Truecharge 20+/40+ Amp Owners Manual
Contents
1. C5 Product and System I nformation 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 22 eee eee eee eee eee Index 1 vii viii I mportant Safety I nstructions WARNING AN 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 fir2. 4 2 Typical Problems 4 4 Specifications Physical Specifications A 2 Electrical Specifications A 2 AC Input Specifications A 4 Protection Features A 4 Approvals A 5 Battery Charging Charging Algorithms B 2 Battery Type B 2 Charge Algorithm Stages B 2 Equalization Charge B 4 Two Stage Charging B 4 Battery Maintenance Contents Maintenance Guidelines C2 Preparation for Cleaning Batteries C3 Clothing C 3 Tools eee C 3 Equipment C 3 Supplies C 3 Maintaining and Cleaning C4 Battery Enclosure and Batteries C4 Terminals amp Lugs C4 Cables
3. 2 7 Installing Truecharge 2 8 Mounting 2 8 Connecting DC Wiring For A Single Battery Or Multiple Batteries 2 9 Contents vi Connecting to AC Wiring 2 11 Grounding 2 14 Installing Optional Accessories 2 14 Battery Temperature Sensor 2 14 Remote Display Panel 2 15 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 Maintenance and Troubleshooting Care and Maintenance 4 2 Troubleshooting 4 2 Indicator Light Flashing Sequences
4. 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 14 Optional Accessories 1 4 Indicator Lights and Settings on the Front Panel 14 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
5. only needs equalizing every two to four months Truecharge provides a high quality charge so batteries will not need to be equalized as often as with a lower quality charger 3 7 Operation Battery type Duration Battery charge state Recommended Truecharge equalizes only flooded lead acid batteries It does not equalize sealed lead acid batteries since they can be damaged by this process If the battery type selector is set for Gel or AGM and you try to equalize them the indicator lights on the front panel flash but Truecharge does not enter equalization mode Equalization is manually terminated when the specific gravity in each cell is about 1 265 and remains constant at that level Truecharge automatically exits the equalization mode after six hours whatever the specific gravity in the event you cannot terminate the equalization yourself Equalization is only performed on fully charged batteries If they are not charged the first part of the process is similar to the absorption charge and ensures the battery is fully charged 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 equalization cycle it does not indicate when the charging has finished and the equalization begins It is a recommended practice to only equalize batteries which are fully charged Performing An Equalization 3 8 CAUTION Ris
6. tariffs and deposits Product and System Information D 6 If you are returning a product to 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 verify any return procedures that may apply to that particular facility Information about your Truecharge Information about your Truecharge Please record the following information when you unpack your Truecharge unit Model Number Serial Number Purchased From OO oO Q Purchase Date If you need to contact Customer Service please gather the following information before calling The information will assist the service representative in providing you with better service O Type of installation for example home boat RV O Length of time unit has been installed O Battery bank size O Battery type Flooded Gel AGM O AC wiring size and length O DC wiring size and length O Battery Temperature Sensor installed Product and System Information D 8 Index A absorption charge battery activity during B 3 AC input specifications A 4 AC wiring requirements 2 6 AGM absorbed glass mat batteries B 2 AGM batteries selector switch for 1 3 anti corrosion grease C 2 B baking soda C 3 batteries AGM absorbed glass mat B 2 first aid when working with 1 x
7. SPECIAL DIRECT INDIRECT INCIDENTAL 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 PERSONAL INJURY ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE OR THE INCORRECT INSTALLATION INTEGRATION OR OPERATION OF THE PRODUCT If this product is a consumer product federal law does not allow an exclusion of implied warranties To the extent you are entitled to implied warranties under federal law to the extent permitted by applicable law they are limited to the duration of this Limited Warranty Some states and provinces do not allow limitations or exclusions on implied warranties or on the duration of an implied warranty or on the limitation or exclusion of incidental or consequential damages so the above limitation s or exclusion s may not apply to you This Limited Warranty gives you specific legal rights You may have other rights which may vary from state to state or province to province WARNING LI MI TATIONS ON USE D 4 Please refer to your product user manual for limitations on uses of the product Return Material Authorization Policy Return Material Authorization Policy Before returning a product directly to Xantrex you must obtain a Return Material Authorization RMA number and the correct factory Ship To address Products must also be shipped prepaid Produc
8. current reading This happens because the current is between the two values indicated by the two indicator lights Note that the indicator light values are minimums For example the 10 amp indicator light indicates current in excess of 10 amps Before you start to charge batteries read the Important Safety Instructions on page ix and take all safety precautions when working with batteries To charge your batteries 1 If possible disconnect all loads from the battery by removing battery cables by opening a disconnect switch or by switching loads off The charger detects a battery is fully charged when its charging current drops below a preset limit The presence of electrical loads on the battery may interfere with this detection method A timer based charge termination feature acts as a backup but the charging current based method is preferable 3 5 Operation 2 Set the Battery Type selector switch according to the table below If your battery is then select Flooded has removable caps Flooded intended for refilling Any sealed type but AGM Gel Absorbed glass mat AGM 3 Set the Battery Temperature selector switch for the temperature of your battery as follows If battery temperature is Select Below 50 F 10 C Cold Between 50 F 10 C and Warm 80 F 27 C Above 80 F 27 C Hot If temperatures fluctuate near the batteries set this switch each time you charge th
9. gravity of each cell of the battery remains constant Most lead acid batteries have a specific gravity of approximately 1 265 when fully charged To terminate the equalization charge when the battery reaches the target specific gravity momentarily press the equalization button The charger will go to float mode for three stage charging or monitor mode for two step charging If the specific gravity is still rising when the charger automatically exits equalization to float mode after 6 hours you can initiate further equalization by pressing the Equalize button for five seconds When equalization has finished check the battery electrolyte level If necessary refill with distilled water only 3 9 Maintenance and Troubleshooting 2 Chapter 4 Maintenance and Troubleshooting provides information for maintaining and troubleshooting Truecharge Maintenance and Troubleshooting Care and Maintenance Cleaning Routine checks i WARNI NG Risk of electrical shock Truecharge contains no user serviceable components Do not attempt servicing unless you are a qualified technician or electrician Contact your dealer or the manufacturer for service information Truecharge contains solid state electronic components that require no maintenance The best care you can give the unit is to protect it from contact with liquids spray or fumes which may cause corrosion Disconnect all AC and DC power and clean the outside of t
