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Xantrex Truecharge TC1012, Installation Manual, Page: 15 / 74

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Xantrex Truecharge TC1012 Installation Manual Download Page 15

This guide for use by qualified installers only

1

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 
including information on the optional remote panel.

Truecharge™ 2 Battery Charger

The Truecharge™ 2 Battery Charger

 

ships

 

with the following 

items.

•

one Truecharge™ 2 Battery Charger unit

•

installation and operation guides

•

rubber boots for DC terminals

•

ring terminals, nuts, and washers

•

strain relief clamp for AC input cables

TC2 Series BattChg Install Guide.book  Page 1  Monday, June 30, 2008  3:18 PM

Summary of Contents for Truecharge TC1012

Page 1: ...allation Guide TC1012 TC1512 TC2012 TC3012 TC4012 TC5012 TC6012 TC1524 TC2024 TC3024 TC5024 10A 12V 15A 12V 20A 12V 30A 12V 40A 12V 50A 12V 60A 12V 15A 24V 20A 24V 30A 24V 50A 24V This guide for use b...

Page 2: ......

Page 3: ...This guide for use by qualified installers only Truecharge 2 Series Battery Chargers Installation Guide...

Page 4: ...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...

Page 5: ...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 install...

Page 6: ...ed to individually the product will be referred to by its model name The 24V models are TC1524 TC2024 TC3024 and TC5024 When being referred to individually the product will be referred to by its model...

Page 7: ...ire 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...

Page 8: ...maged see the Warranty section 7 Do not disassemble the Truecharge 2 Battery Charger there are hazardous voltages within It contains no user serviceable parts See Warranty for instructions on obtainin...

Page 9: ...nit 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 1 Have someone within range of your...

Page 10: ...8 If you need to remove a battery always remove the ground terminal from the battery first Make sure all accessories are off so you don t cause an arc 9 Never charge a frozen battery PREPARING TO CHAR...

Page 11: ...y 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...

Page 12: ...nstructions 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 inte...

Page 13: ...eparing 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 11 Installing the Truecharge 2 Battery Charger 2...

Page 14: ...ge 2 Battery Charger 2 26 Configuring the Charger Mode 2 27 Configuring the Battery Bank Type 2 29 Configuring the Battery Temperature without the BTS 2 30 Configuring the Maximum Output Current Perce...

Page 15: ...information on the different parts of the Truecharge 2 Battery Charger including information on the optional remote panel Truecharge 2 Battery Charger The Truecharge 2 Battery Charger ships with the...

Page 16: ...mote panel4 which can be mounted up to 15 m 50 ft away for remote control and monitoring an optional battery temperature sensor5 BTS provides battery temperature voltage compensation from 25 to 70 C 1...

Page 17: ...on the charger s output ignition protected rating enabling installation in engine spaces isolated design over temperature and short circuit protection for the BTS and communication connector ports dri...

Page 18: ...1 Onboard control and status display panel or simply onboard display see Rear Panel on page 1 6 for more information for controlling the Truecharge 2 Battery Charger settings and for monitoring charge...

Page 19: ...the DC fuse in the event of an accidental reverse polarity installation 5 AC wiring compartment cover provides the installer with easy access to the AC wiring compartment to allow for a trouble free...

Page 20: ...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 See Impo...

Page 21: ...8 AC wiring line neutral and ground input wires Important When installing only a single bank or one battery for Truecharge 2 Battery Chargers that have multiple outputs positive bank 1 must be utilize...

Page 22: ...ery when AC power is not present the panel s LED control and status lights are automatically turned off and the buttons are disabled Important A press and hold action on any panel button means that th...

Page 23: ...1 Fault and Warning Indicators on page 1 11 for details 3 Charger Status LEDs Displays the current status of the charger Ready a solid light indicates batteries are fully charged and in rest stage Rea...

Page 24: ...ndicator LED corresponds to each setting Each setting maximizes charger performance for its corresponding battery type AGM Absorbent Glass Mat lead acid battery Flooded Lead acid battery default setti...

Page 25: ...mportant A warning condition notifies the user of an impending problem and will not stop the charger from charging while a fault condition will stop the charger from charging the battery Figure 1 4 Ch...

Page 26: ...input out of range fault 90V or 265V See Figure 1 5 AC frequency out of range fault 45 Hz or 65 Hz High Battery voltage fault 16 6V High Charger Temp warning 50 C High Charger Temp fault 70 C Locked...

Page 27: ...ernal fault Flashing LED Solid LED Figure 1 5 Input Voltage Operating and De rating Curve Table 1 1 Fault and Warning Indicators Fault or Warning Condition Temp Fan AC Battery Fuse Charger Remote Faul...

