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Owner`s Guide

1. Installing the Truecharge 2 Battery Charger 7 Install crimp lugs on the charger end of the DC battery cables using the For one battery or bank crimp manufacturer s instructions and tool Connect the negative cable from the negative terminal on the battery to the negative DC terminal on the Truecharge2 Battery Charger Use a flat washer a lock washer and a nut five of each included in the installation kit to secure the connection For more than one battery or bank Connect the negative cable from the negative terminal on the negative ground bar or bus to the negative DC terminal on the Truecharge2 Battery Charger Use a flat washer a lock washer and a nut five of each included in the installation kit to secure the connection CAUTI O N 9 Tighten the nuts to 2 3 N m 20 Ib in torque and test that the wire is REVERSE POLARITY DAMAGE secure Do not over tighten as this may result in damage to the charger Before proceeding to the nex step carefully check the wiring polarity 10 Connect each positive cable to the correct positive DC terminal on the Do not reverse the connections See note below Truecharge2 Battery Charger Failure to follow these instructions can damage the unit and or Use a flat washer a lock washer and a nut five of each included in the damage other equipment installation kit to secure the connection 11 Tighten the nuts to 2 3 N m 20 Ib in torque and test that the wire is NOTE Make sur
2. NOTE If you have two BTSs you may connect the two separate cable plugs to each of the battery chargers BTS ports You may then connect each of the sensors to two separate batteries However during operation the BTS that is detecting a higher temperature will be used for battery temperature compensation e Both Truecharge2 Battery Chargers must be correctly installed 975 0526 01 02 25 4 Z gt IN amp TC2 204060 Series BattChg Owners Guide book Page 26 Friday July 8 2011 11 44 AM amp Installing a Parallel Configuration Y Powering up after installing a parallel configuration Fault and Warning Conditions 1 Follow the procedures in Step 5 Powering Up on page 24 e When one charger encounters a fault condition the other charger remains charging but the remote panel will stop synchronizing the two chargers settings at this point The remote panel will display the fault condition via Fault Warning LED the same way as the faulty charger displays it on its onboard display 2 Observe that the Parallel LED on the remote panel lights up to indicate that two chargers are in parallel configuration charging mode During Charging e Remote panel s Fault Warning LED only clears when fault or warning The two Truecharge2 Battery Chargers output currents are synchronized conditions at both chargers are cleared The remote panel will resume during most of the charging cycle When a battery is approach
3. AGM DC wiring size and length Alarm sounding Description of indicators on front panel Appliances operating when problem occurred Description of problem _ Truecharge2 Series Battery Charger Owner s Guide Pe di WD DI TC2 204060 Series BattChg Owners Guide book Pagei Friday July 8 2011 11 44 AM Z D e DI amp TC2 204060 Series BattChg Owners Guide book Page ii Friday July 8 2011 11 44 AM Xantrex Technology USA Inc 1 800 670 0707 Tel 1 800 994 7828 Fax www xantrex com 975 0526 01 02 Printed in China
4. Requirement Close to The Truecharge2 Battery Charger should be installed as batteries close as possible to the batteries but not in the same compartment to prevent corrosion Avoid excessive cable lengths and use the recommended wire sizes Xantrex recommends installing with cables sized to achieve less than 3 voltage drop on battery cables under full load This will maximize the performance of the charger a Applicable to Non IEC models only See Product Numbers on page i b See Product Numbers on page i DANGER EXPLOSION HAZARD FOR IEC MODELS ONLY Do not place the battery charger in machinery space or in areas containing gasoline tanks or fittings in which ignition protected equipment is required Failure to follow these instructions will result in death or serious injury NOTES When planning to install the Truecharge2 Battery Charger be sure that you consider the location and orientation carefully The Truecharge2 Battery Charger is considered to have an IP rating of IP 32 if installed in either of two specific orientations shown in Figure 5 a and b and only if all Truecharge2 Series Battery Charger Owner s Guide S2 D amp TC2 204060 Series BattChg Owners Guide book Page 11 Friday July 8 2011 11 44 AM amp Preparing For Installation Y D panel covers are attached and secured This rating means that it meets standards to prevent dripping water from entering the
5. The following tables show some typical wire sizes for various cable length runs based on 3 voltage drop on DC cables 75 C 167 F rated wire with wiring being inside the engine compartment assumed ambient of 50 C 122 F Table 1 DC Wiring Examples for 12 V chargers Wire Length Wire Size AWG and mm max length one way feet meters TC2012 TC4012 TC6012 5 1 5 No 10 No 8 No 6 5 3 mm 8 4 mm 13 3 mm 7 5 2 25 No 10 No 6 No 4 5 3 mm 13 3 mm 21 2 mm 20 6 No 6 No 2 No 1 13 3 mm 33 6mm 42 4 mm a Values based on American Boat amp Yacht Council E 11 2008 Table VI A and Table IX NOTE In the event of a conflict between the voltage drop table Table IX and the ampacity table Table VI A use the larger wire size 975 0526 01 02 _ _ e Preparing For Installation Table 2 DC Wiring Examples for 24 V chargers Wire Length Wire Size AWG and mm max length one way feet meters TC1024 TC2024 TC3024 5 1 5 No 16 No 10 No 10 1 3 mm 5 3 mm 5 3 mm 7 5 2 25 No 16 No 10 No 10 1 3 mm 5 3 mm 5 3 mm 20 6 No 10 No 8 No 6 5 3 mm 8 4 mm 13 3 mm a Values based on American Boat amp Yacht Council E 11 2008 Table VI A and Table IX NOTE In the event of a conflict between the voltage drop table Table TX and the ampacity table Table VI A use the larger wire size Over current Pro
6. 4 e Remove all personal metal items like rings bracelets and watches when working with batteries See notes 5 and 6 Never smoke or allow a spark or flame near the engine or batteries When removing a battery always remove the negative terminal from the battery first for systems with grounded negative If it is grounded positive remove the positive terminal first Make sure all loads connected to the battery and all accessories are off so you don t cause an arc e Never charge a frozen battery Failure to follow these instructions can result in death or serious injury NOTES 1 Locate the Truecharge2 Series Battery Charger unit away from batteries in a well ventilated compartment 2 Always have someone within range of your voice or close enough to come to your aid when you work near a lead acid battery 3 Always have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes 4 Ifbattery acid contacts skin or clothing wash immediately with soap and water If acid enters your eye immediately flood it with running cold water for at least twenty minutes and get medical attention immediately vi Truecharge2 Series Battery Charger Owner s Guide _ 16 DI TC2 204060 Series BattChg Owners Guide book Page vii Friday July 8 2011 11 44 AM Precautions When Preparing to Charge Precautions When Placing the Battery Charger A WARNING CAUTION EXPOSURE TO CHEMICALS AN
7. 8 2011 11 44 AM Configuring the Truecharge2 Battery Charger Once the charger is connected to at least one battery bank and to AC it is live and it may be configured The indicator LEDs on the onboard display F do A E will illuminate for a second power on test before reporting charging and battery status information lt 5 5 10 20 40 60 80 100 Configuring the Charger Mode 3 Ready Charging Equalize Fault NOTE By default the Charger Mode is set to 3 Stage 1 Press and hold the Charger Mode Select button for three seconds to i 3 Stage 2 Stage advance to the next setting 2 Select the proper charger mode h AGM Flooded Gel Lead Calc The LEDs will indicate which of the two modes is being selected three stage default or two stage Cold Warm Hot Configuring the Battery Bank Type Figure 11 Onboard Display Panel NOTE By default the battery type is set to Flooded 1 Press and hold the Battery Type Select button for three seconds to advance to the next setting 2 Select the proper battery type The LEDs will indicate which of the five types is being selected Flooded default GEL Lead Calc AGM and Custom The Custom setting is indicated when all four battery type LEDs are illuminated This setting should only be used if a custom algorithm has been programmed by Xantrex or a designated OEM 34 Truecharge2 Series Battery Charger Owner s Guide hai q 4 TC2 204060 Series BattChg Owners Guide book Pa
8. AC input lines come from the same circuit branch that is both AC input lines should have a common circuit breaker CAUTI O N 3 Designate a primary charger and a secondary charger between the two DAMAGE TO THE BATTERY CHARGER chargers Remember that only the primary charger or remote panel can Do not parallel Truecharge2 Battery Chargers together without a be used to configure and operate the parallel system Truecharge2 Remote Panel part number 808 8040 01 4 Connect the primary charger s battery bank 1 to the secondary charger s battery bank 1 Do the same for battery banks 2 and 3 NOTE A maximum of three battery banks can be connected to a parallel configured charger system Failure to follow these instructions can damage the unit and or damage other equipment Parallel configuration can only be done when the following conditions are 5 Leave any unused DC output s unconnected met 6 Connect the remote panel s communications cable to the primary charger s remote port and to the remote panel s primary port Do the e Two Truecharge2 Battery Chargers must have the same output same for the secondary charger voltage rating Never parallel a 24 volt charger with a 12 volt charger 7 Connect the BTS or battery temperature sensor s cable plug to the Both Truecharge2 Battery Chargers must connect to a primary charger s BTS port Then connect the BTS s sensor to the Truecharge2 Remote Panel battery
9. E Fault indicator LED illuminates Temp and Battery A indicator LEDs flash A WARNING EXPLOSION HAZARD Never charge a frozen battery injury Failure to follow these instructions can result in death or serious Possible Cause Solution Battery temperature is either too hot or too cold for safe charging 975 0526 01 02 If battery is too hot allow battery to cool Improve ventilation or install in a cooler location If the optional remote panel is available you may reduce the output current using the Set Max Output button If battery is too cold allow batteries to warm up e Troubleshooting Symptom Truecharge2 Battery Charger completes a charging cycle but the battery voltage seems too low Possible Cause Solution Battery has a shorted cell Disconnect AC to the charger and check the battery voltage approximately one hour later NOTE If the charger is functioning properly but the charge cycles fail to bring the resting voltage up above 10 V for 12 volt chargers and 20 V for 24 volt chargers then this confirms the battery has a damaged or shorted cell Replace battery The battery has reached the end of its useful life and can no longer accept a charge 51 SW e S is a TC2 204060 Series BattChg Owners Guide book Page 52 Friday July 8 2011 11 44 AM VY Troubleshooting Symptom Symptom The Truecharge2 Battery Charg
10. ELECTRICAL SHOCK HAZARD without the installation of additional drip protection They are only Disconnect all sources of AC and DC power before proceeding acceptable for use in locations that are always dry Failure to follow these instructions will result in death or serious injury To mount the Truecharge2 Battery Charger 1 Select a mounting surface that is flat and allows for a minimum of 10 cm 4 in of clearance on the top and bottom ends for air flow and at Installation Sequen ce least 6 cm 2 5 in of clearance on either sides see Figure 7 Ventilation Clearance on page 12 To make charger installation quick and easy Xantrex recommends that the 2 Drill the four pilot holes for the mounting screws taking care that installation tasks be performed in the following sequence there is nothing behind the surface that can be damaged by the drill 1 Mount the charger in position 3 Mount the Truecharge2 Battery Charger using corrosion resistant 6 2 Connect the DC ground 3 mm round pan head or similar screws The top two keyhole style mounting holes can be used to hold the Truecharge2 Battery Charger in place while fastening the bottom two screws For secure permanent mounting use the holes in all four mounting flanges and fasten all four screws Do not rely on screws 3 Install DC wiring including installing required disconnects fuses or breakers Install AC wiring including earth grounds 5 Power up th
11. July 8 2011 11 44 AM Installing Batteries Three Stage Charging The three stage charging mode employs the following sequence Bulk Voet Nee lout lt 10 trating Absorption and Float During the Bulk stage the batteries are accepting a Battery Voltage Viti VE constant maximum current In the Absorption stage the battery voltage is for 1 minute E EN for 15 minutes held constant and the current declines A battery will gas produce hydrogen and oxygen when its voltage exceeds the gassing voltage Veas Voltage i bs Finally in the Float stage the charger continues to provide voltage ata UTA I lower level to maintain the battery in a fully charged state If there 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 Charge start The charger will restart the charging cycle in the Bulk stage if the lowest battery voltage of the three banks drops below 12 5 V 12 Vdc chargers or 25 V 24 Vdc chargers for 15 minutes After seven days the charger will automatically restart charging in order to refresh the batteries Time I ABS CV timeout I I I_max5 hrs N J Start of l FLOAT timeout charging cycle I max 7 days Total ABS timeout max 8 hrs Figure 9 Three Stage Charging Process 975 0526 01 02 29 Y MZ be DI TC2 204060 Series BattChg Owners Gui