10. of indicator lights in 4 2 two stage charging difference from three stage B V voltage range when charging 1 2 W warranty terms and conditions D 2 wiring order for installation figure 2 9 Index Index 3 Xantrex Technology Inc Toll free 1 800 670 0707 Direct 1 360 925 5097 Fax 1 360 925 5143 CustomerService xantrex com Www xantrex com
11. of your batteries The Battery Temperature Sensor Installation sheet offers suggestions for the most appropriate battery to monitor and the best placement of the temperature sensor on the battery Effect on charging Installing Optional Accessories With the BTS the charging setpoints are temperature compensated up to 140 F 60 C If the battery temperature exceeds 140 F the charger stops charging The BTS also provides more accurate compensation over a wider range of temperatures than the front panel temperature settings For example with the switch in the HOT position the charger compensation is equivalent to the BTS compensation at 95 F 35 C At 95 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 if you are just using the temperature setting switch Remote Display Panel The Remote Display Panel allows you to monitor battery charger activity away from the charger whenever Truecharge is operating The panel displays the total charging current and the voltages of the two batteries or battery banks connected to the two positive terminals closest to the negative terminal The insert card which accompanies the panel provides the directions for installing it Operation Chapter 3 Operation provides background information for charging batteries with Truec
12. provides Xantrex does not recommend the use of Truecharge with MSW generators due to increased heating of the charger Indicator Light Activity On The Front Panel 3 4 Indicator light activity shows what is happening during the charging process and is also helpful in troubleshooting Refer to Chapter 4 Maintenance and Troubleshooting for more information about interpreting indicator lights During the charging process indicator lights are interpreted as follows Activity Charger status Charging indicator light is The unit is charging in bulk or absorption lit mode Both Ready and Charging The unit is performing the pre equalization indicator lights illuminate absorption charge or is performing the equalization charge Activity Charging batteries Charger status 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 of all indicator lights Truecharge can t respond to your request You may have pressed the equalization button for an inappropriate setting such as a gel battery Check your settings Charging Current indicator lights Charging batteries Before you start These lights indicate the charging current At transition points when the current is changing two indicator lights may flash alternately then settle into the new charging
13. 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 Tr
14. Smart choice for power Aqa ntrex Owner s Guide Xantrex Truecharge 20 40 Amp Multistage Battery Charger www xantrex com Truecharge 20 40 Amp Multistage Battery Charger Owner s Guide xantrex Smart choice for power 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
15. ainst floating their batteries The Truecharge goes into a monitoring mode instead where the charger monitors the batteries but does not charge or float them A new charge cycle will be initiated under the same conditions as for three step charging B 4 Battery Maintenance 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 Battery Maintenance Maintenance Guidelines Electrolyte Battery connections C 2 WARNING Risk of acid burns Wear appropriate eye protection and rubber gloves when carrying out battery maintenance activities Use caution when wearing jewellery or working with metal tools around batteries Do not allow any metal object to contact both battery terminals at the same time The metal may become welded to the battery terminals causing extreme heating or fire WARNING Risk of fire explosion burns At a minimum check the level of the electrolyte in each battery cell once a month for flooded batteries It should be above the top of the plates but not completely full Most batteries have a plastic cup that just touches the electrolyte when the cell is full Don t overfill the batteries or the electrolyte will spill out when the batteries are being charged Refill the batterie
16. al 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 Owner s Guide Wiring cover with 2 blunt tip screws and two lock washers AC cable clamp Three twist on wire nuts Three crimp on butt splices Recording After unpacking the unit record the serial number and other purchase information information on page D 7 of this guide Preparing for I nstallation Mounting Truecharge is designed to be permanently mounted It is virtually maintenance free when properly installed Conditions Before mounting and connecting Truecharge be sure you meet the requirements for 2 2 location circuits wiring tools and materials Location Circuits Preparing for Installation 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 Dry The unit is intended for use in a dry location Do not allow water or other fluids to drip or splash on Truecharge Do not mount the charger in an area subject to rain spray or splashing bilge water Clean Do not expose Truecharge to metal filings or any other form of conductive contamination The presence of co
17. are no stray wire strands protruding from the terminal Tighten the connector 20 in lbs torque and test that the wire is secure Repeat this step for up to three batteries or battery banks 7 Connect the positive cable from the positive wire terminals on the charger to the battery fuse or breaker which should be installed on the battery positive terminals Figure 2 3 4 5 6 Leave the DC disconnects or breakers in the Off position until installation is complete Leaving them off helps prevent sparking when you actually make the connections 10 11 Installing Truecharge Before proceeding carefully check the wiring polarity make sure the positive on the charger is going to the positive on the batteries fuse or breaker and make sure the negative on the charger is going to the battery negative terminal or engine negative bus or DC negative bus Do not reverse the connections If you reverse the polarity of any one of the DC connections the internal fuse for that output bank opens A qualified technician must replace this fuse for that bank to function The other banks should continue to function normally To make a single battery bank connection e Connect the negative cable to the battery negative terminal e Fully insert the negative wire into the negative terminal on the charger Figure 2 3 14 Make sure there are no stray wire strands protruding from the terminal Tighten the connector 20 in lbs torque and tes
