Xantrex Technology TC2 204060 User Manual

TC2 204060 Series BattChg Owners Guide.book Page i Friday, July 8, 2011 11:44 AM

TM

TM

Owner’s Guide

Series Battery Charger

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TC2_204060_FrontMatter_SE.fm Page i Thursday, August 4, 2011 1:11 PM

Trademarks

Xantrex, Truecharge, and Smart choice for power are trademarks of Schneider
Electric Services International sprl, registered in the U.S. and other countries. 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

Truecharge2 Series Battery Charger Owner’s Guide © August 2011 Xantrex
Technology USA Inc. All rights reserved. No part of this document may be
reproduced in any form or disclosed to third parties without the express written
consent of: Xantrex Technology USA Inc., 541 Roske Drive, Suite A, Elkhart,
Indiana USA 46516. Xantrex Technology USA Inc. 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 USA INC. (“XANTREX”)

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

(

TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION;

B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES,

(

WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE
OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY
AT THE USER’S RISK; AND

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

ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE
ACCURACY CANNOT BE GUARANTEED. APPROVED XANTREX CONTENT IS CONTAINED WITH THE

ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW.XANTREX.COM.

Date and Revision

August 2011 Rev C

Document Part Number

975-0526-01-02

Product Numbers

Non-IEC Models IECa Models

804-1220-02,
804-1240-02,
804-1260-02,
804-2410,
804-2420,
804-2430

a.IEC refers to the international standard from the International
Electrotechnical Commission for "plugs, socket-outlets and cou­plers for industrial purposes". IEC models have an AC input recep­tacle that connects with an IEC cable (not provided).

804-1220-03,
804-1240-03,
804-1260-03
804-2410-01,
804-2420-01,
804-2430-01

Contact Information

Telephone: [phone]

Fax: [phone]

Web: www.xantrex.com

975-0526-01-02 i

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About This Guide

Purpose

The purpose of this Owner’s Guide is to provide explanations and
procedures for installing, troubleshooting, operating and maintaining the
Truecharge2 Series Battery Charger.

Scope

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

Audience

The Guide is intended for users and operators of the Truecharge2 Series
Battery Charger. The Installation section is primarily intended for qualified
installers who need to install and configure any unit model of the
Truecharge2 Series Battery Charger. The installer should have 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. A qualified
technician or electrician has this knowledge and experience.

Conventions Used

The following conventions are used in this guide.

STATEMENT OF HAZARD

Contains statements of avoidance or strict compliance.

Failure to follow these instructions will result in death or serious
injury.

STATEMENT OF HAZARD

Contains statements of avoidance or strict compliance.

Failure to follow these instructions can result in death or serious
injury.

STATEMENT OF HAZARD

Contains statements of avoidance or strict compliance.

Failure to follow these instructions can result in minor or moderate
injury.

ii Truecharge2 Series Battery Charger Owner’s Guide

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STATEMENT OF HAZARD

Contains statements of avoidance or strict compliance.

Failure to follow these instructions can damage the unit and/or
damage other equipment.

IMPORTANT:

know, however, they are not as serious as a danger, warning, or caution.

These notes describe things which are important for you to

Related Information

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

The product marking on the left when found imprinted on
electrical and electronic units and appliances means that you
are to refer to this guide for cautions and warnings.

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Important Safety Instructions

IMPORTANT: READ AND SAVE THIS OWNER’S GUIDE FOR FUTURE

REFERENCE.

This chapter contains important safety and installation instructions for the
Truecharge2 Series Battery Chargers. Each time, before using the
Truecharge2 Series Battery Charger, READ ALL instructions and
cautionary markings on or provided with the battery charger, the batteries,
and all appropriate sections of this guide.

NOTE: The Truecharge2 Series Battery Charger contains no user­serviceable parts with the exception of the DC output fuse(s) which are
user-replaceable. See “Replacing the DC Output Fuse” on page 48 for
instructions. For obtaining service other than replacing the fuse, see
“Warranty and Return Information” on page 58 for guidance.

NOTE: The Truecharge2 Series Battery Charger must be provided with
equipment-grounding conductors connected to the AC input ground and to
the DC chassis ground. See “Step 2: Connecting the DC Chassis Ground
(Earth)” on page 17 for instructions.

ELECTRICAL SHOCK HAZARD

• Do not expose the Truecharge2 Battery Charger to rain, snow, spray,
or bilge water.

• Do not operate the 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.