12. Panel Owner s Guide 46 Truecharge2 Series Battery Charger Owner s Guide 0 i amp TC2 204060 Series BattChg Owners Guide book Page 47 Friday July 8 2011 11 44 AM amp Maintaining the Charger Periodically disconnect all AC and DC sources and check all DC and AC wiring connections to be sure they have not loosened or deteriorated Also check all cable clamps to ensure they are tightly fastened ELECTRICAL SHOCK HAZARD Loose battery terminals and lugs exposed to open air corrode rapidly The Do not disassemble the battery charger See note below corrosion appears as a white powder or granular foam on the terminals and Failure to follow these instructions will result in death or serious any nearby exposed metal parts If it contacts your skin it will cause burns injury unless you rinse it off immediately To clean battery terminals follow the recommendations and procedures of NOTE The Truecharge2 Series Battery Charger contains no user the battery manufacturer serviceable parts with the exception of the DC output fuse s which are user replaceable See Replacing the DC Output Fuse on page 48 for instructions For obtaining service other than replacing the fuse see Warranty and Return Information on page 58 for guidance The Truecharge2 Battery Charger contains solid state electronic components that require no maintenance The best care you can give the charger is to protect it from contact with liq
13. Truecharge 2 Battery Charger Features This section describes the different parts of the Truecharge2 Battery Charger Item Description 1 Onboard control and status display panel or simply Front Panel onboard display see Onboard Control and Status Display Panel on page 5 for more information for controlling the Truecharge2 Battery Charger settings and for monitoring charger status and charging current 1 N 2 Mounting flanges are used to permanently install the product 3 DC wiring compartment cover protects the DC terminals as well as the communication and BTS ports Remove and replace when installing cables gt 2 ELECTRICAL SHOCK HAZARD 3 Disconnect the batteries and AC power before opening the fuse access gt panel 4 Failure to follow these instructions will result in death or serious injury 5 injury 4 Fuse access panel cover provides access to the DC fuse in the 6 event of an accidental reverse battery polarity installation Remove and replace the cover when replacing a fuse or fuses Figure 1 Truecharge2 Battery Charger Front Panel 975 0526 01 02 3 4 YV N amp TC2 204060 Series BattChg Owners Guide book Page 4 Friday July 8 2011 11 44 AM E Truecharge 2 Battery Charger Features Item Description Item Description 5 AC wiring compartment cover provides the installer with 1 BTS port battery temperat
14. any maintenance or cleaning or working on any circuits connected to the battery charger See note below Do not operate the battery charger with damaged or substandard wiring Make sure that all wiring is in good condition and is not undersized See Wiring Requirements on page 12 for guidance Failure to follow these instructions will result in death or serious injury NOTE Turning off the battery charger using the on standby button on the optional remote panel will not reduce an electrical shock hazard Truecharge2 Series Battery Charger Owner s Guide _ 16 AZ G lt TC2 204060 Series BattChg Owners Guide book Page v Friday July 8 2011 11 44 AM i DANGER A WARNING FIRE AND BURN HAZARD PERSONAL INJURY HAZARD Do not cover or obstruct the air intake vent openings and or install in a This battery charger is not intended for use by persons including zero clearance compartment See Location on page 10 for proper children with reduced physical sensory or mental capabilities or lack of location requirements experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Children should be supervised to ensure that they do not play with the battery charger Failure to follow these instructions can result in death or serious A DANGER a EXPLOSION HAZARD e Charge only properly rated such as
15. 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 warranty 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 58 e Hawaii and outside of the United States and Canada are excluded Contact Xantrex Customer Service for details on freight policy for return shipments from excluded areas How do you get service If your product requires troubleshooting or warranty service contact your merchant If you are unable to contact your merchant or the merchant is unable to provide service contact Xantrex directly at Telephone 1 800 670 0707 Fax 1 800 994 7828 Website www xantrex com Direct returns may be performed according to the Xantrex Return Material Authorization Policy described in your product manual For some products Xantrex
16. e Allow the battery or batteries to warm up to a temperature that is above freezing before charging See Specifications on page 54 High Battery voltage Non Discontinue charging or disconnect AC power source fault 0 z from supplying power to the charger gt 16 5V for 12 volt Disconnect voltage sensitive DC loads from DC chargers supply to prevent damage gt 33V for 24 volt Ifthe DC bus voltage is still measuring high after AC chargers power has been disconnected call a qualified and certified electrician High Charger Temp E O e Allow the Truecharge2 Battery Charger to cool while fault 2 O the AC is connected so the fan stays on Improve ventilation or install the charger in a cooler location Loss of Remote Connection warning e Reconnect the communication cable to the port It takes about 15 seconds to re establish communication og Flashing LED O Solid LED Truecharge2 Series Battery Charger Owner s Guide D IS 4 TC2 204060 Series BattChg Owners Guide book Page 45 Friday July 8 2011 11 44 AM Accessing Charger Information Table 9 Interpreting Fault and Warning Indicators Fault or Warni ng Fi Fani AC Battery 14 no pa Fault So lution Condition W a 3 E Reverse Polarity Fuse ui e Check for reverse battery polarity negative fault connected to negative positive connected to positive is
17. eyes and wiping your forehead while working near batteries See following note Failure to follow these instructions can result in death or serious injury 38 Truecharge2 Series Battery Charger Owner s Guide Y e _ 16 S 7 is a TC2 204060 Series BattChg Owners Guide book Page 39 Friday July 8 2011 11 44 AM Equalizing Flooded Batteries 3 Press and hold for five seconds the Charger Mode Select button and Battery Temp Select button at the same time to put the Truecharge2 Battery Charger into equalization mode IMPORTANT The onboard display and remote panel buttons will not allow selection of equalization for AGM and GEL batteries When the charger is performing the equalization the Equalize LED illuminates as a solid light It will flash intermittently when programmed prior to reaching float or rest mode 4 Monitor the specific gravity of each cell of the battery during equalization with a battery hydrometer NOTE The equalization cycle is preset to last for one hour It is not possible to program another equalization cycle when the present cycle has not ended yet Carefully check the specific gravity of each cell and repeat the equalization cycle until they all meet the battery manufacturer s specifications for specific gravity or until the specific gravity stabilizes relative to each other for an hour The charger automatically exits equalization to float mode or rest mode after
18. 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 Truecharge2 Series Battery Charger Owner s Guide 016 DI TC2_204060 Chapters fm Page 59 Thursday August 4 2011 1 12 PM Warranty and Return Information What proof of purchase is required In any warranty claim dated by Xantrex at your direction for incorporation into the product proof of purchase must accompany the product and the product must not f the product if its original identification trade mark serial number have been disassembled or modified without prior written authorization by markings have been defaced altered or removed Xantrex g the product if it is located outside of the country where it was Proof of purchase may be in any one of the following forms purchased and The dated purchase receipt from the original purchase of the h any consequential losses that are attributable to the product losing product at point of sale to the end user or power whether by product malfunction installation error or misuse 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 Claims are limited to repair and replacement or if in Xantrex s discretion that is not possible reimbursement up to the purc
19. polarity fault which caused the fuse to blow prior to reconnecting all AC and DC sources to the charger 8 Reconnect all AC and DC sources to the charger ELECTRICAL SHOCK HAZARD Disconnect all AC and DC sources to the charger and wait five minutes for internal voltage and energy levels to reduce to safe levels Failure to follow these instructions will result in death or serious injury To replace the DC Output Fuse 1 Locate the fuse cover on the charger s top panel see Front Panel on page 3 2 Loosen the screw on the fuse cover using a Phillips screwdriver NOTE The screw will not separate from the cover 48 Truecharge2 Series Battery Charger Owner s Guide a La e 4 TC2 204060 Series BattChg Owners Guide book Page 49 Friday July 8 2011 11 44 AM Replacing the DC Output Fuse Fuse Replacement Ratings CAUTION RISK OF EQUIPMENT DAMAGE For continued protection replace only with Littelfuse type 257 or equivalent with ratings as shown below Failure to follow these instructions can damage the unit and or damage other equipment Model Amperage Voltage TC2012 30 A green 32 Vde TC4012 2x30 A green 32 Vdc TC6012 3x30 A green 32 Vdc TC1024 30 A green 32 Vdc TC2024 15 A blue 32 Vde TC3024 40 A amber 32 Vdc 975 0526 01 02 49 YV e e 6 Co LA TC2 204060 Series BattChg Owners Guide book Page 50 Friday July 8 2011 11 44 AM
20. warning The icons above the LEDs represent the various types of fault and warning conditions See Reading Onboard Display LEDs on page 41 6 Z gt gt amp TC2 204060 Series BattChg Owners Guide book Page 6 Friday July 8 2011 11 44 AM Truecharge 2 Battery Charger Features L Item Description Item Description 2 Fault LED 4 Charger Mode Select button The LED may illuminate a solid light indicating a fault or e Press and hold the button for three seconds to select one of flash intermittently indicating a warning in combination with two settings An indicator LED corresponds to each setting flashing Charging Output LEDs See Interpreting Fault Each setting optimizes the charging sequence differently in and Warning Indicators on page 43 for details charging the batteries by stages e Three stage Bulk Absorption and Float default setting Two stage Bulk and Absorption only e When setting or cancelling an Equalization program Press and hold for five seconds both the Charger Mode and Battery Temp Select buttons 3 Charger Status LEDs Displays the current status of the charger Ready a solid light indicates batteries are fully charged and the charger is in rest stage Ready and Charging solid lights indicate batteries are fully charged and the charger is in float stage e Charging a solid light indicates charger is performing a 5 Battery Type Select button normal
21. 12 V and 24 V lead acid GEL AGM Flooded or lead calcium rechargeable batteries because other battery types may explode and burst Do not work in the vicinity of lead acid batteries Batteries generate explosive gases during normal operation See note below Failure to follow these instructions will result in death or serious injury Failure to follow these instructions will result in death or serious injury NOTE Follow these instructions and those published by the battery manufacturer and the manufacturer of any equipment you intend to use in the vicinity of the battery Review cautionary markings on these products and on the engine 975 0526 01 02 v 4 DI TC2 204060 Series BattChg Owners Guide book Page vi Friday July 8 2011 11 44 AM Precautions When Working With Batteries 5 Use extra caution to reduce the risk or dropping a metal tool on the A WARNIN G battery It could spark or short circuit the battery or other electrical parts and could cause an explosion BURN FROM HIGH SHORT CIRCUIT CURRENT FIRE AND EXPLO 6 Batteries can produce a short circuit current high enough to weld a ring SION FROM VENTED GASES HAZARDS or metal bracelet or the like to the battery terminal causing a severe e Always wear proper non absorbent gloves complete eye protection burn and clothing protection Avoid touching your eyes and wiping your 7 forehead while working near batteries See note
22. 204060 Series BattChg Owners Guide book Page 57 Friday July 8 2011 11 44 AM Specifications Protection Features Protection Features Battery reverse polarity Protected by replaceable DC output Battery under temperature Charger shuts down if battery fuses protection temperature below 25 C 13 F is Over voltage limits The Truecharge2 Battery Charger will o da battery temperature stop charging if the output voltage is EER above 16 6 0 5 Vdc for 12 Vdc units 33 2 40 1 Vdc for 24 Vdc units Regulatory Approvals Output current limit Safety North America NRTL approved to CSA E60335 2 29 UL1236 including TC2012 20 10 A the marine supplement and UL1564 TC4012 40 10 A E ABYC E11 Alternating Current and Direct Current TC6012 60 10 A Electrical Systems on Boats and TC1024 10 10 A ABYC A31 Battery Chargers and Inverters TC2024 20 10 A European Union CE marked for the Low Voltage Directive 2006 95 EC TC3024 30 10 A complying with EN60335 2 29 Battery Chargers EN 28846 Small Craft Electrical Devices Protection Over temperature Shutdown at 65 5 C 149 9 F against ignition of surrounding flammable gases measured internally Australia Designed to IEC60335 2 29 including Australian Restart at 60 5 C 140 9 F deviations EMC Battery over temperature Charger shuts down if battery North America Class B according to FCC Part 15B and Industry C