18. arger 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 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 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 Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Important Safety Information Wear complete eye protection and clothing protection Avoid touching your eyes while working near batteries 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 imm
19. ation Indicator Lights and Settings on the Front Panel 1 4 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 Status Charging Current A Ready ami ECU I I E 2 P Equalize 9 1 3 51020 Charger Mode Bulk Absorption Bulk Absorption Float 13 5V fixed Battery Temperature z 6 P gt Battery Type Flooded Cold Warm Hot IN 14 8 13 9 14 0 13 1 N 14 6 14 2 13 8 13 4 NI 14 6 13 7 14 0 13 1 Output Volts Absorption Float TRUECHARGE Multi Stage Battery Charger Figure 1 1 Front panel of Truecharge 20 battery charger Indicator Lights and Settings on the Front Panel Table 1 1 Truecharge front panel Panel Item Description 1 Status indicator lights which indicate that batteries are charged and ready for use or that the batteries are being charged or equalized 2 Indicator 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 3 The recessed Equalize button is triggered manually to enter or leave the equalization mode 4 The 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 5 The battery selection switch for choosing flooded gel
20. cations AC Input Specifications Truecharge 20 Truecharge 40 AC input voltage range 90 135 VAC 50 60 Hz 120 VAC Maximum AC input current at 6 5 Aims 12 A ums 90 VAC Typical AC input current at 4 6 Aims 8 5 Anns No load AC power draw without remote panel less than 3 watts less than 3 watts 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 Protection features Battery reverse polarity Internal fuses for each output non user replaceable Safe non operating battery voltage 24 VDC maximum Over voltage limits Will not start charging if any battery voltage is greater than 15 0 VDC Will not continue charging if any battery voltage is greater than 16 0 VDC Output current limit Truecharge 20 20 5 22 5 Adc Truecharge 40 41 0 44 0 Adc Approvals Protection features Over temperature Internal charger temperature is measured Unit shuts down and restarts as follows e Over temperature shutdown at 62 C e Over temperature restart at 61 C Current derating in Truecharge 20 Truecharge 40 ambient temperatures 20 A at 30 C to 10 A at 50 C 40 A at 30 C to 20 A at 50 C automatic output Battery over temperature Battery temperature as sensed by the battery temperature sens
21. charger is connected to an AC receptacle Possible Cause Solution 1 No power at AC receptacle 2 Defective wiring 3 Open fuses in charger 1 Ensure that power is available at receptacle Replace wiring Have charger serviced by qualified person Symptom Indicator lights continue to blink when charger connected to battery Charging indicator light does not turn on continuously Possible Cause 1 Charger does not detect battery for one of following reasons e poor connection e reverse polarity connection e damaged wiring e open fuse in charger 2 Battery voltage is too low 4 4 Solution 1 Check polarity and quality of battery connection If cables are damaged or internal fuse open have the charger serviced by a qualified person Check the battery Do not attempt to charge a 6 volt battery If battery is rated for 12 volts leave it connected for 8 hours to see if it will recover If battery doesn t start charging after 8 hours it is permanently damaged and will not accept a charge Troubleshooting Symptom Charging light blinks but does not come on steadily Other indicator lights are off Possible Cause Solution 1 Battery voltage is too 1 high above 15 5 volts 2 Battery is connected to 2 another charging source with voltage above 15 5 VDC Check battery Do not charge a battery rated at more than 12 volts nominal Disconnect or tu
22. conditions beyond the maximum or minimum limits listed in the Xantrex product specifications including high input voltage from generators and lightning strikes c the product if repairs have been done to it other than by Xantrex or its authorized service centers hereafter ASCs d the product if it is used as a component part of a product expressly warranted by another manufacturer e the product if its original identification trade mark serial num ber markings have been defaced altered or removed D 3 Product and System Information DI SCLAI MER Product Exclusions THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS WHERE PERMITTED BY LAW IN LIEU OF ALL OTHER WARRANTIES CONDITIONS GUARANTEES REPRESENTATIONS OBLIGATIONS AND LIABILITIES EXPRESS OR 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 INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED WARRANTY IN NO EVENT WILL XANTREX BE LIABLE FOR ANY
23. cting the AC and DC circuits If the over current protection device is a circuit breaker it will also serve as the disconnect If a fuse is used a disconnect switch is needed ahead of the fuse 2 6 Tools Materials Preparing for Installation To mount and connect Truecharge you need m a slot screwdriver with a maximum 3 16 in wide blade for the DC terminals a No 1 Phillips screwdriver for securing the AC wiring compartment cover a wire stripper the manufacturer s recommended crimp tool for any crimp terminals that are being used You need the following material Oo Oo m 3 conductor No 14 AWG AC cable Appropriately sized DC cables for each battery with suitable connectors at the battery end DC fuse and disconnect or circuit breaker for each battery bank Mounting hardware 8 recommended minimum 4 Other means to route and secure AC and DC wiring 2 7 Installing Truecharge Installing Truecharge 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 responsible for ensuring compliance with the installation codes for your particular application Disconnect all sources of AC and DC power before proceeding CAUTION Reverse polarity Before making the final DC connection check the cable polarity at both the battery and the charger Positive must be connec
24. d 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 e 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 Installing Truecharge AC Wiring Be sure that your AC wiring meets the following requirements before you install the Truecharge e Input wiring The AC input wiring for Truecharge should be three conductor cable providing a line neutral and ground conductor in an outer jacket The conductors must be No 14 AWG or larger For marine applications the ABYC requires stranded wire It stands up to vibration better than solid wire For RV applications the NEC allows solid wire in multi conductor cable but stranded wire will again withstand vibration better e 120 VAC 15 amp branch circuit The circuit supplying the Truecharge must be rated 120 VAC single phase 15 amps maximum It may be either a 15 amp shorepower connection or a dedicated 15 amp branch circuit from your 30 amp or 50 amp shorepower connection In either case the charger must be protected by a 15 amp breaker or fuse maximum e Disconnect devices Each system requires a method of disconne
25. e 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 Important Safety Information As 10 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 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 The charger must be provided with an equipment grounding conductor connected to the AC input ground For marine applications in the United States external connections to the ch