• Do not disassemble the battery charger. Internal capacitors remain
charged after all power is disconnected.

• Disconnect both AC and DC power from the battery charger before
attempting any maintenance or cleaning or working on any circuits
connected to the battery charger. See note below.

• Do not operate the battery charger with damaged or substandard
wiring. Make sure that all wiring is in good condition and is not
undersized. See “Wiring Requirements” on page 12 for guidance.

Failure to follow these instructions will result in death or serious
injury.

NOTE: Turning off the battery charger using the on/standby button on the
optional remote panel will not reduce an electrical shock hazard.

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FIRE AND BURN HAZARD

Do not cover or obstruct the air intake vent openings and/or install in a
zero-clearance compartment. See “Location” on page 10 for proper
location requirements.

Failure to follow these instructions will result in death or serious
injury.

EXPLOSION HAZARD

• Charge only properly rated (such as 12 V and 24 V) lead-acid (GEL,
AGM, Flooded, or lead-calcium) rechargeable batteries because other
battery types may explode and burst.

• Do not work in the vicinity of lead-acid batteries. Batteries generate
explosive gases during normal operation. See note below.

Failure to follow these instructions will result in death or serious
injury.

NOTE: 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 INJURY HAZARD

This battery charger 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 battery charger.

Failure to follow these instructions can result in death or serious
injury.

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Precautions When Working With Batteries

BURN FROM HIGH SHORT-CIRCUIT CURRENT, FIRE AND EXPLO­SION FROM VENTED GASES HAZARDS

• Always wear proper, non-absorbent gloves, complete eye protection,
and clothing protection. Avoid touching your eyes and wiping your
forehead while working near batteries. See note #4.

• Remove all personal metal items, like rings, bracelets, and watches
when working with batteries. See notes #5 and #6.

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

• Never charge a frozen battery.

Failure to follow these instructions can result in death or serious
injury.

NOTES:

1. Locate the Truecharge2 Series Battery Charger unit away from
batteries in a well ventilated compartment.

2. Always have someone within range of your voice or close enough to
come to your aid when you work near a lead-acid battery.

3. Always have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing, or eyes.

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.

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

6. 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.

7. When removing 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.

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Precautions When Preparing to Charge

EXPOSURE TO CHEMICALS AND GASES HAZARD

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

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

• Be careful to keep corrosion from coming into contact with your eyes
and skin when cleaning battery terminals.

Failure to follow these instructions can result in death or serious
injury.

NOTES:

1. 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.

2. 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.

Precautions When Placing the Battery Charger

RISK OF DAMAGE TO THE BATTERY CHARGER

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

• Never place the Truecharge2 Series Battery Charger unit directly
above batteries; gases from a battery will corrode and damage the
charger.

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

Failure to follow these instructions can damage the unit and/or
damage other equipment.

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

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FCC Information to the User

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

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

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

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

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

Unauthorized changes or modifications to the equipment could void the
user’s authority to operate the equipment.

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Contents

Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Truecharge 2 Battery Charger Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preparing For Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installing the Truecharge 2 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Installing a Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Installing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Configuring the Truecharge2 Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Charging Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Equalizing Flooded Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Transitioning the Charger to ON, Standby, or Disabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Accessing Charger Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Using A Generator As Source Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Maintaining the Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Replacing the DC Output Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Warranty and Return Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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Introduction

This chapter describes the standard features of a Truecharge2 Battery
Charger, as well as its protection features. It also provides information on
the different parts of the Truecharge2 Battery Charger.

Truecharge2 Battery Charger

The Truecharge2 Battery Charger ships with the following items:

• one Truecharge2 Battery Charger unit,

• owner’s guide,

• rubber boots for DC terminals,

• nuts and washers (M6) for DC terminals and ground stud,

• 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 Truecharge2 Battery Charger for servicing.

1.Not included with IEC models of Truecharge2 Battery Chargers.

1

,

1

.

Standard and Protection Features

The Truecharge2 Battery Charger provides the following standard features:

• up to three

• battery monitoring functions,

• 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

• ability to operate two Truecharge2 Battery Chargers in parallel mode
with the use of the optional remote panel.

The Truecharge2 Battery Charger provides the following protection
features:

• battery reverse polarity protection via user-replaceable output fuse(s),

• AC input out-of-range derating and shutdown,

• ambient over-temperature derating and shutdown,

• battery over-charging protection,

2.Each output can charge different batteries that either have the same chemistry or can
tolerate the same charge sequence and voltage/current ratings.