23. AC connections Change to a more stable AC fault lt 85 V or gt 265 V power source and check that the voltage and voltage frequency are within acceptable operating range See Specifications on page 54 High Battery Temp fault uil e Check the batteries Do not charge a battery that is gt 70 C O rated other than 12 V nominal for all 12 volt chargers i a or 24 V nominal for all 24 volt chargers Check that the battery type and temperature settings match the actual battery and its conditions Disconnect or turn off other charging sources such as an alternator or the charger on a generator with an electric start e Allow the battery or batteries to cool to normal operating temperature See Specifications on page 54 1 am 8 P Flashing LED Solid LED 975 0526 01 02 43 Y e e cd amp TC2 204060 Series BattChg Owners Guide book Page 44 Friday July 8 2011 11 44 AM Accessing Charger Information Table 9 Interpreting Fault and Warning Indicators Fault or Warning Temp Fan 8 amp AC N Battery Fuse Charger Remote R Fault Solution Condition im 5 9 a Low Battery Temp fault EF e Check the batteries Do not charge a frozen battery lt 25 C Charging a frozen battery may present a risk of explosion Check that the battery type and temperature settings match the actual battery
24. AC power source from the charger If you have the optional remote panel you can put the charger in Standby mode by pressing the ON STANDBY button to interrupt the charging process Table 8 Charger Status LED Sequences Charger Status LED Charger status Activity Ready LED The charger is in standby or rest mode of two illuminates solid stage charging All batteries have been fully charged Ready and Charging The charger is in float mode of three stage LEDs illuminate charging All batteries have been fully charged solid Charging LED The charger is charging in bulk or absorption illuminates solid mode Equalize LED flashes The charger will perform an equalization cycle after the absorption stage Equalize LED The charger is currently implementing an illuminates solid equalization cycle for all batteries Fault LED flashes A warning condition See Interpreting Fault and Warning Indicators on page 43 Fault LED A fault condition See Interpreting Fault and illuminates solid Warning Indicators on page 43 42 Truecharge2 Series Battery Charger Owner s Guide 4 TC2 204060 Series BattChg Owners Guide book Page 43 Friday July 8 2011 11 44 AM Accessing Charger Information El Table 9 Interpreting Fault and Warning Indicators Fa u It o r Warni ng ry Fan AC Battery ES pa pa Fault So lution i E e Condition os A ed ee a os AC input out of range ct e Check
25. Battery Charger for servicing features e battery reverse polarity protection via user replaceable output fuse s AC input out of range derating and shutdown e ambient over temperature derating and shutdown battery over charging protection 2 Each output can charge different batteries that either have the same chemistry or can tolerate the same charge sequence and voltage current ratings 3 The charger can be programmed with custom charge setpoints using PC interface This programming can only be done using a special configuration tool operated by Xantrex or a designated OEM 1 Not included with IEC models of Truecharge2 Battery Chargers 4 The charger can initiate charging a non damaged but zero voltage battery 975 0526 01 02 1 is MZ de DI TC2 204060 Series BattChg Owners Guide book Page 2 Friday July 8 2011 11 44 AM Introduction e electronic current limiting provides protection against short circuit The optional Battery Temperature Sensor BTS provides these protection conditions on the charger s output features e ignition protected rating enabling installation in engine spaces battery under temperature charging protection preventing battery e isolated design charging at 25 C 13 F or below e short circuit protection for the BTS and communication connector e battery over temperature charging protection preventing battery ports including protection from incorrectly inserting the rem
26. D GASES HAZARD RISK OF DAMAGE TO THE BATTERY CHARGER e Make sure the area around the battery is well ventilated e Never allow battery acid to drip on the battery charger when reading e Make sure the voltage of the batteries matches the output voltage of gravity or filling battery the battery charger e Never place the Truecharge2 Series Battery Charger unit directly e Be careful to keep corrosion from coming into contact with your eyes above batteries gases from a battery will corrode and damage the and skin when cleaning battery terminals charger Failure to follow these instructions can result in death or serious Do not place a battery on top of the battery charger injury Failure to follow these instructions can damage the unit and or damage other equipment NOTES 1 Study and follow all of the battery manufacturer s specific precautions NOTE For North American marine installations external connections to the such as removing or not removing cell caps while charging whether charger shall comply with the United States Coast Guard Electrical equalization is acceptable for your battery and recommended rates of Regulations 33CFR183 Sub Part I charge 2 For flooded non sealed batteries add distilled water in each cell until battery acid reaches the level specified by the battery manufacturer This helps to purge excessive gas from cells Do not overfill For a battery without removable cell caps carefully follow m
27. ECIFICALLY AGREED TO IN WRITING XANTREX TECHNOLOGY USA INC XANTREX A MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION B ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES DAMAGES COSTS OR EXPENSES WHETHER SPECIAL DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK AND C REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION THE ACCURACY CANNOT BE GUARANTEED APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW XANTREX COM Date and Revision August 2011 Rev C Document Part Number 975 0526 01 02 975 0526 01 02 Product Numbers Non IEC Models IEC Models 804 1220 02 804 1220 03 804 1240 02 804 1240 03 804 1260 02 804 1260 03 804 2410 804 2410 01 804 2420 804 2420 01 804 2430 804 2430 01 a IEC refers to the international standard from the International Electrotechnical Commission for plugs socket outlets and cou plers for industrial purposes IEC models have an AC input recep tacle that connects with an IEC cable not provided Contact Information Telephone 1 800 670 0707 Fax 1 800 994 7828 Web www xantrex com NI Z NIZ a TC2 204060 Seri
28. ES 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 PROVINCE TO PROVINCE OR JURISDICTION TO JURISDICTION Truecharge2 Series Battery Charger Owner s Guide DIO NI E amp TC2_204060 Chapters fm Page 61 Thursday August 4 2011 1 14 PM Return Material Authorization Policy For those products that are not being repaired in the field and are being returned to Xantrex 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 Product 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 A copy of your dated proof of purchase Record these details on page 62 Return Procedure Package the unit safely preferably using the original box and packing materials Please ensure that your product is shipped fully in
29. Electrical Regulations 33CFR183 G 3 e Failure to follow these instructions can damage the unit and or T 9 damage other equipment A gt G 4 NOTE In some jurisdictions a NOTE The Truecharge2 Battery Charger is designed to be permanently double pole breaker may be mounted Figure 4 shows a typical installation with three batteries a battery required temperature sensor BTS and a remote panel both optional It also shows the AC and DC wiring and protection devices required for a typical 5 installation Means of over current protection and disconnection must be incorporated into the fixed wiring in accordance with the electrical code that governs each installation Figure 4 Configuration for Normal Loads AC input wiring compartment 2 AC mains source protected by correct size and type of branch rated circuit breaker 3 DC negative cable 8 Truecharge2 Series Battery Charger Owner s Guide 4 MZ de O TC2 204060 Series BattChg Owners Guide book Page 9 Friday July 8 2011 11 44 AM gt 7 DC positive cables DC circuit breakers or DC fused disconnects Battery or battery bank ND M A Battery Temp Sensor optional accessory part number 808 0232 01 Engine ground bus or DC negative bus N 00 Ground bus 10 DC chassis ground earth 11 Remote panel optional accessory part number 808 8040 01 Tools and Materials To mount a
30. ING FROM OR AS A RESULT OF MISUSE OR ABUSE OR THE INCORRECT INSTALLATION INTEGRATION OR OPERATION OF THE PRODUCT BY PERSONS NOT AUTHORIZED BY XANTREX 60 CONSUMERS IN THE EUROPEAN UNION IF YOU ARE A CONSUMER RATHER THAN A PURCHASER OF THE PRODUCT IN THE COURSE OF A BUSINESS AND PURCHASED THE PRODUCT IN A MEMBER STATE OF THE EUROPEAN UNION THIS LIMITED WARRANTY SHALL BE SUBJECT TO YOUR STATUTORY RIGHTS AS A CONSUMER UNDER THE EUROPEAN UNION PRODUCT WARRANTY DIRECTIVE 1999 44 EC AND AS SUCH DIRECTIVE HAS BEEN IMPLEMENTED IN THE EUROPEAN UNION MEMBER STATE WHERE YOU PURCHASED THE PRODUCT FURTHER WHILE THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS YOU MAY HAVE OTHER RIGHTS WHICH MAY VARY FROM EU MEMBER STATE TO EU MEMBER STATE OR IF YOU DID NOT PURCHASE THE PRODUCT IN AN EU MEMBER STATE IN THE COUNTRY YOU PURCHASED THE PRODUCT WHICH MAY VARY FROM COUNTRY TO COUNTRY AND JURISDICTION TO JURISDICTION CONSUMERS IN THE REST OF THE WORLD Exclusions 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 PROVINCES AND JURISDICTIONS 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 DAMAG
31. NCE This chapter contains important safety and installation instructions for the Truecharge2 Series Battery Chargers Each time before using the Truecharge2 Series Battery Charger READ ALL instructions and cautionary markings on or provided with the battery charger the batteries and all appropriate sections of this guide NOTE The Truecharge2 Series Battery Charger contains no user serviceable parts with the exception of the DC output fuse s which are user replaceable See Replacing the DC Output Fuse on page 48 for instructions For obtaining service other than replacing the fuse see Warranty and Return Information on page 58 for guidance NOTE The Truecharge2 Series Battery Charger must be provided with equipment grounding conductors connected to the AC input ground and to the DC chassis ground See Step 2 Connecting the DC Chassis Ground Earth on page 17 for instructions DANGER ELECTRICAL SHOCK HAZARD Do not expose the Truecharge2 Battery Charger to rain snow spray or bilge water e Do not operate the battery charger if it has received a sharp blow been dropped has cracks or openings in the enclosure including if the fuse cover has been lost damaged or will not close or otherwise damaged in any other way Do not disassemble the battery charger Internal capacitors remain charged after all power is disconnected Disconnect both AC and DC power from the battery charger before attempting
32. NIZ amp TC2 204060 Series BattChg Owners Guide book Page i Friday July 8 2011 11 44 AM Smart choice for power xantrex e Owner s Guide oe SIC N e uid day Ju 2 4 T C 2 2 0 4 0 6 0 S e ri s B atti C h 8 O W n e rs G ide b o o k P a ge ii F ri a y J ly 8 gt 0 1 1 1 1 i 4 A M is A TC2_204060_FrontMatter_SE fm Page i Thursday August 4 2011 1 11 PM Trademarks Xantrex Truecharge and Smart choice for power are trademarks of Schneider Electric Services International sprl registered in the U S and other countries Other trademarks registered trademarks and product names are the property of their respective owners and are used herein for identification purposes only Notice of Copyright Truecharge2 Series Battery Charger Owner s Guide August 2011 Xantrex Technology USA Inc All rights reserved No part of this document may be reproduced in any form or disclosed to third parties without the express written consent of Xantrex Technology USA Inc 541 Roske Drive Suite A Elkhart Indiana USA 46516 Xantrex Technology USA Inc reserves the right to revise this document and to periodically make changes to the content hereof without obligation or organization of such revisions or changes unless required to do so by prior arrangement Exclusion for Documentation UNLESS SP
33. Troubleshooting In the event that you have a problem with your Truecharge2 Battery Charger the following tables will help you to identify the problem and offer possible solutions to the problem Symptom Symptom Indicator LEDs do not illuminate when charger is connected to an AC The initial power up display test is not performed upon connection of power source battery or batteries Possible Cause Solution Possible Cause Solution No power at AC source Ensure that power is available at Truecharge2 Battery Charger Check quality of battery connection and charger AC input and it is within does not detect battery for one of wires acceptable range the following reasons Ensure correct polarity negative e poor connection connected to negative positive Defective AC wiring or Wiring must be inspected and replaced e reverse polarity connection connected to positive switches breakers by a qualified installer blown fuse In case there is an accompanying fault e damaged wiring check the type of fault from Remote panel has been used to Press the On Standby button on the e open DC breaker or external Interpreting Fault and Warning put the charger into Standby remote panel to turn the charger on fuse Indicators on page 43 mode battery voltage is below 9 V 50 Truecharge2 Series Battery Charger Owner s Guide e El Symptom 4 TC2 204060 Series BattChg Owners Guide book Page 51 Friday July 8 2011 11 44 AM A