26. e batteries If your batteries are in different locations with different temperature ranges set the switch to Hot or to the temperature of the warmest location Note The remote temperature sensor if installed overrides this setting and it controls the charge voltage based only on the battery to which the sensor is attached 4 Ventilate the area around the battery thoroughly Review the charging instructions supplied by the manufacturer of your batteries and take any steps required such as removing battery caps adding distilled water and so forth 5 Apply AC power 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 yellow charging indicator light illuminates During charging the charging current indicator lights show the total current being delivered to the batteries When charging a discharged battery the 20 A indicator light on Truecharge 20 40 A indicator 3 6 After charging Recharging Equalizing Flooded Batteries light on Truecharge40 will light for most of the charging cycle Near the end of the cycle the charging current decreases and the other indicator lights illuminate in sequence The charger pauses every 15 minutes for approximately 10 seconds to measure the battery voltage and to check for new or disconnected batteries It then resumes charging You may n
27. e rapidly The corrosion appears as a white powder or granular foam on the terminals 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 exposed to this corrosive eventually dissolve The most common cause of battery system failure is loose or corroded battery terminals and cable lugs If any white powdery residue forms between the battery cable lug and the battery terminal remove the cable for cleaning When it is necessary to detach a battery cable from the battery disconnect all loads and charging sources Using the appropriate tool remove the negative battery cable first and re install it last To remove any stubborn residue sprinkle baking soda directly on the area scrub with a wet toothbrush or other soft bristle brush add water as required and then rinse Cables Maintaining and Cleaning Reconnect the battery cable terminals to the battery lugs and tighten to approximately 10 15 foot pounds using the torque wrench If you do not have a torque wrench use an appropriate tool to tighten the bolts reasonably snug Do not over tighten After tightening the cables evenly coat all the exposed metal surfaces of the battery terminals and lugs with liquid neoprene This will cure to form an airtight protective layer If liquid neoprene is not available use a light coating of anti cor
28. ediately xi 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 thei
29. ensor e state of charge The three automatic stages are e bulk e absorption e float There is a fourth stage equalization that is initialized manually since it is only performed occasionally and only on flooded batteries Bulk Charge Absorption Charge Float Charge Charging Algorithms In the first stage known as the bulk charge Truecharge delivers its full rated output current This constant current is delivered to the batteries until the battery voltage approaches its absorption voltage typically around 14 4 volts for 12 volt batteries The bulk charge stage restores about 75 of the battery s charge During the absorption charge the charging voltage is held constant near the gassing voltage and the battery gradually reduces the charging current it demands as it attains full charge Once the current drops below 4 Adc for three minutes the charger either exits to Float for gel and 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 The float charge is a maintenance mode in which the output voltage of the charger is reduced to a lower level typically about 13 5 volts to maintain the battery s charge without losing electrolyte through gassing Unlike many standalone chargers Truecharge can be left connected to your battery indefinitely without risk of overcharging I
30. erature Gap tovr oO VAMI EOF OoCoDFRZO S Eme FZO Effect of Cold battery temperature If you choose the Cold setting temperature Truecharge delivers for example 14 8 volts in absorption mode and 13 9 volts in float for a Flooded battery Hot battery temperature If you choose the Hot setting for the same battery the charger delivers 14 0 volts in absorption mode and 13 1 volts in float nearly one volt of difference from the cold battery charge Consequence of wrong selection If you choose 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 to reduce the risk of overcharging The same is true for Gel and AGM type batteries The life of your battery will be extended if all banks are in a similar temperature environment and you make sure the switch setting is correct each time you charge You should consider purchasing a Xantrex battery temperature sensor if you expect wide temperature fluctuations 3 3 Operation Using A Generator As Source Power The Truecharge can be run from a regular power source or from an alternate power source such as a generator Refer to Appendix A Specifications for AC input draw to determine the size of generator you need Many generators provide output voltage that is modified sine wave MSW rather than the true sine wave TSW that your utility
31. eturn Material Authorization Policy described in your product manual For some products Xantrex maintains a network of regional Authorized Service Centers Call Xantrex or check our website to see if your product can be repaired at one of these facilities In any warranty claim dated proof of purchase must accompany the product and the product must not have been disassembled or modified without prior written authorization by Xantrex Proof of purchase may be in any one of the following forms e The dated purchase receipt from the original purchase of the product at point of sale to the end user or e The dated dealer invoice or purchase receipt showing original equipment manufacturer OEM status or e The dated invoice or purchase receipt showing the product exchanged under warranty What does this warranty not cover This Limited 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 Xantrex will not be responsible for any defect in or damage to a the product if it has been misused neglected improperly installed physically damaged or altered either internally or externally or damaged from improper use or use in an unsuitable environment b the product if it has been subjected to fire water generalized cor rosion biological infestations or input voltage that creates oper ating
32. h inspection establishes the existence of such a defect and that it is covered by this Limited Warranty Xantrex will at its option use new and or reconditioned parts in performing warranty repair and building replacement products 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 watranty continues for the remaining portion of the original Warranty Period or 90 days from the date of the return shipment to the customer whichever is greater All replaced products and all parts removed from repaired products become the property of Xantrex Xantrex covers both parts and labor necessary to repair the product and return shipment to the customer via a Xantrex selected non expedited surface freight within the contiguous United States and Canada Alaska and Hawaii are excluded Contact Xantrex Customer Service for details on freight policy for return shipments outside of the contiguous United States and Canada How do you get service If your product requires troubleshooting or watranty service contact your merchant If you are unable to contact your merchant or the merchant is unable to provide service contact Xantrex directly at Phone 1 800 670 0707 toll free in North America or 1 360 925 5097 direct Fax 1 360 925 5143 Email CustomerService xantrex com Warranty Direct returns may be performed according to the Xantrex R
