TC20+
TC40+
Owner’s Guide
Xantrex
Truecharge 20+/40+ Amp
Multistage Battery Charger
Truecharge 20+/40+ Amp
Multistage Battery Charger
Owner’s Guide
About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to 1 MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and standalone 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 is a trademark of Xantrex International. 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 20+/40+ Owner’s Guide © June 2005 Xantrex International.
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 INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.
Date and Revision
June 2005, Revision A
Part number
445-0050-01-01
Contact information
Phone: |
1-800-670-0707 |
(toll free in North America) |
Phone: |
1-360-925-5097 |
(outside of North America) |
Fax: |
1-360-925-5143 |
|
Email: |
CustomerService@xantrex.com |
|
Web: |
www.xantrex.com |
About This Guide
Purpose and scope
This guide introduces the Truecharge+ battery chargers, describes their features, explains how they charge batteries, and provides procedures for their installation and operation. The guide does not provide details for particular brands of batteries. Please consult the battery manufacturer for this information.
This guide provides information for two products, Truecharge 20+ and Truecharge 40+. Where information is specific to one product, that product is referred to by name. Where information applies to both products, they are referred to collectively as Truecharge+.
Audience
The guide is written for anyone intending to install and operate a Truecharge+ battery charger. Xantrex recommends, however, that the product be installed by a certified technician or electrician.
Organization
This guide contains four chapters and four appendixes.
Chapter 1, “Introduction” introduces and describes features of the Truecharge+ multistage battery chargers.
Chapter 2, “Installing Truecharge+” lists the materials you receive, provides site recommendations for installing Truecharge+, and provides the materials and procedures for its installation.
About This Guide
Chapter 3, “Operation” provides background information for charging batteries with Truecharge+ and procedures for charging and for equalizing batteries. Chapter 3 also explains how to calculate charging times, how generators affect Truecharge+ and explains how the front panel indicator lights are interpreted.
Chapter 4, “Maintenance and Troubleshooting” provides information for maintaining and troubleshooting Truecharge+.
Appendix A “Specifications” contains the Truecharge+ physical, electrical, AC input, and protection feature specifications.
Appendix B “Battery Charging” describes the Truecharge+ multistage charging algorithm.
Appendix C “Battery Maintenance” contains procedures for maintaining the battery enclosure, battery terminals and lugs, and battery cables. It also provides a list of the clothing, tools, equipment, and supplies you should have before you begin battery maintenance.
Appendix D “Product and System Information” contains the Xantrex warranty for your product and return instructions. It also contains a place for you to record the serial number and date of purchase and other details of your battery charger.
iv
Contents
Important Safety Instructions
Explosive gas precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–x Precautions When Working With Batteries - - - - - - - - - - - - - - - - - - - - - - - - - 1–x
1 Introduction
Truecharge+ Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 20/40 Amp Continuous Rating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Simultaneous Three-Battery Bank Charging - - - - - - - - - - - - - - - - - - - - - - - 1–2 Wide Voltage Range Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Selector Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Extensive Protection Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Isolated Design - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Fixed Voltage Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4 Optional Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Indicator Lights and Settings on the Front Panel - - - - - - - - - - - - - - - - - - - - - - 1–4 How Truecharge+ Works - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
2 Installing Truecharge+
Materials List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 Preparing for Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3 Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3 Wiring Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5 DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–5 AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–6 Tools- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7 Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7 Installing Truecharge+ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8 Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8 Connecting DC Wiring For A Single Battery Or Multiple Batteries- - - - - - - - 2–9
v
Contents
Connecting to AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11 Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14 Installing Optional Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14 Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14 Remote Display Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–15
3 Operation
About Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2 Charging Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2 Battery Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3 Using A Generator As Source Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4 Indicator Light Activity On The Front Panel - - - - - - - - - - - - - - - - - - - - - - - 3–4
Charging batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5 Equalizing Flooded Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7 About Equalizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7 Performing An Equalization - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
4 Maintenance and Troubleshooting
Care and Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Indicator Light Flashing Sequences - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Typical Problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
A Specifications
Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2
AC Input Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4
Protection Features- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4
Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–5
B Battery Charging
Charging Algorithms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2
Battery Type- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2
Charge Algorithm Stages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2
Equalization Charge- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–4
Two-Stage Charging- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–4
C Battery Maintenance
vi
Contents
Maintenance Guidelines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2 Preparation for Cleaning Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3 Clothing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3 Tools- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3 Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3 Supplies- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3 Maintaining and Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4 Battery Enclosure and Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4 Terminals & Lugs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4 Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–5
D Product and System Information
Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–2 DISCLAIMER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–4 Product - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–4 Exclusions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–4 WARNING: LIMITATIONS ON USE - - - - - - - - - - - - - - - - - - - - - - - - - - - D–4 Return Material Authorization Policy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–5 Return Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–5 Information about your Truecharge+- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–7
Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Index–1
vii
viii
Important Safety Instructions
WARNING
This chapter contains important safety and operating instructions as prescribed by UL and CSA standards for chargers used in residential, RV, and marine applications. Read and keep this Owner’s Guide for future reference.