34. Xantrex recommends that you install a DC chassis ground earth wire from the ground stud on the Truecharge2 Battery Charger to the engine bus or DC ground bus The DC chassis ground earth wire should be sized correctly with the power conductors and both must be sized for the battery fuses that are used to protect the DC wiring Refer to your local electrical codes to verify the requirements in your jurisdiction for your application 975 0526 01 02 17 Y e _ 16 4 TC2 204060 Series BattChg Owners Guide book Page 18 Friday July 8 2011 11 44 AM Installing the Truecharge 2 Battery Charger VW e 4 Install a DC circuit breaker or fused disconnect in each positive cable Step 3 Installing DC Wiring that is as close to the battery positive terminal as possible Consult your local electrical codes regarding the distance allowed Th dure for installing the DC wiri lies t ingle battery A ee E O e between the battery and the fuse or breaker For example for most 11 Itiple batteri battery banks a a a situations ABYC standard E 11 requires no more than 7 inches 17 8 cm Be sure the breaker or fused disconnect is open A WARNIN G 5 Route the wiring to the batteries and to the Truecharge2 Battery Charger Avoid routing wiring through an electrical distribution panel ACCIDENTAL SHORT OR SPARK HAZARD battery isolator or other device that will add voltage drops Leave the DC disconnects or breakers in the Off
35. a determine the end ofth li I e Ventilate the area around the battery thoroughly using ventilators CR A E with brushless motors and ensure that there are no sources of flame or Failure to follow these instructions can damage the unit and or sparks in the vicinity damage other equipment Failure to follow these instructions can damage the unit and or damage other equipment Failure to follow these instructions will result in death or serious injury The Truecharge2 Battery Charger cannot automatically determine when to stop the equalization of a battery The one hour time out is intended as a safety feature to require the user to continually re activate it as necessary after checking batteries manually but may not be sufficiently short to prevent battery damage 1 In this case an equalization cycle can be programmed to start once the charge cycle is done 975 0526 01 02 37 4 4 TC2 204060 Series BattChg Owners Guide book Page 38 Friday July 8 2011 11 44 AM Equalizing Flooded Batteries Performin g An Equa lization NOTE If battery acid contacts skin or clothing wash immediately with soap and water If acid enters your eye immediately flood it with running cold water for at least twenty minutes and get medical attention immediately El CAUTION RISK OF EQUIPMENT DAMAGE To equalize your batteries e Turn off or disconnect all DC loads on the battery during IMPORTANT Rem
36. anada protection temperature above 70 C 158 F is ICES 003 sensed by the battery temperature European CE marked for the EMC Directive 2004 108 EC sensor BTS complying with EN55014 1 EN55014 2 EN61000 3 2 and EN61000 3 3 975 0526 01 02 57 10 e amp TC2_204060_Chapters fm Page 58 Thursday August 4 2011 1 12 PM Warranty and Return Information Warranty What does this warranty cover and how long does it last This Limited Warranty is provided by Xantrex Technology USA Inc Xantrex and covers defects in workmanship and materials in your Truecharge2 Series Battery Charger This warranty period lasts for 24 months from the date of purchase at the point of sale to you the original end user customer unless otherwise agreed in writing the Warranty Period You will be required to demonstrate proof of purchase to make warranty claims This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the Warranty Period Subsequent owners also require original proof of purchase as described in What proof of purchase is 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 notify Xantrex of the product defect within the Warranty Period and provided that Xantrex through inspection establishes the existence of such a
37. anufacturer s instructions 975 0526 01 02 vii 4 P cu LS TC2 204060 Series BattChg Owners Guide book Page viii Friday July 8 2011 11 44 AM FCC Information to the User This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna Increase the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected Consult the dealer or an experienced radio TV technician for help CAUTION Unauthorized changes or modifications to the equipment could void the user s authority to operate the equipment viii Truecharge2 Series Battery Charger Owner s G
38. arger must be 12 Vdc Models Minimum Battery Bank Size Ah protected by the correct size and type of branch circuit rated fuse or breaker to meet the applicable installation codes If a fuse is used instead of a TC2012 40 breaker a correctly rated disconnect switch is required ahead of the fuse so TC4012 80 that power can be turned off allowing fuse replacement and safe RIA TC6012 120 maintenance of other equipment on the mains circuit 24 Vdc Models Minimum Battery Bank Size Ah TC1024 20 TC2024 40 TC3024 60 975 0526 01 02 15 Se 204060 Series BattChg Owners Guide book Page 16 Friday July 8 2011 11 44 AM Installing the Truecharge 2 Battery Charger Be sure to read the safety guidelines and pay attention to all cautions and Step 1 Mounting the Battery Cha rger warnings throughout the installation procedure The installer is responsible for ensuring compliance with the installation codes for your particular Mount the Truecharge2 Battery Charger using all four mounting slots and application See CAUTION statement under Preparing For Installation on holes which are provided Mounting orientations a and b in Figure 5 meet page 8 IP 32 and drip proof requirements that are needed to ensure safety in the presence of condensation The other possible mounting orientations c and d shown in Figure 6 will not prevent the entry of dripping water and are not suitable for use in marine installations or other moist environments
39. ate at 100 of maximum current NOTE For Negative chassis systems disconnect the negative cable first then the positive cable For Positive chassis systems disconnect the positive cable first then the negative cable Inspect all AC and DC cables for damage and repair if necessary 4 Replace the old battery with the new battery 975 0526 01 02 27 4 is MZ be O TC2 204060 Series BattChg Owners Guide book Page 28 Friday July 8 2011 11 44 AM VY Installing Batteries Multi Stage Charging Most Truecharge2 Battery Charger models have three outputs that share the full rated current enabling it to charge three different batteries or battery banks that either have the same chemistry or can tolerate the same charge sequence and thresholds The Truecharge2 Battery Charger can perform either three stage charging Bulk Absorption and Float or two stage charging Bulk and Absorption IMPORTANT The battery banks are not galvanically isolated from each LA other They share a common negative as shown in the diagram below N a The negative bus to chassis connection as shown below may not be suitable G in some applications e Da optional required Negative bus Battery banks Figure 8 Typical Three Battery Installation 28 Truecharge2 Series Battery Charger Owner s Guide S AZ o gt amp TC2 204060 Series BattChg Owners Guide book Page 29 Friday
40. b o o k P a ge ii F ri a y J ly 8 gt 0 1 1 1 1 i 4 A M is TC2 204060 Series BattChg Owners Guide book Page 1 Friday July 8 2011 11 44 AM Introduction This chapter describes the standard features of a Truecharge2 Battery Standard and Protection Features Charger as well as its protection features It also provides information on the different parts of the Truecharge2 Battery Charger The Truecharge2 Battery Charger provides the following standard features upto three full current rated outputs Truecharge2 Battery Charger battery monitoring functions correct charging voltage for batteries when connected to almost any The Truecharge2 Battery Charger ships with the following items single phase AC power outlet in the world one Truecharge2 Battery Charger unit e low electromagnetic interference EMI e owner s guide e automatic charge resumption if required after AC power interruption rubber boots for DC terminals programmable custom charge settings3 e nuts and washers M6 for DC terminals and ground stud e fully discharged battery charging e strain relief clamp for AC input cables e ability to operate two Truecharge2 Battery Chargers in parallel mode e three crimp connectors for AC wiring with the use of the optional remote panel NOTE Keep the carton and packing material in case you need to return The Truecharge2 Battery Charger provides the following protection the Truecharge2
41. c Absorption voltage Flooded GEL AGM Lead calcium 12 volt units 25 C 77 F 14 4 0 1 14 2 0 1 14 3 0 1 15 5 0 1 24 volt units 25 C 77 F 28 8 40 2 28 4 40 2 28 6 0 2 31 0 0 2 975 0526 01 02 o 55 Pe d amp TC2 204060 Series BattChg Owners Guide book Page 56 Friday July 8 2011 11 44 AM Specifications DC Output Specifications DC Output Specifications e Voltage regulation Float voltage 12 volt units 24 volt units 25 C 77 F 25 C 77 F Flooded 13 5 0 1 27 0 0 2 GEL 13 8 0 1 27 6 0 2 AGM 13 4 0 1 26 8 0 2 Lead calcium 13 5 0 1 27 0 0 2 Equalize mode current 50 rated output 6 Uncompensated load voltage regulation lt 0 1Vde drop from 0 Amps to rated current output at charger output terminals adds in series with recommended 3 limit for user s battery cable voltage drop Equalize mode maximum output voltage Environmental Specification S Operating range 0 60 C 32 140 F anes units O with up to 80 current derating 24 volt units 32 0 2 Vdc above 40 C 104 F and up to 50 current derating Off state current draw above 50 C 122 F without remote installed lt 35 mA de Storage _40 to 80 C 40 to 176 F Humidity 5 95 RH non condensing 56 Truecharge2 Series Battery Charger Owner s Guide _ Pe e d DI TC2
42. charge cycle Press and hold the button for three seconds to select one of five Equalize a solid light indicates that the charger is settings An indicator LED corresponds to each setting performing an equalization cycle NOTE The fifth setting is a custom battery type setting and is a flashing light indicates that the equalization indicated when all four LEDs illuminate See Custom below cycle will begin after the absorption stage is done Each setting maximizes charger performance for its corresponding battery type e AGM Absorbent Glass Mat lead acid battery Flooded Lead acid battery default setting e GEL Gel type lead acid battery e Lead Cale Lead calcium battery e Custom Only available if a custom algorithm has been programmed by Xantrex or a designated OEM 6 Truecharge2 Series Battery Charger Owner s Guide _ 4 TC2 204060 Series BattChg Owners Guide book Page 7 Friday July 8 2011 11 44 AM Truecharge 2 Battery Charger Features Hem Beseipuon Item Description 6 Battery Temp Select button e Press and hold the button for three seconds to select one of three settings An indicator LED corresponds to each setting If an optional BTS is connected the indicator LEDs represent real time battery temperature When the optional BTS is not used this selection changes the charger s output voltage settings to compensate for the battery temperature selected The Cold set
43. correct at battery and charger output terminals e Disconnect AC and DC sources before replacing the fuse s on the charger See Replacing the DC Output Fuse on page 48 Internal fault is e Call Xantrex for support 9 Flashing LED O Solid LED 975 0526 01 02 45 YV e e 6 Co DI a 204060 Series BattChg Owners Guide book Page 46 Friday July 8 2011 11 44 AM Using A Generator As Source Power The Truecharge2 Battery Charger can be run from a regular AC power source or from an alternate power source such as a generator Refer to AC Input Specifications on page 54 for AC input current draw to determine the size of generator you need Many generators provide output voltage that is modified sine wave or modified square wave MSW rather than the true sine wave TSW that your utility provides If a generator needs to run on full load capacity to supply charging current to the battery via the battery charger its output frequency and amplitude may become unstable This scenario can cause the battery charger to shutdown Using the current limiting feature from the remote panel can help avoid this scenario The Truecharge2 Battery Charger may be used with MSW generators but its lifetime may be reduced somewhat depending on the severity of any peak voltage overshoots and the severity of waveshape rise times 1 See Configuring the Maximum Output Current Percentage of the Charger on the Truecharge2 Remote
44. ctor at rated 20 95 Y inch North American trade size strain ee load relief included 22 AC input connections IEC 60320 C14 male connector receptacle Frequency 47 63 Hz IEC models only Efficiency peak DC output Four M6 studs 3 positives and 1 common 12 24 volt units 80 120 Vac connections negative for battery cable ring terminals and 12 24 volt units 84 230 Vac one M6 mm DC equipment ground Surge protection Line to neutral surge protector rated at 275 Vac 54 Truecharge2 Series Battery Charger Owner s Guide Va gt TC2 204060 Series BattChg Owners Guide book Page 55 Friday July 8 2011 11 44 AM DC Output Specifications DC Output Specifications e Specifications Number of isolated battery bank outputs 3 separated outputs DC output voltage range including dead battery charging voltage Normal operating output range 12 volt units 0 16 Vdc 24 volt units 0 32 Vdc Maximum equalization voltage 12 volt units 16 Vdc 24 volt units 32 Vdc 12 volt units 0 16 Vdc 24 volt units 0 32 Vdc Maximum DC output current total TC2012 20 10 A TC4012 40 10 A TC6012 60 10 A TC1024 10 10 A TC2024 20 10 A TC3024 30 10 A Voltage accuracy no load 12 volt units 24 volt units 14 4 0 1 Vde 25 C 77 F 28 8 0 2 Vde 25 C 77 F Nominal battery voltage 12 volt units 24 volt units 12 Vdc 24 Vd
