Xantrex Truecharge TC1012 Owner'S Manual Download

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Series Battery Charger

Owner’s 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

TC2 Series BattChg Owners Guide.book Page i Tuesday, July 1, 2008 11:55 PM

Summary of Contents for Truecharge TC1012

Page 1: ...eries Battery Charger Owner s 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...

Page 2: ......

Page 3: ...Truecharge 2 Series Battery Chargers Owner s Guide...

Page 4: ...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 AS...

Page 5: ...e a certified technician or electrician and should use the Truecharge 2 Battery Charger Installation Guide doc part number 975 0402 01 01 Organization This Guide is organized into three chapters and o...

Page 6: ...rred to individually the product will be referred to by its model name When all models are being referred to they will be referred to as Truecharge 2 Battery Chargers Related Information You can find...

Page 7: ...r or obstruct the air intake vent openings Do not install the Truecharge 2 Battery Charger in a zero clearance compartment Overheating may result 3 This appliance is not intended for use by persons in...

Page 8: ...ection 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 obtaining service Attempting to...

Page 9: ...he 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 voice or close enough to...

Page 10: ...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 CHARGE 10 Make sure the area...

Page 11: ...from a battery will corrode and damage the charger 17 Never allow battery acid to drip on the charger when reading gravity or filling battery 18 Do not operate the charger in a closed in area or restr...

Page 12: ...rmful 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 tel...

Page 13: ...Charging 2 3 Two Stage Charging 2 4 Charging Voltage Setpoints 2 5 Charging Overview 2 6 Charging Batteries 2 8 Equalizing Flooded Batteries 2 10 About Equalization 2 10 Performing An Equalization 2 1...

Page 14: ...Optional Remote Panel 3 4 Replacing the DC Output Fuse 3 11 Troubleshooting 3 12 A Specifications Physical Specifications A 2 Electrical Specifications A 3 AC Input Specifications A 5 DC Output Specif...

Page 15: ...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...

Page 16: ...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 13 to 158 F 1 Model TC101...

Page 17: ...g installation in engine spaces isolated design over temperature and short circuit protection for the BTS and communication connector ports drip proof rubber boots for DC terminals for added moisture...

Page 18: ...atus 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 charger status and charging cu...

Page 19: ...t 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 installation Remove and...

Page 20: ...sor 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 Important note below 6 Batte...

Page 21: ...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 utilized Bypassing bank 1 and u...

Page 22: ...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 the button must be held do...

Page 23: ...cators 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 Ready and Charging solid li...

Page 24: ...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 setting GEL Gel type lead aci...

Page 25: ...dition 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 Charging Output and Faul...

Page 26: ...t 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 Fan fault Loss of Remote...

Page 27: ...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 Fault F u s e C h g r R e m...

Page 28: ...1 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 20 15 10 5 0 5 10 20 30 4...

Page 29: ...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 allowed for GEL and AGM Im...

Page 30: ...ncel an Equalization program Press and hold both the Status and ON STANDBY buttons for more than five seconds 2 Charging Output LEDs The LEDs illuminate a progress bar displaying the present total out...

Page 31: ...esents 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 Press to select the Bat...

Page 32: ...1 18...

Page 33: ...ualizing Flooded Batteries on page 2 10 Transitioning the Truecharge 2 Battery Charger to ON Standby or Disabled on page 2 13 Accessing Charger Information on page 2 14 WARNING The battery charger mus...

Page 34: ...that share the full rated current output The Truecharge 2 Battery Charger can perform either three stage charging Bulk Absorption and Float or two stage charging Bulk and Absorption Important The batt...

Page 35: ...is no load on the battery it will typically draw very little current The charger however is able to provide current to its full rating to power auxiliary DC loads on the battery The charger will rest...

Page 36: ...t the charging cycle in the Bulk stage if the lowest battery voltage of the three banks drops below 12 5V 12 V chargers or 25 V 24 V chargers for 15 minutes After 21 days the charger will automaticall...

Page 37: ...um Voltages for 12 V Chargers Battery Type Bulk Absorption Volts Float Volts Equalization Volts Flooded 14 4 13 5 16 0 GEL 14 2 13 8 not applicable AGM 14 3 13 4 not applicable Lead Calcium 15 5 13 5...

Page 38: ...in most need of charging is the one that receives the most charge For example if Bank 1 and Bank 2 are both charged but Bank 1 has a load and Bank 2 does not then the charger may rarely charge Bank 2...

Page 39: ...panel WARNING Fire hazard and battery damage Ensure that the battery temperature setting Cold Warm or Hot is set to the environment where the battery will be installed If the temperature is set incorr...

Page 40: ...cturer of your batteries and follow all safety precautions and the required steps 3 Apply AC power to the Truecharge 2 Battery Charger by closing the AC breaker or turning the generator on All onboard...

Page 41: ...lected the two stage charging mode the ready indicator LED shows the charger is now in rest mode and is checking battery voltage and elapsed time since the last charge cycle With either charging mode...

Page 42: ...s set to sealed lead acid batteries GEL or AGM since they will be damaged by this process Use the correct settings for your battery types WARNING Explosion hazard During equalization the battery gener...

Page 43: ...ut the absolute maximum is 16 V for 12 V chargers and 32 V for 24 V chargers within operational temperature range If this level of equalization voltage does not comply with the battery manufacturer s...

Page 44: ...repeat Step 3 5 Check the battery electrolyte level If necessary refill with distilled water only and repeat a normal charge cycle Important If equalization is programmed prior to float or rest mode...