1.Before using the charger, read all instructions and cautionary markings on the charger, the batteries, and all appropriate sections of this guide.
2.Do not expose the charger to rain, snow, spray, or bilge water. To reduce risk of fire hazard, do not cover or obstruct the ventilation openings. Do not install the charger in a zero-clearance compartment. Overheating may result.
3.Use only attachments recommended or sold by the manufacturer. Doing otherwise may result in a risk of fire, electric shock, or injury to persons.
4.The charger is designed to be permanently connected to your AC and DC electrical systems. Xantrex recommends that all wiring be done by a certified technician or electrician to ensure adherence to the local and national electrical codes applicable in your application.
5.To avoid a risk of fire and electric shock, make sure that existing wiring is in good condition and that wire is not undersized. Do not operate the charger with damaged or substandard wiring.
6.Do not operate the charger if it has received a sharp blow, been dropped, or otherwise damaged in any way. If the unit is damaged, see the Warranty section in Appendix D, “Product and System Information”.
ix
Important Safety Information
7.Do not disassemble the charger. See Appendix D, “Product and System Information” for instructions on obtaining service. Attempting to service the unit yourself may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is disconnected.
8.To reduce the risk of electrical shock, disconnect both AC and DC power from the charger before attempting any maintenance or cleaning or working on any circuits connected to the charger. Turning off controls will not reduce this risk.
9.The charger must be provided with an equipment-grounding conductor connected to the AC input ground.
10.For marine applications 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 precautions
1.Working in the vicinity of lead-acid batteries is dangerous. Batteries generate explosive gases during normal operation. Therefore you must read this guide and follow the instructions exactly before installing or using your charger.
2.TrueCharge 20+ and TrueCharge 40+ have been approved as Ignition Protected. They may be installed in areas containing gasoline tanks and fittings which require Ignition Protected equipment. Xantrex recommends, nevertheless, that it is safest not to install electrical equipment in these areas.
3.To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed.
Precautions When Working With Batteries
1.Have someone within range of your voice or close enough to come to your aid when you work near a lead-acid battery.
2.Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
x
Important Safety Information
3.Wear complete eye protection and clothing protection. Avoid touching your eyes while working near batteries.
4.If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately.
xi
1 Introduction
Chapter 1, “Introduction” introduces and describes features of the Truecharge+ multistage battery chargers.
Introduction
Truecharge+ Features
Truecharge+ is an advanced battery charger designed specifically for high performance, deep-cycle lead-acid batteries. It is smaller and lighter than many other chargers and can be installed or stored in small compartments. It has AC to DC isolation, a surge protector, and many other safety features which reduce potential shock and fire hazards.
20/40 Amp Continuous Rating
Truecharge 20+ delivers a 20 amp charging current and the
Truecharge 40+ delivers 40 amps for approximately 75% of the charging cycle. The chargers only reduce the charging current below these rated levels when the battery is approaching full charge or when there may be overheating in high ambient temperatures. Because it delivers rated current over most of the charge cycle, Truecharge+ charges your batteries faster than many other chargers with a higher rating.
Many other chargers only deliver their rated charging current for a short initial part of the charge cycle.
Simultaneous Three-Battery Bank Charging
Truecharge+ has three separate DC positive terminals to allow charging of three separate batteries (or battery banks). The total current into the batteries is a maximum of either 20 amperes or 40 amperes, depending on the model, which is divided amongst the batteries according to their state of discharge.
Note: The three outputs are not independently voltage regulated so it is important to avoid systems with mixed types of batteries.
Wide Voltage Range Operation
Truecharge+ maintains the correct charging voltage for your battery when the AC line voltage drops as low as 90 VAC, or rises as high as 135 VAC. A surge protector in Truecharge+ protects it from surges and spikes on the AC power line.