45. de book Page 30 Friday July 8 2011 11 44 AM Installing Batteries Two Stage Charging Vbat Vabs lout lt 10 Irating The two stage charging mode employs the following sequence Bulk and Battery Voltage ES Laica Absorption It runs similar to the three stage sequence except that there is Merita W no float stage after the absorption stage the charger stops providing current to the battery and the charger output drops to 9 V 12 Vdc chargers or 18V 24 Vdc chargers In this manner DC loads draw power supplied by te eee petites Ja meatal dele ieee aud batteries and the charger enters a rest or standby stage Like the three stage sequence the charger will restart the charging cycle in the Bulk stage if the lowest battery voltage of the three banks drops below 12 5 V 12 Vdc chargers or 25 V 24 Vdc chargers for 15 minutes After seven days the charger will automatically restart charging in order to refresh the batteries GO TO BULK when Vbat lt 12 5 V for 15 minutes I I ABS REST I sl Standby NI I I I Time ABS CV timeout I l max 5 hrs y JI Start of I REST Standby charging cycle I _ timeout max 7 days Total ABS timeout max 8 hrs Figure 10 Two Stage Charging Process BO Truecharge2 Series Battery Charger Owner s Guide Y _ amp TC2 204060 Series BattChg Owners Guide book Page 31 Friday July 8 2011 11 44 AM Charging Voltage Setpoints The Truecha
46. e Bank 2 Temperature Considerations Xantrex strongly recommends that you purchase and install the optional Battery Temperature Sensor BTS to protect your battery and improve charging accuracy Attach the BTS to the warmest battery If no BTS is connected the charger defaults to the Battery Temp selection on the onboard display as well as on the optional remote panel 31 4 TC2 204060 Series BattChg Owners Guide book Page 32 Friday July 8 2011 11 44 AM e VY Installing Batteries Setting the Battery Temperature without a BTS NOTE Cold is for battery temperature below 5 C 41 F Warm default setting is for battery temperature between 5 and 30 C 41 and 86 F Hot is for battery temperature above 30 C 86 F See Table 7 Battery Temperature Compensation Levels on page 32 to see how output voltage is offset by varying the temperature selection CAUTION RISK OF BATTERY DAMAGE Do not set a battery temperature that is lower than the actual temperature in the absence of a BTS as this may cause the battery to be overcharged Similarly do not set a battery temperature that is higher than the actual temperature in the absence of a BTS as this may result in under charging Table 7 Battery Temperature Compensation Levels the battery Recommended Fai PORRO 3 4 iena Temperature for battery Voltage added for temperature o o l ese msirucuons can damage theunitando
47. e charger only in the keyhole slots for the installation of the charger 16 Truecharge2 Series Battery Charger Owner s Guide 0 4 TC2 204060 Series BattChg Owners Guide book Page 17 Friday July 8 2011 11 44 AM Installing the Truecharge 2 Battery Charger VW Step 2 Connecting the DC Chassis Ground Earth To connect the DC chassis ground earth A WARNING 1 Locate the ground stud on the Truecharge2 Battery Charger 2 Connect the DC chassis ground earth from the ground stud to the ground bus See Figure 4 Configuration for Normal Loads on page 8 Failure to follow these instructions can result in death or serious Use a flat washer a lock washer and a nut included in the installation injury kit to secure the connection 3 Tighten the nuts to 2 3 N m 20 Ib in torque and test that the wire is NOTE Have an electrician install a properly grounded circuit if one is not secure Do not over tighten as this may result in damage to the charger avallable ELECTRICAL SHOCK HAZARD Improper connection can result in risk of electric shock See note below The Truecharge2 Battery Charger must be connected to a grounded metal permanent wiring system or an equipment grounding conductor should be run with the circuit conductors and connected to the equipment grounding lead on the charger Connections to the battery charger must comply with all local and application specific codes and ordinances
48. e the positive terminals of the Truecharge2 Battery Charger secure will be connected to the correct terminals of the battery fuses or breakers 12 Connect the free end of each positive cable assembly to the correct and from there to the positive terminals of the battery Make sure the positive terminal of the battery using sufficient torque as negative terminal of the Truecharge2 Battery Charger will be connected to recommended by your battery manufacturer the cada ina orbe FR bus l 13 Connect the free end of the negative cable to the negative terminal on 8 Connect the negative cable to the negative DC terminal on the charger the battery using sufficient torque as recommended by your battery See Figure 4 Configuration for Normal Loads on page 8 manufacturer 975 0526 01 02 19 4 TC2 204060 Series BattChg Owners Guide book Page 20 Friday July 8 2011 11 44 AM Installing the Truecharge 2 Battery Charger NOTE If you are using more than one battery you will need to connect the negative cable from each ofthe batteries to the negative ground bar or bus The negative ground bar or bus will then have a single negative cable connecting to the negative charger terminal 14 Secure cables in place using tie wraps or cable straps according to electrical codes 15 Slide the rubber boots to cover the DC terminals 16 Ifavailable route the optional battery temperature sensor BTS from the battery one which is located in the warm
49. ect panel buttons l Geum i lt 5 5 10 20 40 60 80 100 lt Ready Charging Equalize Fault 3 Stage 2 Stage AGM Flooded Gel Lead Calc Cold Warm Hot Figure 3 Onboard Control and Status Display Panel 975 0526 01 02 _ e Truecharge 2 Battery Charger Features To reduce current draw from the connected battery when AC power is not present the panel s LED control and status lights are automatically turned off and the buttons are disabled However to temporarily check the status of the connected battery when AC power is not present press the Status button on the optional remote panel Item Description 1 Charging Output LEDs The LEDs illuminate like a bar graph displaying the present total output charge current as a percentage of the maximum rated charge current For example unit model TC4012 has a maximum rated charge current of 40 A so at 60 the charger s current output is 24 A The numbers below the LEDs represent the percentage values See Reading Onboard Display LEDs on page 41 NOTE When the maximum Charge Output current is limited via the optional remote panel the LEDs will still display the total charge output current as a percentage of the maximum rated charge current and NOT as a percentage of the limited charge current e One or two LEDs may flash intermittently in combination with a solid Fault LED indicating a fault or with a flashing Fault LED indicating a
50. edge of the injury applicable installation codes and awareness of the hazards involved in performing electrical work and how to reduce those hazards A qualified A C AUTI O N technician or electrician has this knowledge and experience STATEMENT OF HAZARD Contains statements of avoidance or strict compliance Failure to follow these instructions can result in minor or moderate injury ii Truecharge2 Series Battery Charger Owner s Guide e 16 Zs TC2 204060 Series BattChg Owners Guide book Page iii Friday July 8 2011 11 44 AM CAUTION STATEMENT OF HAZARD Contains statements of avoidance or strict compliance Failure to follow these instructions can damage the unit and or damage other equipment IMPORTANT These notes describe things which are important for you to know however they are not as serious as a danger warning or caution Related Information You can find more information about Xantrex Technology USA Inc as well as its products and services at www xantrex com The product marking on the left when found imprinted on electrical and electronic units and appliances means that you are to refer to this guide for cautions and warnings 975 0526 01 02 ili Y e e NIZ a TC2 204060 Series BattChg Owners Guide book Page iv Friday July 8 2011 11 44 AM Important Safety Instructions IMPORTANT READ AND SAVE THIS OWNER S GUIDE FOR FUTURE REFERE
51. ember that all connected batteries will undergo the equalization equalization If only one bank is intended to undergo equalization then the Do not equalize if the level of equalization voltage see note below other banks must be disconnected prior to equalization t I ith th tt fi i ti i Kg oe a e wi e battery manutactuter s recommendation 1 Check the battery electrolyte level If necessary refill with distilled Failure to follow these instructions can damage the unit and or water only All the cells should have similar electrolyte levels If the damage other equipment levels are widely different it will influence the relative concentration of acid thereby affecting the specific gravity measurements If NOTE The voltage applied to the battery during equalization may be above distilled water is added batteries must undergo a complete charge safe levels for some loads but the absolute maximum is 16 V for 12 volt cycle chargers and 32 V for 24 volt chargers within operational temperature 2 Program or initiate an equalize cycle Equalization will begin if all range banks are in either float or rest mode A WARNING IMPORTANT If equalization is programmed prior to float or rest mode the Equalize LED will flash and equalization will start prior to reaching float or rest mode EXPLOSION FIRE AND BURN HAZARDS Always wear proper non absorbent gloves complete eye protection and clothing protection Avoid touching your
52. enclosure and causing shock hazard and damage to equipment a The other possible mounting orientations shown in Figure 6 c and d A Deck Mount this orientation will not prevent the entry of dripping water and are not suitable for marine E meets IP 32 requirements and is or other moist environments without the installation of additional drip drip proof protection They are only acceptable for use in locations that are always dry The environment therefore will determine the mounting orientations that are suitable for each installation Is the installation environment one that b will always be dry or will moisture or condensation sometimes enter the Horizontal Wall Mount with AC a 5 area wiring higher than DC terminals I only this orientation meets IP AC le i 32 requirements and is drip I DANGER proof e ELECTRICAL SHOCK HAZARD ne E In marine environments there is a likelihood that condensation will be present and may drip on to the charger Use the appropriate mounting loo J Orientations as shown in Figure 5 and ges Figure 5 Mounting Orientations Deck and Horizontal Failure to follow these instructions will result in death or serious injury 975 0526 01 02 11 4 amp TC2 204060 Series BattChg Owners Guide book Page 12 Friday July 8 2011 11 44 AM Prepari
53. eplaced for a flat fee To return your product for out of warranty service contact Xantrex Customer Service for a Return Material Authorization RMA number and follow the other steps outlined in Return Procedure on page 61 Payment options such as credit card or money order will be explained by the Customer Service Representative In cases where the minimum flat fee does not apply as with incomplete units or units with excessive damage an additional fee will be charged If applicable you will be contacted by Customer Service once your unit has been received 61 N TC2_204060 Chapters fm Page 62 Thursday August 4 2011 1 14 PM Warranty and Return Information Information About Your System e If you need to contact Customer Service please record the following details before calling This information will help our representatives give you better service As soon as you open your Truecharge2 Series Battery Charger package record the following information and be sure to keep your proof of purchase DD Serial Number DD Product Number s Purchased From Purchase Date OO 62 804 1220 02 804 1240 02 804 1260 02 804 2410 804 2420 804 2430 804 1220 03 804 1240 03 804 1260 03 804 2410 01 804 2420 01 804 2430 01 m O OF OOF Ya 1 Type of installation e g RV truck Length of time unit has been installed Battery battery bank size Battery type e g flooded sealed gel cell
54. er appears to be taking too long to charge The Truecharge2 Battery Charger appears to have quickly charged the battery Ready indicator LED does not illuminate after 24 hours of battery Ready indicator LED illuminates sooner than expected charging Possible Cause Solution Possible Cause Solution Battery capacity is too low for Use a lower capacity charger Battery capacity is too high for Use a higher capacity charger the Truecharge2 Battery Charger Using the optional remote panel if the Truecharge2 Battery Charger model installed reduce the output current model delivered to the smaller battery Load connected to battery is Disconnect all loads or switch loads off Battery has a damaged cell or Replace battery draining charge current so that has reached the end of its useful battery does not recharge life Battery has a damaged cell or Replace battery has reached the end of its useful life The remote panel Max Output Increase the Max Output setting setting is too low for the battery capacity 52 Truecharge2 Series Battery Charger Owner s Guide S N TC2 204060 Series BattChg Owners Guide book Page 53 Friday July 8 2011 11 44 AM Symptom The Truecharge2 Battery Charger will not perform equalization Possible Cause Solution Battery is the wrong type or set to the wrong type to equalize Not all batteries are fully charged An active fault is present on the bank you are atte
55. es BattChg Owners Guide book Page ii Friday July 8 2011 11 44 AM About This Guide Purpose Conventions Used The purpose of this Owner s Guide is to provide explanations and The following conventions are used in this guide procedures for installing troubleshooting operating and maintaining the Truecharge2 Series Battery Charger DANGER Scope STATEMENT OF HAZARD The Guide provides safety and operating guidelines procedures for I i Contains statements of avoidance or strict compliance installing the battery charger as well as information on configuring the battery charger It also provides information about troubleshooting the unit Failure to follow these instructions will result in death or serious It does not provide details about particular brands of batteries You need to injury consult individual battery manufacturers for this information Audience A WARNING The Guide is intended fi d t f the Truecharge2 Seri e Guide is intended for users and operators of the Truecharge2 Series STATEMENT OF HAZARD Battery Charger The Installation section is primarily intended for qualified I 3 installers who need to install and configure any unit model of the Contains statements of avoidance or strict compliance Truecharge2 Series Battery Charger The installer should have knowledge Failure to follow these instructions can result in death or serious and experience in installing electrical equipment knowl