Page 45: ...ess ON STANDBY on the remote panel while batteries and AC power are both connected to the charger from ON The charger stops charging but continues to monitor the batteries There is only ONE way to saf...

Page 46: ...terpreting the onboard display panel and the optional remote panel if installed indicator LEDs Reporting While Charging or Equalizing After configuring the charger and during charging the remote panel...

Page 47: ...the status of the batteries The remote panel will turn itself off after 30 seconds of inactivity Using A Generator As Source Power The Truecharge 2 Battery Charger can be run from a regular AC power...

Page 48: ...2 16...

Page 49: ...3Troubleshooting Chapter 3 contains information and procedures for troubleshooting your Truecharge 2 Battery Charger...

Page 50: ...g connections to be sure they have not loosened or deteriorated Also check all cable clamps to ensure they are tightly fastened Loose battery terminals and lugs exposed to open air corrode rapidly The...

Page 51: ...es evenly coat all the exposed metal surfaces of the battery terminals and lugs with liquid neoprene If liquid neoprene is not available use a light coating of anti corrosion grease or other non adhes...

Page 52: ...ing AC power and all LEDs are functioning The Truecharge 2 Battery Charger will recover from fault conditions automatically when the cause of the fault or warning has disappeared In most cases the cha...

Page 53: ...or 24 V nominal for all 24 V chargers Check that the battery type and temperature settings match the actual battery and its conditions Disconnect the battery or batteries to stop charging Allow the b...

Page 54: ...Low Battery Temp warning 0 C Check the batteries Do not charge a frozen battery Charging a frozen battery may present a risk of explosion Check that the battery type and temperature settings match th...

Page 55: ...to a more stable AC power source and check that the voltage and voltage frequency are within acceptable operating range See Appendix A Specifications AC input out of range fault 90V or 265V Check AC...

Page 56: ...er location If the temperature increases the Truecharge 2 Battery Charger will display a fault and stop functioning If the optional remote panel is installed set a lower limit on the output current to...

Page 57: ...ect the communication cable to the port It takes 15 minutes to re establish communication Reverse Polarity Fuse fault Check for reverse battery polarity negative connected to negative positive connect...

Page 58: ...ree stage charging All batteries have been fully charged Charging LED illuminates solid The charger is charging in bulk or absorption mode Equalize LED flashes The charger will perform an equalization...

Page 59: ...The screw will not separate from the cover 4 Pull out the blown fuse s gently using the provided fuse puller NOTE The fuse puller is located on the inside of the cover 5 Install a brand new fuse s wit...

Page 60: ...ower is available at charger AC input and a battery or bank is connected on bank 1 Wiring must be inspected and replaced by a qualified technician Possible Cause Solution Truecharge 2 Battery Charger...

Page 61: ...nel is available you may reduce the output current using the Set Max Output button If battery is too cold allow batteries to warm up WARNING Do not charge a frozen battery Charging a frozen battery is...

Page 62: ...r the Truecharge 2 Battery Charger model Load connected to battery is draining charge current so that battery does not recharge Battery has a damaged cell or has reached the end of its useful life Use...

Page 63: ...k you are attempting to equalize Determine if the battery type is set to GEL or AGM These battery types cannot be equalized The charger will wait for all batteries to be in float stage of three stage...

Page 64: ...3 16...

Page 65: ...ASpecifications Appendix A contains physical electrical performance and regulatory approval specifications for the Truecharge 2 Battery Charger Note Specifications are subject to change without notice...

Page 66: ...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 connection of a inch North...

Page 67: ...4 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 15 10 A TC2012 20 10 A...

Page 68: ...4 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 12 V units 16 0 1 Vdc 24...

Page 69: ...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 TC1524 3 5 A TC2024 9 0 A T...

Page 70: ...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 at charger output termin...

Page 71: ...10 A TC6012 60 10 A TC1524 15 10 A TC2024 20 10 A TC3024 30 10 A TC5024 50 10 A Over temperature Internal charger temperature is measured Charger shuts down and restarts as follows Shutdown at 70 C 15...

Page 72: ...with EN60335 2 29 Battery Chargers including Australian deviations ISO 8846 Ignition Protection for Small Craft ABYC E11 Alternating Current and Direct Current Electrical Systems on Boats ABYC A31 Ba...

Page 73: ...s required What will Xantrex do During the Warranty Period Xantrex will at its option repair the product if economically feasible or replace the defective product free of charge provided that you noti...

Page 74: ...any one of the following forms The dated purchase receipt from the original purchase of the product at point of sale to the end user or The dated dealer invoice or purchase receipt showing original eq...

Page 75: ...IMPLIED STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT HOWEVER ARISING WHETHER BY CONTRACT TORT NEGLIGENCE PRINCIPLES OF MANUFACTURER S LIABILITY OPERATION OF LAW CONDUCT STATEMENT OR OTHERWISE...

Page 76: ...the wrong location When you contact Xantrex to obtain service please have your instruction manual ready for reference and be prepared to supply The serial number of your product Information about the...

Page 77: ...incorrect installation if other conditions of the warranty have not been met or if no dated proof of purchase is available your unit may be serviced or replaced for a flat fee To return your product f...

Page 78: ...Purchased From _________________________________ Purchase Date _________________________________ Type of installation e g RV truck _________________________ Length of time inverter has been installed...

Page 79: ......

Page 80: ...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 0401 01 01...

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