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Xantrex Truecharge 20+ Amp, Owner'S Manual, Page: 45 / 78

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Xantrex Truecharge 20+ Amp Owner'S Manual Download Page 45

4 

Maintenance and 

Troubleshooting 

Chapter 4, “Maintenance and Troubleshooting”

 

provides information for maintaining and 

troubleshooting Tru. 

Summary of Contents for Truecharge 20+ Amp

Page 1: ...Owner s Guide Truecharge 20 40 Amp Multistage Battery Charger...

Page 2: ...espective owners and are used herein for identification purposes only Notice of Copyright Truecharge 20 40 Owner s Guide November 2002 Xantrex International Disclaimer UNLESS SPECIFICALLY AGREED TO IN...

Page 3: ...oduct 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 True...

Page 4: ...ains the Truecharge physical electrical AC input and protection feature specifications Appendix B Battery Charging describes the Truecharge multistage charging algorithm Appendix C Battery Maintenance...

Page 5: ...k 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 Setting...

Page 6: ...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...

Page 7: ...pment 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 Exclusion...

Page 8: ...viii...

Page 9: ...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...

Page 10: ...83 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...

Page 11: ...d found to comply with the limits for a Class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equ...

Page 12: ......

Page 13: ...1 Introduction Chapter 1 Introduction introduces and describes features of the Truecharge multistage battery chargers...

Page 14: ...r 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...

Page 15: ...ttery you will be ensuring that it receives the best possible charge Extensive Protection Features Truecharge provides the following protection features Opening of the internal output fuse if a batter...

Page 16: ...ensor BTS automatically adjusts the charge according to the temperature of one of the batteries With a BTS installed the unit provides a more accurate temperature compensated charge for the battery to...

Page 17: ...ights show 1 3 5 10 20 A Truecharge20 2 5 10 20 40 A Truecharge 40 3 The recessed Equalize button is triggered manually to enter or leave the equalization mode 4 The Charger Mode switch from which you...

Page 18: ...rsion 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 charg...

Page 19: ...charge 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...

Page 20: ...nformation After unpacking the unit record the serial number and other purchase information on page D 7 of this guide Preparing for Installation Mounting Truecharge is designed to be permanently mount...

Page 21: ...contamination can cause damage and void your warranty Cool For best performance the ambient air temperature should be between 32 F 0 C and 95 F 30 C the cooler the better At higher ambient temperature...

Page 22: ...14 8 13 9 Bulk Absorption Battery Temperature 1 3 5 10 20 Status Charging Current A Charger Mode 2 3 4 5 6 7 8 9 1 L N G 1 120 VAC source with 15 amp breaker 2 AC input wiring compartment 3 DC negativ...

Page 23: ...sists 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...

Page 24: ...re in multi conductor cable but stranded wire will again withstand vibration better 120 VAC 15 amp branch circuit The circuit supplying the Truecharge must be rated 120 VAC single phase 15 amps maximu...

Page 25: ...r a wire stripper the manufacturer s recommended crimp tool for any crimp terminals that are being used Materials You need the following material 3 conductor No 14 AWG AC cable Appropriately sized DC...

Page 26: ...AC connections at the top WARNING Shock and Energy Hazards Be sure to read the safety guidelines and pay attention to all cautions and warnings throughout the installation procedure The installer is r...

Page 27: ...rging profiles at each output Therefore all the batteries you are charging must be the same type that is all should be flooded or all gel or all AGM 13 8 13 4 Cold Warm H ot 14 4 13 5 14 0 13 1 14 2 1...

Page 28: ...e to the battery 4 Route the wiring to the batteries and to the charger but don t connect it yet Try to avoid routing wiring through an electrical distribution panel battery isolator or other device t...

Page 29: ...ing a DC negative bus Connect up to three negative cables to the DC negative bus or engine negative bus Figure 2 3 7 8 9 one for each battery bank Connect each negative cable to the battery negative t...

Page 30: ...plied or with other approved connectors suitable for your installation For boat installations use the crimp on butt splice connectors following the procedure To connect AC wires with the crimp on butt...

Page 31: ...2 for the other end of the butt splice 4 Tighten the cable clamp to secure the wiring so that it grips the outer cable jacket not the individual wires 5 When all connections are completed push the wi...

Page 32: ...you have purchased the accessories you can also install the Battery Temperature Sensor BTS and the Remote Display Panel at this time For maximum battery life Xantrex strongly recommends the use of the...

Page 33: ...5 F absorption voltage for a gel battery is reduced to 13 8 VDC At 122 F 50 C the absorption voltage for the same battery is reduced to 13 4 VDC if the BTS is installed It would still be at 13 8 VDC i...

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Page 35: ...mation 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 expl...

Page 36: ...calculates an approximate charging time where Example A Group 27 size battery rated at 82 amp hours is 40 discharged that is it has a DOD 40 Charging time with a Truecharge 20 unit is calculated as f...

Page 37: ...a cold temperature setting for a hot battery you risk overcharging your battery If you are in doubt about which to choose or if you are leaving the charger connected for an extended time select Hot t...

Page 38: ...erators due to increased heating of the charger Indicator Light Activity On The Front Panel Indicator light activity shows what is happening during the charging process and is also helpful in troubles...

Page 39: ...is preferable Ready indicator is lit Charging indicator is not The unit is either in float mode of three step charging monitor mode of two step charging or in fixed voltage output mode Rapid flashing...

Page 40: ...er to Truecharge by closing the AC breaker and or applying shorepower The indicator lights will blink as an initialization sequence runs lasting typically 10 seconds or so After initialization the yel...

Page 41: ...elapsed time since the last charge cycle Recharging With either charging mode the Truecharge will begin a charging cycle 21 days after the last cycle or when battery voltage drops to below 12 5 VDC f...