56. est ambient temperature to the charger location 17 Proceed to Step 4 Installing AC Wiring 20 Truecharge2 Series Battery Charger Owner s Guide AB _ e ud amp TC2 204060 Series BattChg Owners Guide book Page 21 Friday July 8 2011 11 44 AM amp Installing the Truecharge 2 Battery Charger hi Step 4 Installing AC Wiring Before connecting AC wiring make sure the AC source circuit is protected 4 Unscrew the wiring compartment cover from the left rear of the by a breaker switch of the correct size and type to comply with the Truecharge2 Battery Charger to expose the AC wiring access hole and electrical code for your location and application The current rating of the charger s AC pigtail leads input breaker should not be larger than 20 A for 120 Vac applications and 16 A for 230 Vac applications but may be required to be lower depending on the wire size used A DANGER ELECTRICAL SHOCK HAZARD Disconnect the AC source by turning off the breaker feeding the circuit unplugging from shore power and disconnecting any other power sources such as a generator Failure to follow these instructions will result in death or serious injury AC wiring access hole 1 Plan the route that the AC supply wiring will follow from the source 5 Carefully remove 50 75 mm 2 3 in of the outer jacket from the usually an AC distribution panel to the Truecharge2 Battery Charger AC supply wirin
57. face Te 6 d D amp TC2 204060 Series BattChg Owners Guide book Page 10 Friday July 8 2011 11 44 AM Preparing For Installation Location Install the Truecharge2 Battery Charger in a location that meets the following requirements Condition Requirement Dry The Truecharge2 Battery Charger must be installed in a dry location not subject to moisture especially rain spray or splashing bilge water Clean The Truecharge2 Battery Charger should not be exposed to metal filings or any other form of contamination Cool The ambient air temperature should be between 0 50 C 32 122 F for best performance Ventilated There must be at least 10 cm 4 in of clearance on the top and bottom ends of the Truecharge2 Battery Charger for air flow and at least 6 cm 2 5 in of clearance on either side see Figure 7 Ventilation openings on the charger must not be obstructed Ifthe charger is mounted in a tight fitting compartment the compartment must be ventilated with cut outs to prevent the charger from overheating Safe This battery charger except IEC models is ignition protected equipment so it can be installed in areas containing gasoline tanks or fittings which require ignition protected equipment Nevertheless Xantrex recommends that it is safest not to install any kind of electrical equipment including the Truecharge2 Battery Charger in these areas 10 _ e Condition
58. formation Disclaimer Product 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 A ANY SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOST PROFITS LOST REVENUES FAILURE TO REALIZE EXPECTED SAVINGS OR OTHER COMMERCIAL OR ECONOMIC LOSSES OF ANY KIND EVEN IF XANTREX HAS BEEN ADVISED OR HAD REASON TO KNOW OF THE POSSIBILITY OF SUCH DAMAGE B ANY LIABILITY ARISING IN TORT WHETHER OR NOT ARISING OUT OF XANTREX S NEGLIGENCE AND ALL LOSSES OR DAMAGES TO ANY PROPERTY OR FOR ANY PERSONAL INJURY OR ECONOMIC LOSS OR DAMAGE CAUSED BY THE CONNECTION OF A PRODUCT TO ANY OTHER DEVICE OR SYSTEM AND C ANY DAMAGE OR INJURY ARIS
59. g being careful not to cut or nick the insulation on the individual conductors Extend the charger s AC L N GND pigtail leads wires from the AC wiring compartment of the charger 2 Measure and cut the required length of three conductor L N GND cable allowing some extra length for connections and providing some 6 slack 3 Route the AC supply wiring from the charger in its mounted position to the source 975 0526 01 02 21 4 amp TC2 204060 Series BattChg Owners Guide book Page 22 Friday July 8 2011 11 44 AM Installing the Truecharge 2 Battery Charger Y D 7 Feed the AC supply wiring through the wider end of strain relief and out the tapered end tapered end of strain relief AC supply wiring 25 8 Slide the strain relief on the jacket of the wiring not on the individual conductors approximately 25 mm 1 in from the end of the jacket 9 Connect the AC supply wires to the Truecharge2 Battery Charger pigtail wires NOTE Connect the line conductor to the AC line the neutral to the AC neutral and the ground to the AC ground The wires are color coded as follows Conductor Charger Pigtail AC Supply Wire Color Code Color Code Line Black Black or brown Neutral White White or blue Ground Green with yellow stripe Green with yellow stripe 22 _ _ e To connect AC wires with the provided crimp on butt splice connector a Make the connections using
60. ge 35 Friday July 8 2011 11 44 AM Charging Batteries Before you start to charge batteries read the Important Safety Instructions The charger can be in one of eight different situations which will be on page iv and follow all safety precautions when working with batteries indicated on the onboard display in the Charger Status LEDs To charge your batteries 1 Ifpossible disconnect any heavy loads on the batteries being charged Mode Charger Status LED ON by opening disconnect switches or by switching the loads off Bulk Charging 2 Connect the batteries to the charger by closing the DC disconnect switches NOTE The onboard display LEDs will light up for a second 3 Ventilate the area around the battery thoroughly during charging Absorption Charging Standby or Rest two stage charging Ready Review the charging instructions supplied by the manufacturer of your Float three stage charging Ready and Charging batteries and follow all safety precautions and the required steps Equalize in progress Equalize solid light 4 Apply AC power to the Truecharge2 Battery Charger by Equalize Equalize flashing e closing the AC breaker or waiting for absorption to end turning the generator on Fault a id li All onboard display indicator LEDs will illuminate for one second Fault solid light power on test as the initialization sequence runs Warning Fault flashing After initialization
61. hase price paid for the product Xantrex will be liable to you only for direct damages suffered by you and only up to a maximum amount equal to the purchase price of the product This Limited Warranty does not warrant uninterrupted or error free operation of the product or 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 corrosion biological infestations or input voltage that creates operating conditions beyond the maximum or minimum limits listed in the Xantrex product specifications including but not limited to 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 component parts or monitoring systems supplied by you or purchased 975 0526 01 02 59 TC2_204060_Chapters fm Page 60 Thursday August 4 2011 1 12 PM Warranty and Return In
62. ing a fully synchronizing the two chargers settings at this point charged state it is normal to see one charger s output current drop down earlier than the other charger The output current displayed via the remote panel lights is the sum of both chargers output currents divided by the total maximum current ratings of both chargers Exiting parallel operation Once the remote panel enters parallel operation the only way to exit out of it is to completely power down the remote panel by unplugging both of the communication cables When Configuring the Battery Chargers The secondary charger s configurations are automatically synchronized with the primary charger The configuration can be performed from either the remote panel or the primary charger s onboard display Follow the exact same procedures as a single charger when configuring the paralleled chargers When Equalizing Batteries Equalization can be programmed and cancelled through the remote panel Equalization can be cancelled through both charger s onboard display 26 Truecharge2 Series Battery Charger Owner s Guide amp TC2 204060 Series BattChg Owners Guide book Page 27 Friday July 8 2011 11 44 AM amp Installing Batteries Battery installation should always be treated like a brand new installation 5 Reconnect the battery cables to the new battery This means that all safety and precautionary guidelines that were followed NOTE For Negative chas
63. is disconnected e Disconnect both AC and DC power from the battery charger before attempting any maintenance or cleaning or working on any circuits connected to the battery charger See note below Failure to follow these instructions will result in death or serious injury There is only ONE way to safely turn the Truecharge2 Battery Charger off Disable Disconnect the AC power at the source and disconnect all DC batteries This is the only state where the Truecharge2 Battery Charger is completely de energized When the Truecharge2 Battery Charger is disabled the optional remote panel is inactive Truecharge2 Series Battery Charger Owner s Guide 16 DI a 204060 Series BattChg Owners Guide book Page 41 Friday July 8 2011 11 44 AM Accessing Charger Information The Truecharge2 Battery Charger provides a lot of information about the status of the charger and the batteries E e ny Fan 7 R q yre of fault and warning f Charging Output O O O O O O O O Charging Output LEDs Reading Onboard Display LEDs lt 5 5 10 20 40 60 80 100 4 Charging Output values O lt Fault LED The Fault LED works in conjunction with the Charging Current LEDs Fault The icons at the top row above the Charging Current LEDs represent the various types of fault and warning conditions For example a Figure 12 Charging Output and Fault LEDs temperature warning is represented by a thermo
64. llow these instructions will result in death or serious injury 2 Switch the AC power on at the source breaker It is normal to see a seven to ten second delay while the charger powers up During this time the indicator LEDs on the onboard display and the remote panel will illuminate for a second power on test before reporting charging and battery status information NOTE Battery qualification may not be correctly performed if AC power is switched on first NOTE The onboard display LEDs will also illuminate momentarily with DC power alone when DC power is applied and the minimum battery voltage 1 e the connected batteries is above 9 V 24 Truecharge2 Series Battery Charger Owner s Guide _ 16 Se 204060 Series BattChg Owners Guide book Page 25 Friday July 8 2011 11 44 AM Installing a Parallel Configuration A parallel configuration is when two Truecharge2 Battery Chargers are Installing a parallel configuration coupled together to increase the output capacity For example a 40 amp 1 Truecharge2 Battery Charger can be connected with another 40 amp Truecharge2 Battery Charger for a combined 80 amp capacity charger This configuration is possible only with the use of the optional remote panel Follow the installation sequence from steps through 4 for a single unit Installing the Truecharge 2 Battery Charger on page 16 In Step 4 Installing AC Wiring on page 21 make sure that the two
65. meter icon Table 9 Interpreting Fault and Warning Indicators on page 43 summarizes the various fault conditions that might occur during the operation of the charger The Charging Current LEDs will normally illuminate as a solid progress bar when they are indicating the amount of output charging current If any of the LEDs start to flash intermittently at the same time that the Fault LED is either solid or flashing a fault or warning condition is indicated Reporting While Charging or Equalizing IMPORTANT A warning condition notifies the user of an impending After configuring the charger and during charging the onboard display problem and will not stop the charger from charging while a fault panel and the optional remote panel if installed will show the following condition will stop the charger from charging the battery information about the charger and the battery Charging Output Current Charger Status Battery Status available on the optional remote panel only If there is a fault or warning related to one of the banks the fault or warning information will display in the form of illuminating or flashing Fault indicator LEDs Charging for all banks will stop and will only resume once the fault condition is cleared However charging will continue during waming conditions 975 0526 01 02 41 4 amp TC2 204060 Series BattChg Owners Guide book Page 42 Friday July 8 2011 11 44 AM Acces
66. minal voltage drops to below 12 5 V 12 V chargers or 25 V 24 V chargers for 15 minutes or e when AC is disconnected for more than 15 minutes and then reconnected 36 Truecharge2 Series Battery Charger Owner s Guide s _ DI amp TC2 204060 Series BattChg Owners Guide book Page 37 Friday July 8 2011 11 44 AM amp Equalizing Flooded Batteries In the following conditions the Truecharge2 Battery Charger will not enter C AUTI O N equalization mode RISK OF BATTERY DAMAGE the battery type is set to GEL or AGM 3 any battery is not fully charged all three battery banks must be The Truecharge2 Battery Charger will only equalize flooded lead acid or me ae charged to float or rest stage before equalization can be activated on lead calcium batteries It does not enter equalization when the battery 1 type is set to sealed lead acid batteries GEL or AGM since they will be any bank damaged by this process Use the correct settings for your battery types there is an active fault on the battery you are trying to charge Xantrex recommends that you run a complete normal charge cycle on the batteries before you equalize them DANGER CAUTION EXPLOSION HAZARD RISK OF BATTERY DAMAGE e The battery generates explosive gases during equalization Follow all du of the battery safety precautions listed in this guide You must monitor the battery specific gravity throughout equalization to a