1–2
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Truecharge+ Features |
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Selector Switches |
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Truecharge+ has selector switches for charge mode, battery type, and |
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battery temperature setting. |
Charge mode |
The charge-mode switch allows you to select three-step charge, two-step |
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charge or 13.5 volt fixed output modes. Refer to Appendix B, “Battery |
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Charging” for an explanation of the charging algorithms. |
Battery type |
The battery-type switch allows you to set the Truecharge+ for the |
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charging characteristics of flooded, AGM, and gel batteries. |
Temperature |
The battery temperature switch allows you to set charging characteristics |
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based on the battery temperature. By setting the switches correctly before |
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you begin charging your battery, you will be ensuring that it receives the |
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best possible charge. |
Extensive Protection Features
Truecharge+ provides the following protection features:
•Opening of the internal output fuse if a battery is accidentally connected with reversed polarity
•Fuse opening or electronic shutdown if there is a short circuit on the output of the Truecharge+
•Built-in protection against accidental connection to a higher battery voltage, up to 24 VDC
•Unit shutdown if it becomes overheated because of inadequate ventilation or a high ambient temperature
•Unit shutdown if the battery gets too hot (with battery temperature sensor only)
Isolated Design
The DC battery charging circuits of Truecharge+ are galvanically isolated by a transformer from the AC power circuits. This feature reduces the risk of electric shock and helps to prevent corrosion problems in marine applications.
1–3
Introduction
Fixed Voltage Mode
The fixed voltage mode setting is meant to be used as a power supply or battery eliminator. It is not meant for charging batteries. The battery type, battery temperature, and equalize switches are all ignored in fixed voltage mode. The remote battery temperature sensor does not compensate the voltage, but the battery over-temperature shutdown is still active.
Optional Accessories
Battery |
The remote Battery Temperature Sensor (BTS) automatically adjusts the |
Temperature |
charge according to the temperature of one of the batteries. With a BTS |
Sensor |
installed, the unit provides a more accurate temperature-compensated |
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charge for the battery to which the sensor is attached. |
Remote panel |
The remote panel allows you to monitor the charging progress of two |
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batteries or battery banks, the total charge current, and charger status from |
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a convenient location. |
Indicator Lights and Settings on the Front Panel
This section describes the parts of the front panel of the Truecharge 20+. Figure 1-1 shows the front panel. Descriptions are provided in Table 1-1
12
3
4
6 5
Figure 1-1 Front panel of Truecharge 20+ battery charger
1–4
Indicator Lights and Settings on the Front Panel
Table 1-1 Truecharge+ front panel
Panel
Item Description
1Status indicator lights which indicate that batteries are charged and ready for use or that the batteries are being charged or equalized.
2Indicator lights which show the total charging current, in amps, into the three battery banks.
The indicator lights show:
1, 3, 5, 10, 20 A (Truecharge20+) 2, 5, 10, 20, 40 A (Truecharge 40+)
3The recessed Equalize button is triggered manually to enter or leave the equalization mode.
4The Charger Mode switch from which you can select a three-stage or two-stage charge or a 13.5 volt power supply mode to power 12 volt loads when you don’t have a battery.
5The battery selection switch for choosing flooded, gel or AGM batteries.
6The battery-temperature switch for choosing the battery temperature for the charge. Temperature settings compensate the output voltage for the battery temperature.
Note that a battery temperature sensor overrides the temperature settings on the front panel.
The indicator lights are also used to indicate error codes. See Chapter 4, “Maintenance and Troubleshooting”
1–5
Introduction
How Truecharge+ Works
Truecharge+ changes the alternating current (AC) supply from the utility to the controlled low-voltage, direct current (DC) required to charge the battery by using high-frequency, switched-mode power conversion circuits. The high-frequency power conversion method is similar to that used in power supplies for computers and other electronic equipment. It results in a significantly smaller and lighter charger than other power conversion methods allow.
The controlled DC output is fed to three isolations diodes, one for each battery bank. These diodes isolate the batteries from each other and prevent current flow from one battery to the others.
1–6
2 Installing
Truecharge+
Chapter 2, “Installing Truecharge+” lists the materials you receive, provides site recommendations for installing Truecharge+, and provides the materials and procedures for its installation.
The chapter also makes reference to the installation codes that may be applicable in your application, for example, the US National Electrical Code (NEC, NFPA 70), the Canadian Electrical Code (CEC, CSA C22.1), and the American Boat and Yacht Council (ABYC) Recommended Practices.