Page 28: ...qualified installers only Figure 1 6 Battery and Charger Temperature Thresholds Ambient Temperature derating to 80 Imax Charger ALARM set Charger FAULT set Charger ALARM reset Charger FAULT reset 25 2...

Page 29: ...on port for convenience The Remote Panel can be used to Program the charger for battery type and temperature Set the charger mode two or three stage charging Activate and terminate equalization not al...

Page 30: ...r Mode two or three stage To set or cancel an Equalization program Press and hold both the Status and ON STANDBY buttons 2 Charging Output LEDs The LEDs illuminate a progress bar displaying the presen...

Page 31: ...2 or 3 Each column represents Low Medium or Full battery capacity NOTE This feature is available only on the Remote Panel 5 Status Button Press and hold to enter or exit Setup Mode When in Setup Mode...

Page 32: ...1 18 This guide for use by qualified installers only...

Page 33: ...d configuring the Truecharge 2 Battery Charger It covers the following major topics Preparing for Installation on page 2 2 Installing the Truecharge 2 Battery Charger on page 2 12 Installing Optional...

Page 34: ...the AC and DC wiring and protection devices required for a typical installation Means of disconnection must be incorporated into the fixed wiring in accordance with the electrical code that governs e...

Page 35: ...ted circuit breaker 2 AC input wiring compartment 3 DC negative cable 4 DC positive cables 5 DC circuit breakers or DC fused disconnects 6 Battery or battery bank 7 Engine ground bus or DC negative bu...

Page 36: ...g used You need the following materials 3 conductor AC input wiring Use the information in Planning AC Wiring on page 2 15 and your local electrical codes to determine the correct wire and breaker or...

Page 37: ...entilated There must be at least 10 cm 4 in of clearance on the top and bottom ends of the Truecharge 2 Battery Charger for air flow and at least 6 cm 2 5 in of clearance on either side see Figure 2 3...

Page 38: ...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...

Page 39: ...on meets IP 32 marine requirements and is drip proof Vertical Wall Mount Rear panel facing down or up this orientation is allowed in locations that are always dry but is not approved for marine instal...

Page 40: ...es with all applicable codes and standards WARNING Shock and fire hazard Ensure that both wires and fuses are correctly sized Maximum continuous current available from the charger may be an additional...

Page 41: ...ly The current rating of the DC fuses must be correctly matched to the size of the DC wiring used in accordance with the applicable codes This helps to protect the installation against fire in case of...

Page 42: ...irements as will each application so research the regulations for your local jurisdiction to determine which wire size and type is correct Another example for marine applications the United States Ame...

Page 43: ...size Each bank should meet the minimum Ah rating shown in Table 2 3 Note If the battery manufacturer has specified the maximum charge current please follow their recommendation Table 2 3 Minimum Batte...

Page 44: ...t the charger page 2 15 4 Mount the charger in position page 2 18 5 Make the final DC see page 2 19 and then AC cable connections including earth grounds page 2 19 6 Apply DC to the charge by closing...

Page 45: ...r connections and to provide slack in the wires for strain relief 3 Identify the positive wires by using color coded wire or by marking both ends of the wire with colored tape or similar kind of marki...

Page 46: ...through an electrical distribution panel battery isolator or other device that will add voltage drops 6 Install crimp lugs on each end of the DC battery cables using the crimp manufacturer s instructi...

Page 47: ...e slack For example in North America for 120 Vac application you may use a 14 AWG wire with a 15 A breaker or 12 AWG for a 20 A breaker or for 230 Vac application you may be able to use either a 2 5mm...

Page 48: ...l to the neutral and the ground to the ground The pigtail wires are color coded as follows Make the connections using crimp on connectors or with other approved connectors required by your code and su...

Page 49: ...e insulation tapers down as shown c Repeat Step b for the other end of the butt splice 9 Slide the strain relief into the bottom half of the strain relief retention hole in the charger 10 When all con...

Page 50: ...to return the Truecharge 2 Battery Charger for servicing 2 Ensure that you have selected a mounting surface that is clear flat and allows for a minimum of 10 cm 4 in of clearance on the top and bottom...

Page 51: ...bank 1 to battery 6 Positive Cable bank 2 to battery 7 Positive Cable bank 3 to battery 8 Negative Cable A to battery terminal bank 1 9 Negative Cable A to DC negative bus bank 1 10 Negative Cable B...

Page 52: ...ge 2 13 3 After the DC cables are connected to the charger slide the boot up the cables and over the DC terminals If you are only using one battery slide the spare boots over the unused DC terminals T...

Page 53: ...ems 5 to 7 using sufficient torque as recommended by your battery manufacturer 4 Connect the free end of the negative cable to the negative terminal on the battery Figure 2 4 items 8 10 and 12 using s...