67. mpting to equalize 975 0526 01 02 _ 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 charging or rest stage of two stage charging before attempting to equalize the ready indicator LED will illuminate Clear the active fault by disconnecting the AC power source and finding the cause of the fault from Interpreting Fault and Warning Indicators on page 43 e Troubleshooting 53 Te d LA TC2 204060 Series BattChg Owners Guide book Page 54 Friday July 8 2011 11 44 AM Specifications NOTE Specifications are subject to change without prior notice Physical Specifications AC Input Specifications Base Unit Dimensions L x W x H AC input voltage range TC2012 TC4012 250x170x70 mm 9 84x6 70x2 76 in ace a ii e a Vac TC1024 TC2024 250x170x70 mm 9 84x6 70x2 76 in EETA T i Automatic derating to TC6012 TC3024 340x170x90 mm 13 38x6 70x3 54 in 80 output 90 108 4 Vac Weight ini A ax AC input curren TC2012 TC4012 2 2 kg 4 8 Ibs TC2012 39A TC6012 TC3024 4 5 kg 9 9 Ibs TC6012 11 6 A AC input connections Three color coded No 14 AWG wires L N TC1024 3 9 A GND minimum 152 mm 6 in long in a TC2024 TIA separate AC wiring enclosure with 21 3 mm TC3024 11 6 A 0 84 in hole provision for connection of a A Power fa
68. nd connect the Truecharge2 Battery Charger you need the following tools 10 mm socket wrench and extension for the DC terminals and ground stud e Phillips screwdriver for removing and re securing the AC and DC wiring compartment covers e power drill screwdriver e drill bit set for pilot holes for mounting screws if using 6 mounting screws use 1 16 drill e wire stripper manufacturer s recommended crimp tool for any crimp terminals that are being used 975 0526 01 02 _ e Preparing For Installation You need the following materials _ 3 conductor AC input wiring Use the information in Step 4 Installing AC Wiring on page 21 and your local electrical codes to determine the correct wire and breaker or fuse AC cable strain relief if the one included is not compliant with your local electrical code requirements appropriately sized DC cables for each battery with suitable connectors at the battery end Use the information in DC Wiring on page 13 and your local electrical codes to determine the correct wire and breaker or fuse appropriately sized DC chassis ground earth cable with suitable connectors ring terminals to fit 6 mm 1 4 in studs at the charger end Marine grade hardware is recommended DC fused disconnect or properly rated circuit breaker for each battery bank mounting screws M3 or 6 marine grade corrosion resistant 4 pieces Length dependent on mounting sur
69. nd type of input breaker based on the jurisdiction and 8 50A application Some basic examples are given below 6 80 A The AC input wiring for the Truecharge2 Battery Charger should be three 4 100 A conductor cable providing a line neutral and ground conductor or L N 2 125 A GND in an outer jacket rated a minimum of 75C and sized based on the 1 150 A AC input current to the charger see AC Input Specifications on page 54 and on the value of overcurrent protection provided DC Chassis Ground F le or example The DC chassis ground earth wire should also be sized correctly to inUS NEC you may use a 14 AWG wire with a 15 A breaker for up to provide proper protection Refer to the local electrical codes for your 12 A continuous current or 12 AWG for a 20 A breaker for up to 16 A specific installation to determine the correct gauge The ABYC standards continuous current or require this DC chassis ground wire to be the same size as the largest DC and conductors connected to the charger or no more than one wire size smaller See Step 2 Connecting the DC Chassis Ground Earth on page 17 for instructions for 230 Vac application you may be able to use either a 2 5mm wire with a 16 A breaker or use 1 5 mm wire with a 10 A breaker 14 Truecharge2 Series Battery Charger Owner s Guide La q BZ IN amp TC2 204060 Series BattChg Owners Guide book Page 15 Friday July 8 2011 11 44 AM amp Prepa
70. nectors inside the AC wiring compartment 11 Place the strain relief on the AC wiring access hole 12 Install the wiring compartment cover to fasten the strain relief and tighten the screw on top to secure the cover Do not over tighten 1 Use crimper product number CT 160 from www panduit com 975 0526 01 02 _ 13 14 15 16 _ e Installing the Truecharge 2 Battery Charger screw to secure the wiring compartment AC wiring access hole with strain relief If applicable install the optional remote panel Connect the AC supply wiring from the charger to the AC panel feeding the charger Connect the line conductor to the breaker the neutral to the neutral bus and the ground to the ground bus Secure cables in place using tie wraps or cable straps according to electrical codes 23 Ip 6 d amp TC2 204060 Series BattChg Owners Guide book Page 24 Friday July 8 2011 11 44 AM Installing the Truecharge 2 Battery Charger Step 5 Powering Up hi Make one last check that all connections are correct and secure The Truecharge2 Battery Charger charger may now be powered up 1 Close the DC disconnect switch or breaker DANGER EXPLOSION AND OR FIRE HAZARD The final connection of the DC battery circuit will generate an arc Ensure all areas of the system including batteries and engine compartments are well ventilated prior to making this connection Failure to fo
71. ng For Installation Y D Wiring Requirements Vertical Wall Mount Rear panel facing o o down or up this o D orientation is alowed 2 ZAN DANGER E ELECTRICAL SHOCK AND FIRE HAZARD a Li marine Do not operate the battery charger with damaged or substandard wiring A gt installations only with o Make sure that all wiring is in good condition and is not undersized See y 9 additional drip J notes below a UE gli protection Failure to follow these instructions will result in death or serious injury c NOTES Figure 6 Mounting Orientations Vertical Wiring and fuse sizes are governed by electrical codes and standards Different requirements apply in different countries and to different types of installations for example boat home or RV It is the responsibility of the installer to ensure that each installation complies with all applicable codes and standards 10 cm Ensure that wires and fuses or breakered disconnects are correctly 4 in sized Maximum continuous DC current available from the charger may be an additional 6 10 above the nominal current rating of the charger 6 cm 2 5 in Figure 7 Ventilation Clearance 12 Truecharge2 Series Battery Charger Owner s Guide 4 VA IN amp TC2 204060 Series BattChg Owners Guide book Page 13 Friday July 8 2011 11 44 AM Y DC Wiring
72. one cycle To manually exit equalization mode early repeat Step 3 5 Check the battery electrolyte level If necessary refill with distilled water only and repeat a normal charge cycle 975 0526 01 02 39 V e o NIZ DI TC2 204060 Series BattChg Owners Guide book Page 40 Friday July 8 2011 11 44 AM Transitioning the Charger to ON Standby or Disabled There are two ways to turn ON the Truecharge2 Battery Charger e Connect the batteries to the charger i e charger is on standby then connect AC power at the source If the batteries are not fully charged then charging begins immediately If the batteries are fully charged then charging will go to either standby two stage or float three stage Or e Press ON STANDBY on the optional remote panel while batteries and AC power are both connected to the charger from Standby The charger begins to charge the batteries from Standby There are two ways to put the Truecharge2 Battery Charger in Standby see Warning below e Disconnect AC power at the source i e only the batteries are connected or Press ON STANDBY on the optional 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 40 _ 4 DANGER ELECTRICAL SHOCK HAZARD Do not disassemble the battery charger Internal capacitors remain charged for five minutes after all power
73. ote panel charging at 70 C 158 F or higher and communication cable plug into the BTS port and vice versa e charging voltage compensation based on the temperature of the battery e drip proof rubber boots for DC terminals for added moisture the optional BTS is connected to protection T e IP 32 drip protection rating The optional Remote Panel provides the following features e Can be mounted up to 15 meters 50 feet away for remote control The following optional accessories are available for the Truecharge2 and monitoring Battery Charger maximum output current limiting for charging smaller capacity an optional battery temperature sensor BTS and batteries or to lower the current drawn from the generator or AC an optional remote panel source e ability to enable or disable the charger while AC power is connected e ability to display individual battery bank levels and e ability to operate two Truecharge2 Battery Chargers in parallel for increased output current capacity 1 In two specific installation orientations see Mounting Orientations Deck and Horizontal on page 11 2 Part number 808 0232 01 4 Remote panel comes standard with a 7 5 m 25 ft cable For longer 15 m 50 ft 3 Part number 808 8040 01 cable order part number 31 6262 00 2 Truecharge2 Series Battery Charger Owner s Guide S NIZ a TC2 204060 Series BattChg Owners Guide book Page 3 Friday July 8 2011 11 44 AM
74. position or DC fuses removed from their fuse holders until installation is complete Failure to follow these instructions can result in death or serious A WARNING ina A SHOCK HAZARD The rubber boots must be installed over the Truecharge2 Battery Charger 1 Remove the DC compartment cover See Front Panel on page 3 DC terminals to keep water off of live parts and to maintain the chargers 2 Plan the route that the DC wires will follow keeping it as short as IP 32 and drip proof ratings possible Measure and cut the required wire length after allowing Failure to follow these instructions can result in death or serious some extra length for connections and to provide slack in the wires for injury strain relief 3 Identify the positive wires by using color coded wire or by marking 6 Insert and slide the rubber boot s over the charger end of the DC both ends of the wire with colored tape or similar kind of marking battery cables Repeat with a different color for the negative Most installation codes recommend coloring the positive red and the negative black IMPORTANT You may find it helpful to label each cable associating it PYT with the battery bank it is connected to For example bank 1 bank 1 i bank 2 gt and so on 18 Truecharge2 Series Battery Charger Owner s Guide Y e _ 16 DI TC2 204060 Series BattChg Owners Guide book Page 19 Friday July 8 2011 11 44 AM
75. r Selection temperature of compensation offset from 25 C damage other equipment Cold below 5 C Flooded PbCa 0 675 41 F Gel NOTE Always be aware of the temperature setting observe the battery s actual temperature and adjust the Battery Temperature setting accordingly AGM 0 525 For varying conditions use the Warm setting Warm bean Flooded PbCa 0 To configure the battery temperature 5 and 30 C Gel NOTE By default the Battery Temp is set to Warm 41 and 86 F 1 Press and hold the Battery Temp Select button for three seconds to AGM g advance to the next setting Hot above 30 C Flooded PbCa 0 27 2 Select the appropriate battery temperature setting 86 F Gel The LEDs will indicate which of the three types is being selected AGM 021 Warm Hot or Cold 32 Truecharge2 Series Battery Charger Owner s Guide SW e N TC2 204060 Series BattChg Owners Guide book Page 33 Friday July 8 2011 11 44 AM Installing Batteries Operating DC Loads When the Truecharge 2 Battery Charger is operating DC loads such as fans and lights may vary in speed or intensity This is normal The Truecharge 2 Battery Charger will not harm any load connected to it as long as the load can withstand the following maximum voltages 16 V for 12 volt chargers e 32 V for 24 volt chargers 975 0526 01 02 33 WW e 4 D DI amp TC2 204060 Series BattChg Owners Guide book Page 34 Friday July
76. rge2 Battery Charger charging process is designed to make the battery or battery banks reach the following voltage setpoints Table 5 Charging Maximum Voltages for 12 volt chargers Battery Absorption Float Volts Equalization Type Volts 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 16 0 Table 6 Charging Maximum Voltages for 24 volt chargers Battery Absorption Float Volts Equalization Type Volts Volts Flooded 28 8 27 0 32 0 GEL 28 4 27 6 not applicable AGM 28 6 26 8 not applicable Lead Calcium 31 0 27 0 32 0 975 0526 01 02 _ _ e Installing Batteries Battery Qualification The Truecharge2 Battery Charger will perform a battery qualification on each application of AC or DC gt 9 V for 12 volt batteries DC gt 18 V for 24 volt batteries to determine if battery banks are present and healthy To force a battery detection sequence 1 Turn off AC and DC 2 Wait approximately 20 seconds or until all lights on the charger or remote have gone out Turn on DC 4 Turn on AC The charger will then perform a battery detection The Truecharge2 Battery Charger charges all banks at the same time but the bank 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 charg
