toll free North America)

Email: customerservice@xantrex.com Web: www.xantrex.com

1 408 987 6030 (direct) +34 93 470 5330 (Europe)

+34 93 473 6093 (Europe)

This guide for use by qualified installers only

About This Guide

Purpose

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

Scope

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

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

Audience

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

This guide for use by qualified installers only

iii

About This Guide

Organization

This Guide is organized into two chapters and one appendix. Chapter 1 describes the standard features of a Truecharge™ 2

Battery Charger, as well as its protection features. It also provides information on the different parts of the Truecharge™ 2 Battery Charger including information on the optional remote panel.

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

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

Conventions Used

The following conventions are used in this guide.

WARNING

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

CAUTION

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

Important:

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

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

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

iv 975-0402-01-01

This guide for use by qualified installers only

These notes describe things which are important

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

When all models are being referred to, they will be referred to as Truecharge™ 2 Battery Chargers.

Related Information

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

About This Guide

975-0402-01-01 v

This guide for use by qualified installers only

Important Safety Instructions

READ AND SAVE THIS INSTALLATION GUIDE FOR FUTURE

REFERENCE.

This chapter contains important safety, installation, and operating instructions for the Truecharge™ 2 Series Battery Chargers.

1. Before installing and using a Truecharge™ 2 Battery Charger, read all instructions and cautionary markings on a Truecharge™ 2 Battery Charger unit, the batteries, and all appropriate sections of this guide.

WARNING: Risk of injury

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

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

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

This guide for use by qualified installers only

vii

Safety

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

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

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

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

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

viii 975-0402-01-01

This guide for use by qualified installers only

Safety

WARNING: Explosion hazard

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

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

Personal Precautions When Working With Batteries

WARNING: B

LECTRICAL SHOCK

IRCUIT CURRENT

ENTED GASES

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

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

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

975-0402-01-01 ix

This guide for use by qualified installers only

ATTERIES PRESENT RISK OF

, B

URN FROM HIGH SHORT

, F

IRE OR EXPLOSION FROM

. O

BSERVE PROPER PRECAUTIONS

Safety

4. If battery acid contacts skin or clothing, wash immediately with soap and water . If ac id enters your eye, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately.

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

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

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

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

9. Never charge a frozen battery.

PREPARING TO CHARGE

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

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

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

13. Study and follow all of the battery manufacturer's specific precautions, such as removing or not removing cell caps while charging, whether equalization is acceptable for your battery, and recommended rates of charge.

x 975-0402-01-01

This guide for use by qualified installers only

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

BATTERY CHARGER LOCATION

15. Locate the Truecharge™ 2 Battery Charger unit away from batteries in a well ventilated compartment.

16. Never place the Truecharge™ 2 Battery Charger unit directly above batteries; gases from a battery will corrode and damage the charger

17. Never allow battery acid to drip on the charger when reading gravity, or filling battery.

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

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

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

Safety

975-0402-01-01 xi

This guide for use by qualified installers only

Safety

FCC Information to the User

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications.

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

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connecte d.

Consult the dealer or an experienced radio/TV technician for help.

xii 975-0402-01-01

This guide for use by qualified installers only

Contents

Important Safety Instructions 1

Introduction

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

Installation

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

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

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

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

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

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

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

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

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

This guide for use by qualified installers only

xiii

Contents

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

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

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

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

Specifications

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

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

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

xiv 975-0402-01-01

This guide for use by qualified installers only

Introduction

Chapter 1 describes the standard features of a Truecharge™ 2 Battery Charger, as well as its protection features. It also provides information on the different parts of the Truecharge™ 2 Battery Charger.

Truecharge™ 2 Battery Charger

The Truechar ge™ 2 Battery Char ger ships with the following items.

• one Truecharge™ 2 Battery Charger unit

• installation and operation guides

• rubber boots for DC terminals

• nuts and washers

• strain relief clamp for AC input cables

• three crimp connectors for AC wiring

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

return the Truecharge™ 2 Battery Charger for servicing.

This guide for use by qualified installers only

Introduction

Standard and Protection Features

The Tr uecharge™ 2 Battery Charger provides the following standard features:

•three

full current rated outputs

• battery monitoring functions while in float mode or rest mode

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

• low electromagnetic interference (EMI)

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

• programmable custom charge settings

• fully discharged battery charging

The Tr uecharge™ 2 Battery Charger provides the following protection features:

• battery reverse polarity protection via a replaceable output fuse

• AC input out-of-range derating and shutdown

• ambient over temperature derating and shutdown

• battery over-charging protection

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

• ignition protected rating, enabling installation in engine spaces

• isolated design

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

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

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

1–2 975-0402-01-01

This guide for use by qualified installers only

Standard and Protection Features

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

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

• IP-32 drip protection rating

• locked fan2 protection

The T ruecharge™ 2 Battery Charger provides the following optional features:

• an optional remote panel

which can be mounted up to

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

• an optional battery temperature sensor

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

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

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

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

• charging voltage compensation based o n the temperature of the battery the optional BTS is connected to

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

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

3.Part number: 808-8040-00

4.Part number: 808-0232-01

975-0402-01-01 1–3

This guide for use by qualified installers only

Introduction

Truecharge™ 2 Battery Charger

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

Figure 1-1

Item Description

1 Onboard control and status display panel or simply

2 Mounting flanges are used to permanently install the

3 DC wiring compartment cover protects the DC

Truecharge™ 2 Battery Charger

onboard display (see “Rear Panel” on page 1–6 for more information) for controlling the Truecharge™ 2 Battery Charger settings and for monitoring charger status and charging current.

product.

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

1–4 975-0402-01-01

This guide for use by qualified installers only

+ 46 hidden pages