Page 42: ...attery is fully charged Recommended Xantrex recommends that you run a normal charge cycle on the batteries before you equalize them While Truecharge will charge discharged batteries as part of the equ...

Page 43: ...zation mode 2 Monitor the specific gravity of each cell of the battery during equalization with a battery hydrometer Equalization is complete when the specific gravity of each cell of the battery rema...

Page 44: ...3 10...

Page 45: ...4 Maintenance and Troubleshooting Chapter 4 Maintenance and Troubleshooting provides information for maintaining and troubleshooting Truecharge...

Page 46: ...ing connections DC and AC to be sure they have not loosened or deteriorated Also check all cable clamps to ensure they are tightly fastened Troubleshooting Indicator Light Flashing Sequences WARNING R...

Page 47: ...t indicator light blinks all others are off Truecharge is in over temperature shutdown due to excessive battery temperature This shutdown only occurs if the BTS is installed Table 4 1 Indicator light...

Page 48: ...charger 1 Ensure that power is available at receptacle 2 Replace wiring 3 Have charger serviced by qualified person Possible Cause Solution 1 Charger does not detect battery for one of following reaso...

Page 49: ...g source with voltage above 15 5 VDC 1 Check battery Do not charge a battery rated at more than 12 volts nominal 2 Disconnect or turn off other charging sources such as the alternator or the charger o...

Page 50: ...Maintenance and Troubleshooting 4 6...

Page 51: ...A Specifications Appendix A Specifications contains the Truecharge physical electrical AC input and protection feature specifications...

Page 52: ...ated for 60 A per pole No 6 14 AWG wire Electrical Specifications Number of battery bank outputs 3 diode isolated no independent regulation Nominal battery voltage 12 VDC Normal operating output range...

Page 53: ...0 14 3 14 6 VDC Float voltage at no load Hot Warm Cold Flooded 13 1 13 5 13 9 VDC Gel 13 4 13 8 14 2 VDC AGM 13 1 13 4 13 7 VDC Equalize mode current Truecharge 20 5 ADC Truecharge 40 10 ADC Equalize...

Page 54: ...atts Power factor rated load 0 66 0 68 Efficiency peak 83 83 Surge protection Line to neutral surge protector rated at 150 V Protection features Battery reverse polarity Internal fuses for each output...

Page 55: ...automatic output Truecharge 20 20 A at 30 C to 10 A at 50 C Truecharge 40 40 A at 30 C to 20 A at 50 C Battery over temperature protection Battery temperature as sensed by the battery temperature sens...

Page 56: ...A 6...

Page 57: ...B Battery Charging Appendix B Battery Charging describes the Truecharge multistage charging algorithm...

Page 58: ...a fibreglass matting Charge Algorithm Stages Three stage charging Truecharge charges batteries in a sequence known as a three stage charge The charging voltage delivered to the battery depends on the...

Page 59: ...AGM batteries or charges flooded batteries for one more hour This extended one hour charge ensures that the batteries are fully topped up and is recommended by the flooded battery manufacturers Float...

Page 60: ...ould be perfomed only if recommended by the battery manufacturer and only as often as specified Two Stage Charging Difference from three stage In a two stage charge the charger finishes the Absorption...

Page 61: ...y 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 ha...

Page 62: ...hat all caps are on tight so solution doesn t enter the battery Rinse the top of the battery with clean water when you have finished To reduce the amount of corrosion on the battery terminals coat the...

Page 63: ...self Be sure to wear rubber gloves and eye protection Tools Adjustable wrench or appropriately sized sockets and ratchet for battery terminals Torque wrench Soft bristled brush a discarded toothbrush...

Page 64: ...and any nearby exposed metal parts This powder is actually a crystallized form of sulfuric acid If it contacts your skin it will cause burns unless you rinse it off immediately Most textiles that are...

Page 65: ...gs with liquid neoprene This will cure to form an airtight protective layer If liquid neoprene is not available use a light coating of anti corrosion grease or other sealant Do not let anything come b...

Page 66: ...C 6...

Page 67: ...pendix 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 oth...

Page 68: ...s Xantrex reserves the right to use parts or products of original or improved design in the repair or replacement If Xantrex repairs or replaces a product its warranty continues for the remaining port...

Page 69: ...d Warranty does not cover normal wear and tear of the product or costs related to the removal installation or troubleshooting of the customer s electrical systems This warranty does not apply to and X...

Page 70: ...AL 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 PERSON...

Page 71: ...and or reason for the return A copy of your dated proof of purchase Return Procedure 1 Package the unit safely preferably using the original box and packing materials Please ensure that your product i...

Page 72: ...a Xantrex Authorized Service Center ASC A Xantrex return material authorization RMA number is not required However you must contact the ASC prior to returning the product or presenting the unit to ver...

Page 73: ...following information before calling The information will assist the service representative in providing you with better service Model Number Serial Number Purchased From Purchase Date Type of instal...

Page 74: ...Product and System Information D 8...

Page 75: ...n of B 2 suitable for equalization 3 8 battery voltage too high 4 4 bulk charge battery activity during B 3 C charge mode selector switch 1 3 charging algorithm three stage B 2 charging batteries proc...

Page 76: ...d 2 1 physical requirements for installing 2 3 procedure for 2 8 tools required for 2 7 wiring diagram 2 4 wiring order 2 9 L liquid neoprene C 5 M maintaining batteries C 2 maintaining the Truecharge...

Page 77: ...rging 1 2 three stage charging algorithm explanation B 2 three stage charging profile diagram B 4 tools required for installation 2 7 troubleshooting use of indicator lights in 4 2 two stage charging...

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