Page 54: ...Connect any optional accessories See Installing Optional Accessories on page 2 24 7 Secure cables in place using tie wraps P clamps or cable straps according to electrical codes Coil and tie any BTS...

Page 55: ...conductors and both must be sized for the battery fuses that are used to protect the DC wiring Refer to your local electrical codes to verify the requirements in your jurisdiction for your application...

Page 56: ...the four conductor communications cable RJ 11 that came with the remote panel 2 Use the enclosed mounting template to predrill mounting holes Take care that there is nothing behind the surface for yo...

Page 57: ...gative battery stud or affix the double sided adhesive backing to the sensor back and attach the sensor to the side of the battery to be monitored NOTE If there are multiple batteries attach the BTS t...

Page 58: ...e onboard display will illuminate for a second power on test before reporting charging and battery status information When the remote panel is connected there will be a short delay of about 1three sec...

Page 59: ...ing the Onboard Display Panel To configure the charger mode Note By default the Charger Mode is set to three stage 1 Press and hold the Charger Mode Select button for three seconds 2 Select the proper...

Page 60: ...ds to enter the Setup mode Entering the Setup mode will enable you to select the charger mode 2 Press ON STANDBY button to select the desired charger mode The LEDs will indicate which of the two types...

Page 61: ...has been programmed by the OEM all four LEDs will light up to indicate a fifth type Using the Remote Panel To configure the battery bank type Note By default the battery type is set to Flooded 1 Press...

Page 62: ...he Battery Temp is set to Warm 1 Press and hold the Status button for three seconds to enter the Setup mode Entering the Setup mode will enable you to select the battery temperature setting 2 Press St...

Page 63: ...Max Output button to select the appropriate maximum output setting The LEDs will indicate which of the five values is being selected 100 80 60 40 or 20 Table 2 4 Battery Temperature Compensation Leve...

Page 64: ...en the positive cable Inspect all AC and DC cables for damage and repair if necessary 4 Replace the old battery with the new battery 5 Reconnect the battery cables to the new battery NOTE Reconnect th...

Page 65: ...alified installers only ASpecifications Appendix A contains physical electrical performance and regulatory approval specifications for the Truecharge 2 Battery Charger Note Specifications are subject...

Page 66: ...5024 5 0 kg 11 0 lbs AC input connections Two color coded No 14 AWG wires L N and one No 14 AWG G minimum 152 mm 6 in long in a separate AC wiring enclosure with 21 3 mm 0 84 in hole provision for con...

Page 67: ...nits 12 Vdc 24 V units 24 Vdc Normal operating output range 12 V units 0 16 Vdc 24 V units 0 32 Vdc Nominal operating AC input voltage 110 250 Vac Maximum DC output current total TC1012 10 10 A TC1512...

Page 68: ...24 V units 12 V units 24 V units 25 C 77 F 25 C 77 F Flooded 13 5 27 0 GEL 13 8 27 6 AGM 13 4 26 8 Lead calcium 13 5 27 0 Equalize mode current 50 rated output 6 Equalize mode maximum output voltage...

Page 69: ...TC1012 2 5 A TC1012 1 5 A TC1512 3 5 A TC1512 2 0 A TC2012 4 5 A TC2012 2 5 A TC3012 7 0 A TC3012 3 5 A TC4012 9 0 A TC4012 4 5 A TC5012 11 5 A TC5012 5 5 A TC6012 13 5 A TC6012 6 5 A TC1524 7 0 A TC1...

Page 70: ...uracy no load 12 V units 0 1 Vdc at 14 4 Vdc 25 C 77 F 24 V units 0 2 Vdc at 28 8 Vdc 25 C 77 F Voltage regulation Uncompensated load voltage regulation 0 1Vdc drop from 0 Amps to rated current output...

Page 71: ...p to 15 5 V TC5012 50 10 A up to 15 5 V TC6012 60 10 A up to 15 5 V TC1524 15 10 A up to 31 V TC2024 20 10 A up to 31 V TC3024 30 10 A up to 31 V TC5024 50 10 A up to 31 V Over temperature Internal ch...

Page 72: ...ive 2006 95 EC complying with EN60335 2 29 Battery Chargers including Australian deviations ISO 8846 Ignition Protection for Small Craft ABYC E11 Alternating Current and Direct Current Electrical Syst...

Page 73: ......

Page 74: ...gy Inc 1 800 670 0707 Tel toll free NA 1 408 987 6030 Tel direct 34 93 470 5330 Europe 1 800 994 7828 Fax toll free NA 34 93 473 6093 Europe customerservice xantrex com www xantrex com 975 0402 01 01...

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