3.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.

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

2

full current rated outputs,

4

3

,

,

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Introduction

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

• ignition-protected rating, enabling installation in engine spaces,

• isolated design,

• 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

The following optional accessories are available for the Truecharge2
Battery Charger:

• an optional battery temperature sensor2 (BTS) and

• an optional remote panel

1

,

3

.

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

• battery under-temperature charging protection preventing battery
charging at -25 °C (-13 °F) or below,

• battery over-temperature charging protection preventing battery
charging at 70 °C (158 °F) or higher, and

• charging voltage compensation based on the temperature of the battery
the optional BTS is connected to.

The optional Remote Panel provides the following features:

4

• Can be mounted up to 15 meters (50 feet)

away for remote control

and monitoring,

• maximum output current limiting for charging smaller capacity
batteries or to lower the current drawn from the generator or AC
source,

• ability to enable or disable the charger while AC power is connected,

• ability to display individual battery bank levels, and

• ability to operate two Truecharge2 Battery Chargers in parallel for
increased output current capacity.

1.In two specific installation orientations–see “Mounting Orientations (Deck and
Horizontal)” on page 11.

2.Part number: 808-0232-01

3.Part number: 808-8040-01

4.Remote panel comes standard with a 7.5-m (25-ft) cable. For longer [15-m (50-ft)]

cable, order part number 31-6262-00

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Truecharge 2 Battery Charger Features

This section describes the different parts of the Truecharge2 Battery
Charger.

Item Description

Front Panel

1 Onboard control and status display panel or simply

onboard display (see “Onboard Control and Status Display

Panel” on page 5 for more information) for controlling the
Truecharge2 Battery Charger settings and for monitoring
charger status and charging current.

1

2 Mounting flanges are used to permanently install the product.

3 DC wiring compartment cover protects the DC terminals, as

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

2

ELECTRICAL SHOCK HAZARD

Disconnect the batteries and AC power before opening the fuse access
panel.

Failure to follow these instructions will result in death or serious
injury.

4 Fuse access panel cover provides access to the DC fuse in the

event of an accidental reverse battery polarity installation.
Remove and replace the cover when replacing a fuse or fuses.

Figure 1

3

4

5

6

Truecharge2 Battery Charger Front Panel

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Truecharge 2 Battery Charger Features

Item Description

5 AC wiring compartment cover provides the installer with

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

6 DC ground stud for connecting the charger’s chassis to

ground.

Rear Panel

This section describes the parts of the rear panel of the Truecharge2 Battery
Charger.

3

7

8

4

9

5

6

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

2

1

Item Description

1 BTS port- battery temperature sensor port

2 Communication port - remote panel port

3 Battery positive (+) for bank 3 (6 mm stud)

4 Battery positive (+) for bank 2 (6 mm stud)

5 Battery positive (+) for bank 1 (6 mm stud)

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

stud)

7 Air vents - located inside is the fan assembly

8 AC wiring compartment

9 AC pigtail wiring - line, neutral, and ground input wires

Figure 2

Truecharge2 Battery Charger Rear Panel

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Onboard Control and Status Display Panel

This section describes the parts of the onboard control and status display
panel of the Truecharge2 Battery Charger. See “Reading Onboard Display
LEDs” on page 41 for more information.

Truecharge 2 Battery Charger Features

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

However, to temporarily check the status of the connected battery when AC
power is not present, press the Status button on the optional remote panel.

IMPORTANT:

panel buttons must be pressed and held down for three seconds to advance
to the next selection.
To set and cancel an equalization program, press and hold for five seconds
both the Charger Mode and Battery Temp. Select panel buttons.

1

3

4

5

6

Figure 3

To prevent any unintentional changes in the setting, Select

Onboard Control and Status Display Panel

Item Description

1 Charging Output (%) LEDs

• The LEDs illuminate like a bar graph displaying the present
total output charge current as a percentage of the maximum
rated charge current. For example, unit model TC4012 has a
maximum rated charge current of 40 A so at 60% the
charger’s current output is 24 A. The numbers below the
LEDs represent the percentage values. See “Reading

2

Onboard Display LEDs” on page 41.

NOTE: When the maximum Charge Output current is
limited via the optional remote panel, the LEDs will still
display the total charge output current as a percentage of the
maximum rated charge current and NOT as a percentage of
the limited charge current.