Installing Truecharge+
Materials List
Figure 2-1 Truecharge 20+ (left) and Truecharge 40+ (right)
Contents |
The unit is packed with the following materials: |
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• |
Owner’s Guide |
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• Wiring cover with 2 blunt-tip screws and two lock washers |
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• |
AC cable clamp |
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• Three twist-on wire nuts |
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• Three crimp-on butt-splices |
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Recording |
After unpacking the unit, record the serial number and other purchase |
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information |
information on page D–7 of this guide. |
Preparing for Installation
Mounting |
Truecharge+ is designed to be permanently mounted. It is virtually |
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maintenance free when properly installed. |
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Conditions |
Before mounting and connecting Truecharge+, be sure you meet the |
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requirements for |
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• |
location |
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• |
circuits |
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• |
wiring |
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• |
tools and materials |
2–2
Preparing for Installation
Location
Install Truecharge+ in a location that meets the requirements set out in
Table 2-1.
Table 2-1 Physical requirements for a Truecharge+ installation
Condition |
Description |
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Dry |
The unit is intended for use in a dry location. Do not allow water |
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or other fluids to drip or splash on Truecharge+. Do not mount |
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the charger in an area subject to rain, spray or splashing bilge |
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water. |
Clean |
Do not expose Truecharge+ to metal filings or any other form of |
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conductive contamination. The presence of conductive |
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contamination can cause damage and void your warranty. |
Cool |
For best performance, the ambient air temperature should be |
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between 32 °F (0 °C) and 95 °F (30 °C)– the cooler the better. At |
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higher ambient temperatures, the output current will be |
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automatically reduced to protect the charger from high internal |
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temperatures. |
Ventilated |
Allow at least 4 inches (10 cm) of clearance around all sides of |
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the Truecharge+ for air flow. Ensure that the ventilation |
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openings on the unit are not obstructed. If mounting in a |
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compartment, ventilate the compartment with louvres or cut-outs |
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to prevent overheating. |
Safe |
This battery charger is Ignition Protected, so it can be installed in |
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areas containing gasoline tanks or fittings which usually require |
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Ignition Protected equipment. Xantrex recommends, however, |
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that it is safest not to install electrical equipment in these areas. |
Close to AC |
Avoid the use of extended wire lengths if possible. |
junction box |
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Close to |
Avoid excessive cable lengths and use the recommended wire |
batteries |
lengths and sizes. Undersized or overly long cables may affect |
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charging accuracy. |
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Circuits
Truecharge+ is designed to operate from a 15 amp, 120 VAC (nominal) branch circuit. The circuit must be protected by a 15 amp circuit breaker. Any switch in the circuit should be rated for a minimum of 10 amps for Truecharge20+ installations and 15 amps for Truecharge40+ installations. Refer to Appendix A “Specifications” for the actual current draw.
2–3
Installing Truecharge+
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N |
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G |
8 |
5 |
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Figure 2-2 Truecharge+ system
1120 VAC source with 15 amp breaker
2AC input wiring compartment
3DC negative cable
4DC positive cables
5DC circuit breaker or DC fuse and disconnect rated at 25 amps maximum for TC 20+ or 50 amps maximum for the TC 40+
6Battery or battery bank
7Engine negative bus or DC ground bus
8Remote panel (optional)
9Battery temperature sensor (optional)
2–4
Preparing for Installation
Wiring Requirements
Figure 2-2 depicts a typical configuration system for the Truecharge+ showing the AC and DC wiring and protection devices required for a successful installation.
DC Wiring
The DC wiring must meet the following requirements:
•Length and size
Wire Length |
Wire Size AWGa |
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(maximum length |
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one way) |
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feet |
meters |
TC 20+ |
TC 40+ |
|
|
|
|
5 |
1.5 |
No. 10 |
No. 8 |
7.5 |
2.25 |
No. 8 |
No. 6 |
20 |
3 |
No. 6 |
No. 6 |
|
|
|
|
a.Based on ABYC Recommended Practice E-9, 75 °C wire, 3% voltage drop
Use the largest recommended size rather than the minimum for best performance and safety.
•DC Disconnect
The DC circuit from the battery to the charger must be equipped with a disconnect and over-current protection device. The device usually consists of a DC-rated circuit breaker, a “fused disconnect”, or a separate fuse and disconnect. These devices must be rated for DC voltage and current. Do not substitute devices rated only for AC voltage: they may not operate properly.
•Over-current protection
The current rating must be matched to the size of the DC wiring used and to the charger output, in accordance with the applicable codes. The following recommended current ratings for the DC fuse or breaker meet the requirements in ABYC, NEC, and CEC codes. Truecharge 20+: 25 A
Truecharge 40+: 50 A
2–5