33. harge 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 Operation About Charging This section provides information about e calculating the charging time e effect of battery temperature on charging e indicator light activity during the charging process e using a generator to run Truecharge Charging Time Formula Charging time will depend on the capacity of your battery and on how deeply it is discharged The following equation calculates an approximate charging time Charging time CAP x DOD CC x 80 where Charging Time Battery recharge time in hours CAP Battery capacity in amp hours DOD Battery depth of discharge in per cent A fully discharged battery has 100 DOD CC Charge current the rated current output of the charger in amperes 80 Typical charging efficiency for lead acid batteries 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 follows Charging time 82 Ah x 40 2 hours 20 A x 80 3 2 About Charging Battery Temperature Temperature Selecting the correct temperature setting selects the appropriate charging switch voltage to compensate for battery temp
34. he case and wiring with a damp cloth if you suspect it has come in contact with battery fluid salt water gasoline or oil or other corrosive material Corrosion on the battery terminal posts may be removed with a solution of water and baking soda Periodically check all wiring 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 Table 4 1 Indicator light sequences on Truecharge Display Condition Charging indicator light is on all Battery is not detected indicator lights light in sequence repeatedly Charging indicator light blinks all The battery voltage is greater than others are off 15 5 VDC Highest charging current indicator Unit is in over temperature or under light blinks all others are off temperature shutdown Troubleshooting Table 4 1 Indicator light sequences on Truecharge Display Condition Middle charging current 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 4 3 Maintenance and Troubleshooting Typical Problems This section lists typical problems you may have with the Truecharge suggests their causes then offers possible solutions to the problems Symptom Indicator lights do not turn on or remain on when
35. k of battery damage Truecharge cannot automatically determine when to stop the equalization of a battery You must monitor the battery specific gravity throughout equalization to determine the end of the equalize cycle The six hour time out is intended as a safety feature but may not be sufficiently short to prevent battery damage i WARNI NG Explosion hazard During equalization the battery generates potentially flammable gases Follow all the battery safety precautions listed in this guide Ventilate the area around the battery thoroughly and ensure that there are no sources of flame or sparks in the vicinity Important Equalizing Flooded Batteries Turn off or disconnect all loads on the battery during equalization The voltage applied to the battery during equalization may be above the safe levels for some loads Be sure to check battery electrolyte before and after equalization Fill only with distilled water To equalize your batteries 1 Using a toothpick or other small object with a fine point such as a paper clip or pen point press the recessed Equalize button on the control panel below the Charging and Ready indicator lights Press and hold for about 5 seconds until both the Charging and Ready indicator lights illuminate The charger is now in equalization mode Monitor the specific gravity of each cell of the battery during equalization with a battery hydrometer Equalization is complete when the specific
36. l follow trying to make it as short as possible Measure the required wire length and cut the cables Allow some extra length for connections and to provide slack in the wires It is possible that the connection to the battery negative circuit may not actually be right at the battery For example on boats the proper location for the negative connection is often at an engine negative bus or a DC negative bus If in doubt consult the boat schematics 2 Identify the positive wires by using color coded wire or by marking both ends of the wire with colored tape or similar kind of marking Repeat with a different color for the negative Most installation codes recommended color codes with the positive usually being red and the negative being black Note You may find it helpful to label each cable associating it with the battery bank it is connected to For example Bank 1 Bank 1 Bank 2 and so on 3 Install the DC circuit breakers or fuses in the battery positive circuits close 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 that will add additional voltage drops 5 Strip 5 16 in 8mm of insulation from the ends to be connected to the charger 6 Fully insert each positive wire into the positive terminal on the charger Figure 2 3 1 2 3 Make sure there
37. lectric shock hazard Do not make an ungrounded connection Have an electrician install a properly grounded circuit if one is not already installed Improper connection can result in risk of an electric shock Truecharge must be grounded to reduce the risk of electrical shock The AC input ground wire must be properly connected to ground in accordance with all applicable electrical codes Meeting electrical codes is achieved by connecting the ground conductor of the AC input cable to a properly grounded ground terminal in the AC distribution panel where the 15 amp branch circuit originates If your installation code allows the use of a flexible AC cord to attach Truecharge to a standard AC socket the cord and plug must be equipped with a ground conductor and a ground pin that is a three prong plug and the socket must be able to accept the plug without modification Installing Optional Accessories If 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 BTS Battery Temperature Sensor Purpose Installation The BTS provides the charger with temperature information which overrides the temperature settings on the front panel If your batteries are located where temperatures are consistently high or consistently low or vary frequently consider the use of a BTS to prolong the life
38. maintenance guidelines C 2 precautions when working with 1 x battery not detected by charger 4 4 battery temperature sensor 2 14 battery temperature importance of in charging 3 3 battery type selector switch 1 3 battery types description of B 2 suitable for equalization 3 8 battery voltage too high 4 5 bulk charge battery activity during B 3 C charge mode selector switch 1 3 charging algorithm three stage B 2 charging batteries procedure for 3 5 charging current 1 2 charging indicator light significance of 3 4 charging time calculating 3 2 charging too slow 4 5 charging effect of battery temperature sensor on 2 15 circuit requirements 2 3 continuous rating 1 2 current reduction of in high ambient temperatures A 5 Customer Service email D 2 fax number D 2 phone number D 2 D DC disconnect device 2 5 DC wiring requirements 2 7 distilled water C 2 electric specifications A 2 electrolyte level checking for C 2 email contacting Customer Service by D 2 Index equalization charge B 4 equalization of batteries understanding 3 7 equalizing procedure 3 9 F failure to operate 4 4 fan speed change in speed of 3 7 fax number for Customer Service D 2 features 1 2 first aid 1 xi fixed voltage mode 1 4 float charge battery activities during B 3 flooded batteries equalizing 3 8 selector switch for 1 3 formula for charging time 3 2 G galvanic isolation 1 3 gel ba