• One or two LEDs may flash intermittently in combination
with a solid Fault LED (indicating a fault) or with a
flashing Fault LED (indicating a warning). The icons
above the LEDs represent the various types of fault and
warning conditions. See “Reading Onboard Display LEDs”
on page 41.

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Truecharge 2 Battery Charger Features

Item Description

2Fault LED

The LED may illuminate a solid light (indicating a fault) or
flash intermittently (indicating a warning) in combination with
flashing Charging Output (%) LEDs. See “Interpreting Fault
and Warning Indicators” on page 43 for details.

3 Charger Status LEDs

Displays the current status of the charger.

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

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

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

• Equalize - a solid light indicates that the charger is

performing an equalization cycle.

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

Item Description

4 Charger Mode Select button

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

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

default setting

• Two-stage - Bulk and Absorption only

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

5 Battery Type Select button

Press and hold the button for three seconds to select one of five
settings. An indicator LED corresponds to each setting.
NOTE: The fifth setting is a custom battery type setting and is
indicated when all four LEDs illuminate. See “Custom” below.

Each setting maximizes charger performance for its
corresponding battery type.

• AGM - Absorbent Glass Mat lead-acid battery

• Flooded - Lead-acid battery; default setting

• GEL - Gel-type lead-acid battery

• Lead Calc. - Lead-calcium battery

• Custom - Only available if a custom algorithm has been
programmed by Xantrex or a designated OEM.

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Truecharge 2 Battery Charger Features

Item Description

6 Battery Temp. Select button

• Press and hold the button for three seconds to select one of
three settings. An indicator LED corresponds to each
setting.
If an optional BTS is connected, the indicator LEDs
represent real-time battery temperature.

• When the optional BTS is not used, this selection changes
the charger's output voltage settings to compensate for the
battery temperature selected. The Cold setting raises the
voltages, and the Hot setting lowers the voltages. See
“Battery Temperature Compensation Levels” on page 32.

RISK OF BATTERY DAMAGE

Be sure the appropriate setting is selected before charging. For varying
conditions, use the Warm setting.

Failure to follow these instructions can damage the unit and/or
damage other equipment.

Item Description

6

continued

• Cold - for battery temperature below 5 °C (41 °F); raises
the charging voltage to compensate

• Warm - for battery temperature between
5 and 30 °C (41 and 86 °F); default setting

• Hot - for battery temperature above 30 °C (86 °F);
lowers charging voltage to compensate

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

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Preparing For Installation

IMPROPER INSTALLATION BY AN UNQUALIFIED INSTALLER

The battery charger must be installed by a qualified installer in
accordance with all applicable local or national installation codes.
Examples of such codes are the US National Electrical Code (NFPA 70),
the American Boat & Yacht Council standards E-11 and A-31, and the
US Coast Guard Electrical Regulations (33CFR183).

Failure to follow these instructions can damage the unit and/or
damage other equipment.

NOTE: The Truecharge2 Battery Charger is designed to be permanently
mounted. Figure 4 shows a typical installation with three batteries, a battery
temperature sensor (BTS) and a remote panel (both optional). It also shows
the AC and DC wiring and protection devices required for a typical
installation. Means of over-current protection and disconnection must be
incorporated into the fixed wiring, in accordance with the electrical code
that governs each installation.

NOTE: Not to scale. For illustration purposes only.

1

L
N
G

L
N
G

NOTE: In some jurisdictions a
double-pole breaker may be
required.

Figure 4

2

3

4

6

5

6

6

Configuration for Normal Loads

10

9

8

7

1 AC input wiring compartment

2 AC mains source protected by correct size and type of branch

rated circuit breaker

3 DC negative cable

11

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TC2 204060 Series BattChg Owners Guide.book Page 9 Friday, July 8, 2011 11:44 AM

4 DC positive cables

5 DC circuit breakers or DC fused disconnects

6 Battery or battery bank

7 Battery Temp. Sensor

(optional accessory part number: 808-0232-01)

8 Engine ground bus or DC negative bus

9 Ground bus

10 DC chassis ground (earth)

11 Remote panel

(optional accessory part number: 808-8040-01)

Tools and Materials

To mount and connect the Truecharge2 Battery Charger you need the
following tools:

• 10 mm socket wrench and extension for the DC terminals and ground
stud,

• Phillips screwdriver for removing and re-securing the AC and DC
wiring compartment covers,

• power drill/screwdriver,

• drill bit set for pilot holes for mounting screws (if using #6 mounting
screws, use 1/16 drill),

• wire stripper,

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

Preparing For Installation

You need the following materials:

• 3 conductor AC input wiring
Use the information in “Step 4: Installing AC Wiring” on page 21 and
your local electrical codes to determine the correct wire and breaker or
fuse.