77. ring For Installation Note that every jurisdiction will have different requirements as will each B attery B ank Size Requirem ents application so research the regulations for your local jurisdiction to G determine which wire size and type is correct based on the maximum AC The Truecharge2 Battery Charger is designed to work with a minimum input current marked on the chargers and given in AC Input battery bank size Each bank should meet the minimum Ah rating shown in Specifications on page 54 Table 4 These minimum values are based on twice the charger s rated maximum charging current For example a 20 amp charger will charge a Other examples of AC wiring requirements minimum 40 Ah battery If you are considering new batteries please consult the battery s manufacturer for their recommendation based on the e For marine applications the American Boat amp Yacht Council ABYC maximum charging current of your charger requires stranded wire which is more robust than solid wire when exposed to vibration e For RV applications the United States National Electrical Code NEC allows solid wire in multi conductor cable however stranded wire is IMPORTANT Tf the battery manufacturer has specified the maximum charge current please follow their recommendation also acceptable which will withstand vibration better Table 4 Minimum Battery Bank Size The AC wiring supplying the Truecharge2 Battery Ch
78. sing Charger Information Reporting Without AC Power or While on Standby If AC power has been disconnected or if you have used the optional remote panel to place the Truecharge2 Battery Charger on Standby mode the onboard display and the optional remote panel if installed LEDs will be turned off to conserve battery power However present settings and battery status can be viewed momentarily by pressing the Status button on the optional remote panel to initialize a view cycle that will show the status of the batteries The remote panel LEDs will turn off after 30 seconds of inactivity Indicator LEDs on the Onboard Display Panel All indicator LEDs on the Onboard Display panel and the optional remote panel if installed will illuminate for one second when AC or DC power is supplied to the Truecharge2 Battery Charger or when the charger is turned on using the ON STANDBY button on the remote panel A power on test indicates that the charger is now receiving AC power and all LEDs are functioning The Truecharge2 Battery Charger will recover from fault conditions automatically when the cause of the fault or warning has disappeared Under fault conditions the charging process will be stopped allowing either the charger or the battery or both to return within acceptable operating ranges See Specifications on page 54 for more information on normal operating ranges e To interrupt or cease the charging process disconnect the
79. sis systems reconnect the positive cable first prior and during the installation of the battery charger must again be then the negative cable followed in order to avoid risks of electrical shock injury or death For Positive chassis systems reconnect the negative cable first then the positive cable DAN G E R IMPORTANT Ifthe new battery is different from the old one in chemistry ELECTRICAL SHOCK HAZARD temperature or size remember to re configure the battery settings Disconnect both AC and DC power from the battery charger before accordingly See Setting the Battery Temperature without a BTS on page attempting before replacing old or defective batteries and even installing 32 and Configuring the Battery Bank Type on page 34 new batteries Failure to follow these instructions will result in death or serious injury A Input Voltage Operating and Derating To replace an old battery When AC input is within the lower range between 90 108 Vac the 1 Turn off the AC source by disconnecting the AC line and or opening Truecharge2 Battery Charger derates to 80 of maximum current the AC source disconnect However when AC input increases above 108 Vac up to 265 Vac 2 Switch off all devices operating from currently installed batteries maximum current returns to 100 capacity Furthermore the Truecharge2 ri i i e 0 i y Disconnect the battery cables from the old battery Battery Charger will continue to oper
80. sured in the original packaging or equivalent This warranty will not apply where the product is damaged due to improper packaging Include the following e The RMA number supplied by Xantrex Technology USA 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 975 0526 01 02 e_ _ e Warranty and Return Information 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 tariffs and deposits 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 and that the ASC repairs this particular Xantrex product Out of Warranty Service If the warranty period for your product has expired ifthe unit was damaged by misuse or 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 r
81. tection Disconnect Electrical codes require the DC circuit from each battery to the charger to be equipped with a disconnect and an over current protection device usually within 7 inches 17 8 cm of each battery The devices are usually DC rated circuit breakers fused disconnects or a separate fuse and disconnect for each circuit These devices must be rated for DC voltage and 1 Per American Boat amp Yacht Council E 11 13 IZ be DI TC2 204060 Series BattChg Owners Guide book Page 14 Friday July 8 2011 11 44 AM Preparing For Installation current and be rated to withstand the short circuit current available from the AC Wiring connected battery bank Do not substitute devices rated only for AC voltage they may not operate properly The current rating of the DC fuses must be correctly matched to the size of the DC wiring used in accordance with the applicable codes This helps to protect the installation against fire in case of any overcurrent or short circuit Di q Ne fault Use only on circuits provided with 20A maximum branch circuit protection in accordance with National Electrical Code NFPA 70 FIRE HAZARD Table 3 Fuse Sizes versus Wire Sizes Based on ABYC Regulations Failure to follow these instructions will result in death or serious AWG Max Fuse Breaker a 14 ISA 12 20 A The AC wiring must be of sufficient size and it must be protected by the 10 30A appropriate size a
82. the indicator LEDs will display present status and settings At this point changes in Battery Type Battery Temperature and or Charger Mode can then be applied a In combination with one or more flashing Charging Output LEDs These settings are stored in memory even when all power sources are disconnected and need not be entered after every initialization During charging the Charging Output LEDs will show the total current being delivered to the battery bank as well as any DC load applied The charger fan may activate as well 5 After charging is completed reconnect all loads to the battery 975 0526 01 02 35 N TC2 204060 Series BattChg Owners Guide book Page 36 Friday July 8 2011 11 44 AM Charging Batteries After charging is complete the Truecharge2 Battery Charger enters into one of these modes Float mode When the ready and charging indicator LEDs both illuminate all batteries are fully charged and ready for use If you selected the three stage charging mode the Truecharge2 Battery Charger is in float mode and will maintain the batteries charge Standby mode Or Rest mode If you selected the two stage charging mode the ready indicator LED shows the charger is now in rest mode and is continuously checking battery voltage With either charging mode the Truecharge2 Battery Charger will begin a charging cycle e seven days after the last completed cycle or when the minimum battery ter
83. the provided crimp on connectors or with other approved connectors required by your code and suitable for your installation For example the ABYC Standards and Recommended Practices for Small Craft prohibit twist on connectors for AC connections on a boat For other types of installation refer to your applicable code A DANGER FIRE HAZARD Improperly connected wires may overheat Exercise care when using any crimp connector use the tool specified by the crimp connector manufacturer and follow all crimping instructions Failure to follow these instructions will result in death or serious injury b Using a wire stripper carefully strip 8 mm 5 16 in from the ends of the two wires being connected 1 Provided butt splice connector catalog number BNYF2 is available from www ksterminals com Truecharge2 Series Battery Charger Owner s Guide amp TC2 204060 Series BattChg Owners Guide book Page 23 Friday July 8 2011 11 44 AM c Insert one wire into one end of the butt splice until the insulation hits the internal metal crimp section insert the butt splice into the crimper and crimp firmly The proper location for the crimp is approximately 1 6 mm 1 16 in past where the butt splice insu lation tapers down as shown lt 1 16 f TOOL d Repeat Step c for the other end of the butt splice gt STRIP 5 16 e 10 When all connections are completed push the wiring and con
84. ting raises the voltages and the Hot setting lowers the voltages See Battery Temperature Compensation Levels on page 32 6 Cold for battery temperature below 5 C 41 F raises continued the charging voltage to compensate e Warm for battery temperature between 5 and 30 C 41 and 86 F default setting Hot for battery temperature above 30 C 86 F lowers charging voltage to compensate When setting or cancelling an Equalization program Press and hold for five seconds both the Charger Mode and Battery Temp Select buttons CAUTION RISK OF BATTERY DAMAGE Be sure the appropriate setting is selected before charging For varying conditions use the Warm setting Failure to follow these instructions can damage the unit and or damage other equipment 975 0526 01 02 7 Y e e DI amp TC2 204060 Series BattChg Owners Guide book Page 8 Friday July 8 2011 11 44 AM Preparing For Installation CA U Tl O N NOTE Not to scale For illustration purposes only IMPROPER INSTALLATION BY AN UNQUALIFIED INSTALLER S The battery charger must be installed by a qualified installer in Li lt accordance with all applicable local or national installation codes Examples of such codes are the US National Electrical Code NFPA 70 La 2 J Pe the American Boat amp Yacht Council standards E 11 and A 31 and the N gt ad 10 US Coast Guard
85. uide SM e We Se DI TC2 204060 Series BattChg Owners Guide book Pagei Friday July 8 2011 11 44 AM Contents Important Safety Instructions 0 2 enn e nen teen ene e tent e eee ene iv Introduction vas ih ses ey A ote at ep RR ced E A Stee dene ete aaa aan 1 Lruecharge 2 Battery Charger Features tad ound w ode DEAL RE RI wl hela aa Balt 3 Pr paring For Installationi isa ia e ai 8 Installing the Truecharge 2 Battery Charger 0 een enn t ent e eee e nee eeee 16 Tnstallinig a Parallel Configuration sess ge Mee he RR eT A A AS Bae aed aE AG e fas ae eee a 25 Installing Batteries e ado Guilty e 27 Configuring the Truecharge2 Battery Charger LL 34 Charging Batteries Regt eR es eee ent BRN cate Sidney the te ed Bea aoe Sean ea 35 Equalizing Flooded Batteries oinline A a a toa tests 37 Transitioning the Charger to ON Standby or Disabled 0 LL 40 Accessing Charger Informatico 41 Using A Generator As Source POWeT o oo oooooooo eee ee enn en en en eee n nets 46 Maintaining the Charger siii A a es 47 Replacing the DG Qutput Fuseri intatti alal ea ola Raed A 48 TProubleshooting 3 2 0c bo ioe ode eka atinn ina a A a a tata 50 Specifications 3 iaia ead eda ead ett ke od aise bad A A aa Rea dea dated da 54 Warranty and Return Information LL 58 q gt e SIC N e uid day Ju 2 4 T C 2 2 0 4 0 6 0 S e ri s B atti C h 8 O W n e rs G ide
86. uids spray or fumes which may cause corrosion and by keeping the air intake vent clean and free from any obstructions Disconnect all AC and DC power and clean the outside of the case and wiring with a damp cloth Wear protective gloves if you suspect it has come in contact with battery fluid salt water gasoline or oil or other corrosive material Do not operate if the charger contains moisture of any kind 975 0526 01 02 47 4 NIZ a TC2 204060 Series BattChg Owners Guide book Page 48 Friday July 8 2011 11 44 AM Replacing the DC Output Fuse 3 Pull out the blown fuse s gently using the provided fuse puller CAUTI O N NOTE The fuse puller is located on the inside of the fuse cover IMPROPER INSTALLATION BY AN UNQUALIFIED INSTALLER 4 fasta a brand new fuse s with same type and rating as the old one Xantrex recommends that the installer should have knowledge and See Puse Replacement Ratmgs on pape 42 experience in installing electrical equipment knowledge of the applicable 5 Replace the fuse cover making sure that it aligns and fits perfectly installation codes and awareness of the hazards involved in performing leaving no space for moisture or small debris to enter the electrical work and how to reduce those hazards compartment Tighten the screw on the fuse cover but do not over tighten Failure to follow these instructions can damage the unit and or damage other equipment 7 Fix the reverse
87. ure sensor port easy access to the AC wiring compartment to allow for a 2 c cati i i har trouble free installation Remove and replace when installing ui al sa a the product 3 Battery positive for bank 3 6 mm stud 6 DC ground stud for connecting the charger s chassis to 4 Battery positive for bank 2 6 mm stud round E 5 Battery positive for bank 1 6 mm stud Rear Panel 6 Battery negative common for all three banks 6 mm stud Thi tion describes the parts of th l of the Truecharge2 Batt AO EA IA OI a aaa 7 Air vents located inside is the fan assembly Charger 8 AC wiring compartment 40 A model TC4012 9 AC pigtail wiring line neutral and ground input wires shown Other models may vary Figure 2 Truecharge2 Battery Charger Rear Panel 4 Truecharge2 Series Battery Charger Owner s Guide V e e DI a TC2 204060 Series BattChg Owners Guide book Page 5 Friday July 8 2011 11 44 AM Onboard Control and Status Display Panel This section describes the parts of the onboard control and status display panel of the Truecharge2 Battery Charger See Reading Onboard Display LEDs on page 41 for more information IMPORTANT To prevent any unintentional changes in the setting Select panel buttons must be pressed and held down for three seconds to advance to the next selection To set and cancel an equalization program press and hold for five seconds both the Charger Mode and Battery Temp Sel

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