39. n the float mode the charger will initiate a new charge cycle under any of these conditions e AC power is disconnected and reconnected e any battery drops below 12 5 VDC for 15 minutes e 21 days have passed from the time the charger completed Absorption The chart in Figure B 1 shows the three stage charging profile B 3 Battery Charging Bulk stage Absorption stage Float stage Charging started Constant voltage Constant voltage at Absorption voltage setting voltage setting DC Voltage Constant current at maximum charge rate Load current on demand DC Current Figure B 1 Three stage charging profile Equalization Charge The equalization charge must be manually initiated because it is not required each time the battery is recharged Equalization is a deliberate overcharge designed to return each cell to optimum condition by reducing sulfation and stratification in the battery The overcharge helps the battery to reach and maintain peak capacity by equalizing the chemistry in the individual battery cells An equalization charge should be performed only on vented flooded non sealed or wet batteries It should be performed only if recommended by the battery manufacturer and only as often as specified Two Stage Charging Difference from In a two stage charge the charger finishes the Absorption charge but does three stage not go to Float mode because some battery manufacturers advise ag
40. nductive 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 temperatures the output current will be automatically reduced to protect the charger from high internal temperatures Ventilated Allow at least 4 inches 10 cm of clearance around all sides of the Truecharge for air flow Ensure that the ventilation openings on the unit are not obstructed If mounting in a compartment ventilate the compartment with louvres or cut outs to prevent overheating Safe This battery charger is Ignition Protected so it can be installed in areas containing gasoline tanks or fittings which usually require Ignition Protected equipment Xantrex recommends however 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 Close to Avoid excessive cable lengths and use the recommended wire batteries lengths and sizes Undersized or overly long cables may affect charging accuracy 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 Truecharge 20 installations and 15 amps for Truecharge40 installations Refer to Appendix A Specifications for the ac
41. or protection if installed results in charger shutdown at a battery temperature of 60 C Approvals Safety CSA NRTL approved to CSA107 2 and UL1236 including the marine supplement ignition protection and UL458 UL1564 A 5 A 6 Battery Charging Appendix B Battery Charging describes the Truecharge multistage charging algorithm Battery Charging Charging Algorithms Battery Type Flooded Gel AGM Truecharge charges lead acid flooded gel and AGM absorbed glass mat batteries Flooded batteries have removable battery caps for refilling with distilled water and testing the electrolyte The sealed gel battery has its electrolyte is in the form of a gel rather than a liquid and does not require topping up Battery caps are not removable AGM absorbed glass mat batteries are similar to gel batteries except the electrolyte is absorbed into a fibreglass matting i WARNING Risk of battery damage Since the Truecharge has only one battery type setting for all batteries connected to its three banks do not mix types All connected batteries should be of one kind Flooded or Gel or AGM Charge Algorithm Stages Three stage charging Stages B 2 Truecharge charges batteries in a sequence known as a three stage charge The charging voltage delivered to the battery depends on the battery e type setting e temperature by switch setting or battery temperature s
42. or AGM batteries 6 The 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 15 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 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 Electric
43. orrosive so wear something you can live without just in case you splash some on yourself Be sure to wear rubber gloves and eye protection m OO oO A E Ea ee E OU oO E Adjustable wrench or appropriately sized sockets and ratchet for battery terminals Torque wrench Soft bristled brush a discarded toothbrush works fine 6 inch scrub brush Inexpensive 2 inch chip brush or soldering brush Eye protection Rubber gloves Water hose with spray nozzle or five gallon watering bucket Empty spray bottle Baking soda Always keep on hand in the event of a spill Hand cleaner or soap Towel After reattaching cables anti corrosion grease available at auto RV and marine stores C 3 Battery Maintenance Maintaining and Cleaning Follow these procedures to maintain the e battery enclosure e battery terminal and lugs e cables WARNING Review the Important Safety Instructions on page ix before you begin Battery Enclosure and Batteries Mix four ounces of baking soda with a gallon of fresh water and fill a spray bottle Spray the solution on all exposed surfaces of the battery compartment and wash down the exposed surfaces of the batteries and their enclosure Scrub stubborn areas with the scrub brush Baking soda will neutralize any acid that may have collected on these surfaces Finish by rinsing with water Terminals amp Lugs Loose battery terminals and lugs exposed to open air corrod
44. otice an occasional change in fan speed on Truecharge 40 as this takes place After charging is complete Truecharge enters into one of these modes Float mode When the Ready indicator light lights the battery is fully charged and ready for use If you selected Bulk Absorption Float mode Truecharge is in Float mode and will maintain the battery s charge Monitor mode If you selected Bulk Absorption mode the Ready indicator light shows the charger is now in Monitor mode and is checking battery voltage and elapsed time since the last charge cycle 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 for 15 minutes or if AC power is disconnected and reconnected Equalizing Flooded Batteries About Equalizing Frequency Important Approximately once a month you may wish to equalize your flooded batteries by using the battery charger equalization mode Equalization can damage your batteries if it is not performed properly Never equalize a battery more than twice a month Always check battery fluid level before and after equalization Fill batteries only with distilled water Battery manufacturers recommendations on equalization vary Always follow the battery manufacturer s instructions so batteries are properly equalized As a guide a heavily used battery may require equalization once a month while a battery in light duty service
45. output of the Truecharge e Built in protection against accidental connection to a higher battery voltage up to 24 VDC e Unit shutdown if it becomes overheated because of inadequate ventilation or a high ambient temperature e 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 Temperature Sensor Remote panel The remote Battery Temperature Sensor 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 which the sensor is attached The remote panel allows you to monitor the charging progress of two batteries or battery banks the total charge current and charger status from a convenient loc