• AC cable strain relief (if the one included is not compliant with your
local electrical code requirements).

• appropriately sized DC cables for each battery, with suitable
connectors at the battery end
Use the information in “DC Wiring” on page 13 and your local
electrical codes to determine the correct wire and breaker or fuse.

• appropriately sized DC chassis ground (earth) cable with suitable
connectors,

• ring terminals to fit 6 mm (1/4 in.) studs at the charger end (Marine
grade hardware is recommended),

• DC fused disconnect or properly rated circuit breaker for each battery
bank,

• mounting screws, M3 or #6 marine grade, corrosion resistant
(4 pieces) (Length dependent on mounting surface).

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Preparing For Installation

Location

Install the Truecharge2 Battery Charger in a location that meets the
following requirements:

Condition Requirement

Dry The Truecharge2 Battery Charger must be installed in a

dry location not subject to moisture especially rain, spray,
or splashing bilge water.

Clean The Truecharge2 Battery Charger should not be exposed

to metal filings or any other form of contamination.

Cool The ambient air temperature should be between

0 – 50 °C (32 – 122 °F) for best performance.

Ventilated There must be at least 10 cm (4 in.) of clearance on the top

and bottom ends of the Truecharge2 Battery Charger for
air flow and at least 6 cm (2.5 in.) of clearance on either
side (see Figure 7). Ventilation openings on the charger
must not be obstructed. If the charger is mounted in a tight
fitting compartment, the compartment must be ventilated
with cut-outs to prevent the charger from overheating.

Safe

a

This battery charger (except IEC modelsb) is ignition­protected equipment, so it can be installed in areas
containing gasoline tanks or fittings which require
ignition-protected equipment. Nevertheless, Xantrex
recommends that it is safest not to install any kind of
electrical equipment including the Truecharge2 Battery
Charger in these areas.

Condition Requirement

Close to
batteries

a.Applicable to Non-IEC models only. See “Product Numbers” on page i.
b.See “Product Numbers” on page i.

The Truecharge2 Battery Charger should be installed as
close as possible to the batteries, but not in the same
compartment to prevent corrosion. Avoid excessive cable
lengths and use the recommended wire sizes. Xantrex
recommends installing with cables sized to achieve less
than 3% voltage drop on battery cables under full load.
This will maximize the performance of the charger.

EXPLOSION HAZARD FOR IEC MODELS ONLY

Do not place the battery charger in machinery space or in areas
containing gasoline tanks or fittings in which ignition-protected
equipment is required.

Failure to follow these instructions will result in death or serious
injury.

NOTES:

When planning to install the Truecharge2 Battery Charger, be sure that you
consider the location and orientation carefully. The Truecharge2 Battery
Charger is considered to have an IP rating of IP-32, if installed in either of
two specific orientations [shown in Figure 5 (a) and (b)] and only if all

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TC2 204060 Series BattChg Owners Guide.book Page 11 Friday, July 8, 2011 11:44 AM

panel covers are attached and secured. This rating means that it meets
standards to prevent dripping water from entering the enclosure, and
causing shock hazard and damage to equipment.

The other possible mounting orientations [shown in Figure 6 (c) and (d)]
will not prevent the entry of dripping water, and are not suitable for marine
or other moist environments without the installation of additional drip
protection. They are only acceptable for use in locations that are always dry.

The environment, therefore, will determine the mounting orientations that
are suitable for each installation. Is the installation environment one that
will always be dry or will moisture or condensation sometimes enter the
area?

ELECTRICAL SHOCK HAZARD

In marine environments, there is a likelihood that condensation will be
present, and may drip on to the charger. Use the appropriate mounting
orientations as shown in Figure 5 and Figure 6.

Failure to follow these instructions will result in death or serious
injury.

(a)

Horizontal Wall Mount (with AC
wiring higher than DC terminals
only) - this orientation meets IP­32 requirements and is drip­proof.

Figure 5

Mounting Orientations (Deck and Horizontal)

Preparing For Installation

Deck Mount - this orientation
meets IP-32 requirements and is
drip-proof.

(b)

AC

DC

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