46. ps the outer cable jacket and not the individual wires Continue the installation by connecting the other end of the AC wiring to your AC source observing the color code described above Installing Truecharge To connect AC wires with the crimp on butt splice connector Note You must exercise care when crimping butt splice connectors Use a crimp tool designed for this type of connector such as a Panduit catalog number CT100 CT160 or CT 260 I Using a wire stripper carefully strip 5 16 8mm from the ends of the two wires being connected Insert one wire into one end of the butt splice insert the butt splice into the crimping tool and crimp firmly The proper location for the crimp is approximately 1 16 1 6mm past where the butt splice insulation tapers down as shown in Figure 2 4 gt 4 ine CRIMP TOOL STRIP 5 16 Figure 2 4 Butt splice connection Repeat Step 2 for the other end of the butt splice Tighten the cable clamp to secure the wiring so that it grips the outer cable jacket not the individual wires When all connections are completed push the wiring with connectors inside the wiring compartment Install wiring compartment cover and fasten with the blunt tip screws and lock washers supplied Continue the installation by connecting the other end of the AC wiring to your AC source observing the color code described above Installing Truecharge Grounding i WARNING E
47. r 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 1 2 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 Truecharge Features Selector Switches Charge mode Battery type Temperature Truecharge has selector switches for charge mode battery type and battery temperature setting The charge mode switch allows you to select three step charge two step charge or 13 5 volt fixed output modes Refer to Appendix B Battery Charging for an explanation of the charging algorithms The battery type switch allows you to set the Truecharge for the charging characteristics of flooded AGM and gel batteries The battery temperature switch allows you to set charging characteristics based on the battery temperature By setting the switches correctly before you begin charging your battery you will be ensuring that it receives the best possible charge Extensive Protection Features Truecharge provides the following protection features e Opening of the internal output fuse if a battery is accidentally connected with reversed polarity e Fuse opening or electronic shutdown if there is a short circuit on the
48. rn off other charging sources such as the alternator or the charger on a generator with electric start Symptom The 20 amp indicator light blinks on Truecharge 20 or the 40 amp light blinks on Truecharge 40 Other indicator lights are off only when temperature sensor is installed Possible Cause Solution Battery temperature is too high for safe charging Allow battery to cool Improve ventilation or install in cooler location It may indicate a shorted cell in the battery or excessive water loss Symptom Truecharge appears to be taking too long to charge battery Ready indicator light does not light after 24 hours of charging Possible Cause Solution 1 Battery capacity is too high for Truecharge model 2 Load connected to battery is draining charge current so that battery does not recharge 3 Battery has a damaged cell 1 Use a higher capacity charger 2 Disconnect load or switch load off 3 Replace battery 4 5 Specifications Appendix A Specifications contains the Truecharge physical electrical AC input and protection feature specifications Specifications Physical Specifications Dimensions 151 8 in x 6 3 4 in x 2 3 4in 385 mm x 172 mm x 70 mm Weight Truecharge 20 6 9 lbs 3 1 kg Truecharge 40 7 4 lbs 3 3 kg AC input connections Three color coded No 16 AWG wires L N G minimum 6 inches long in a separate AC wiring enclosure with p
49. rosion grease or other sealant Do not let anything come between the mating surfaces of the lugs and terminals Inspect all battery cables for missing or damaged insulation or loose connections Inspect any openings that the cables pass through All such openings must be equipped with a rubber grommet or conduit to prevent chafing on the cable If necessary replace worn grommets If the cable insulation is worn replace the cable C 5 C 6 Product and System Information 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 Product and System Information Warranty D 2 What does this warranty cover This Limited Warranty is provided by Xantrex Technology Inc Xantrex and covers defects in workmanship and materials in your Xantrex Truecharge 20 and Truecharge 40 This warranty lasts for a Warranty Period of 12 months from the date of purchase at point of sale to you the original end user customer This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the Warranty Period What will Xantrex do Xantrex will at its option repair or replace the defective product free of charge provided that you notify Xantrex of the product defect within the Warranty Period and provided that Xantrex throug
50. rovision for connection of a 1 2 inch cable clamp or conduit hub DC output Four pole 3 positives and 1 common connections negative terminal strip rated for 60 A per pole No 6 14 AWG wire Electrical Specifications Electrical Specifications Number of battery bank outputs 3 diode isolated no independent regulation Nominal battery voltage 12 VDC Normal operating output range 0 16 VDC Rated DC output current total Truecharge 20 Truecharge 40 20 ADC 40 ADC Charge modes Switch settings for three step two step or fixed voltage Battery type compensation Switch settings for Flooded Gel and AGM batteries Battery temperature compensation Charge voltage is battery temperature compensated manually switch settings for Cold 10 C 50 F Warm 10 27 C 50 80 F and Hot gt 27 C 80 F ranges or automatically with optional remote battery temperature sensor Electrical Specifications Electrical Specifications Absorption voltage Hot Warm Cold Flooded 14 0 144 14 8 VDC Gel 13 8 14 2 14 6 VDC AGM 140 143 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 1 134 13 7 VDC Equalize mode current Truecharge 20 Truecharge 40 5 ADC 10 ADC Equalize mode maximum 16 0 VDC output voltage Fixed voltage mode nominal 13 5 0 12 VDC output voltage Specifi
51. s with distilled water only spring water and regular tap water may have high mineral levels These can poison the battery chemistry and reduce battery life and should not be used It is also good to periodically check the battery connections for tightness and corrosion If you find any corrosion disconnect power from Truecharge disconnect the cables and carefully clean them with a mild solution of baking soda and water Ensure that 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 them with anti corrosion grease or liquid neoprene liquid electrical tape after re assembly This is available from automotive parts stores or battery suppliers Do not apply anything between the terminal and the cable lugs The connection should be metal to metal Apply the protective material only after the bolts have been tightened Dirty batteries can leak current and tend to run warmer Cleaning batteries when necessary is easy and safe when you follow the instructions below Preparation for Cleaning Batteries Preparation for Cleaning Batteries Clothing Tools Equipment Supplies The appropriate clothing tools equipment and supplies are listed below Gather what you need before beginning Appropriate clothing could include old clothes rubber boots or old shoes Battery acid is highly c
52. t shipments will be refused and returned at your expense if they are unauthorized returned without an RMA number clearly marked on the outside of the shipping box if they are shipped collect or if they are shipped to the wrong location When you contact Xantrex to obtain service please have your instruction manual ready for reference and be prepared to supply e The serial number of your product e Information about the installation and use of the unit e Information about the failure and or reason for the return e 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 is shipped fully insured in the original packaging or equivalent This warranty will not apply where the product is damaged due to improper packaging 2 Include the following e The RMA number supplied by Xantrex Technology Inc clearly marked on the outside of the box e A return address where the unit can be shipped Post office boxes are not acceptable e A contact telephone number where you can be reached during work hours e A brief description of the problem 3 Ship the unit prepaid to the address provided by your Xantrex customer service representative If you are returning a product from outside of the USA or Canada In addition to the above you MUST include return freight funds and are fully responsible for all documents duties
53. t that the wire is secure To make multiple battery bank connections using a DC negative bus e 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 e Connect each negative cable to the battery negative terminal Figure 2 3 10 11 12 e Connect a negative cable from the DC negative bus to the negative terminal on the Truecharge Figure 2 3 13 14 Fully insert the negative wire into the negative terminal on the charger Figure 2 3 14 Check all connections for tightness and to ensure the conductors are fully inserted in their terminals with no stray wire strands protruding Tighten the connector 20 in lbs torque recommended and test that the wire is secure Connecting to AC Wiring To connect AC wiring 1 Make sure the AC source circuit is disconnected by turning off the breaker feeding the circuit unplugging from shorepower and disconnecting any other power sources such as a generator Plan the routing the AC wiring will follow from the source usually a 15 amp breaker in an AC distribution panel to the charger Measure the required length of three conductor No 14 AWG wire and cut it Allow some extra length for connections and to provide slack Installing Truecharge 2 12 3 10 Route the wiring without connecting it to the AC source or to the charger yet Install the supplied cable clamp in the knock out of your choice on
54. ted to positive negative must be connected to negative Reversing the positive and negative battery cables can damage your charger and void the warranty This type of damage is easily detected Installation Truecharge is installed in three steps The unit is SRPS 1 mounted page 2 8 2 connected to the batteries page 2 9 3 connected to its AC power source page 2 11 Mounting Mount the Truecharge on a vertical surface such as a bulkhead using the mounting holes provided Mounting hardware should be corrosion resistant and 8 4 mm For secure permanent mounting use all four mounting holes The DC connections should be at the bottom and the AC connections at the top 2 8 Installing Truecharge Connecting DC Wiring For A Single Battery Or Multiple Batteries A Truecharge cannot be set to deliver different charging 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 The procedure for installing the DC wiring applies to a single battery or multiple batteries or battery banks Figure 2 3 shows the connection order re re 14 black 10_ 4 11 5 2 VA 12 6 a Ve D DC Negative Bus O OQ 13 98 7 Figure 2 3 DC wiring connection order 2 9 Installing Truecharge To install the DC wiring 1 Plan the route the DC wires wil
55. the AC wiring compartment on the top end of the charger and tighten the locknut Run the AC wiring through the cable clamp and about 6 inches into the wiring compartment Carefully remove approximately 3 inches of the outer jacket being careful not to cut or nick the insulation on the individual conductors Connect the AC wiring to the Truecharge pigtail wires in the wiring compartment junction box being sure to connect the line conductor to the line the neutral to the neutral and the ground to the ground The pigtail wires are color coded as follows Conductor Color code Line Black or brown Neutral White or blue Ground Green or green with yellow stripe Make the connections with the twist on or crimp on connectors supplied 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 splice connector on page 2 13 The ABYC Standards and Recommended Practices for Small Craft prohibit twist on connectors for AC connections on a boat For non marine installations in locations not subject to vibration either type of connector may be used When all connections are completed push the wiring with connectors inside the wiring compartment Install wiring compartment cover and fasten with the blunt tip screws and lock washers supplied Tighten the cable clamp to secure the wiring Be sure it gri
56. tteries selector switch for 1 3 generator limitations of modified sine wave 3 4 using as source power 3 4 grounding necessity for 2 14 indicator lights activity of 3 4 used in troubleshooting 4 2 installation battery temperature sensor 2 14 codes to be observed 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 Index 2 M maintaining batteries C 2 maintaining the Truecharge unit 4 2 materials list 2 2 monitor mode 3 7 neoprene liquid C 2 O optional accessories 2 14 P physical specifications A 2 power source generator as 3 4 power supply using TrueCharge as 1 4 pre installation requirements 2 2 2 7 problems typical when operating 4 4 protection features description 1 3 specifications A 4 R remote display panel purpose of 2 15 reverse polarity consequences of 2 8 S safety instructions 1 ix 1 xi selector switches 1 3 simultaneous charging 1 2 specifications A 2 A 5 system diagram 2 4 T telephone number for Customer Service D 2 temperature switch description of 1 3 setting for charging 3 3 temperature effect of in charging 3 3 terminals and lugs maintenance of C 4 three battery charging 1 2 three stage charging algorithm explanation B 2 three stage charging profile diagram B 4 tools required for installation 2 7 troubleshooting use
57. tual current draw 2 3 Installing Truecharge 2 4 N Figure 2 2 Truecharge system 120 VAC source with 15 amp breaker AC input wiring compartment DC negative cable DC positive cables al AeA N DC circuit breaker or DC fuse and disconnect rated at 25 amps maximum for TC 20 or 50 amps maximum for the TC 40 Battery or battery bank Engine negative bus or DC ground bus Remote panel optional O o N A Battery temperature sensor optional Preparing for Installation Wiring Requirements DC Wiring 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 The DC wiring must meet the following requirements e Length and size Wire Length maximum length Wire Size AWG one way 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 e 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 an
58. uecharge 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 Contents Important Safety I nstructions Explosive gas precautions
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