Xantrex Technology TC4012 manual

Series Battery Charger Installation Guide TC1012 TC1512 TC2012 TC3012 TC4012 TC5012 TC6012 TC1524 TC2024 TC3024 TC5024 10A–12V 15A–12V 20A–12V 30A–12V 40A–12V 50A–12V 60A–12V 15A–24V 20A–24V 30A–24V 50A–24V This guide for use by qua lified instal lers only[...]

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This guide for use by qualified installers only Truecharge ™ 2 Series Battery Chargers Installation Guide[...]

This guide for use by qualified installers only About Xantrex Xantrex T echnology Inc. is a world-leading supplie r of advanced power electronics and controls with products ranging from small mobile uni ts to utility-scal e systems for wind, solar , batteries, fuel cells, microturbines, and backup power applications in both grid- connected and stan[...]

iii This guide for use by qualified installers only About This Guide Purpose The purpose of this Instal lation Guide is to provide explanations and procedu res for installing and configuring the T r ue charge™ 2 Series Battery Charger. Scope The Guide provides safety gu idelines, procedures for installing the battery char ger , as well as informa[...]

About T his Guide iv 975-0402-01-01 This guide for use by qualified installers only Organization This Guide is organized into two chapters and one appendix. Chapter 1 describes the standard features of a T ruecharge™ 2 Battery Charger , as well as its protection features. It also provides information on the dif ferent parts of the T ruechar ge™[...]

About T his Guide 975-0402-01-01 v This guide for use by qualified installers only The 24 Vdc models are: TC1524, TC2024, TC3 024, and TC5024. When bein g referred to individually , the produc t will be referred to by its model name. When all models are being referre d to, they will be referred to as T ruechar ge™ 2 Battery Char gers. Related Inf[...]

vi This guide for use by qualified installers only[...]

vii This guide for use by qua lified installers only Important Safety Instructions R EAD AND SAVE THIS I NSTALLATION G UIDE FOR FUTURE REFERENCE . This chapter contains import ant safety , installatio n, and operating instructio n s for the T ruecharge™ 2 Series Battery Chargers. 1. Before installing and usin g a T ruecharge™ 2 Battery Charger,[...]

Safety viii 975-0402-01-01 This guide for use by qua lified installers only 4. T o avoid a risk of fire and electric shock, make sure that all wiring is in good condition and is not un dersized. Do not operate the T ruecharge™ 2 Battery Charger with damaged or substandard wiri ng. 5. Do not operate the T ruecharge™ 2 Battery Char ger if it has [...]

Safety 975-0402-01-01 ix This guide for use by qua lified installers only 9. W orking in the vicinity of lead-acid batteries is dangerous. Batteries ge nerate explosive gase s du ring normal operation. Therefo re, it is of utmost importance that you read this manual and follow the instructions exactly each time you use the charger . 10. T o reduce [...]

Safety x 975-0402-01-01 This guide for use by qua lified installers only 4. If battery acid contacts skin or clothing, wash immediately with soap and wate r . If acid enters your ey e, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately . 5. Never smoke or allow a spark or flam e near the e[...]

Safety 975-0402-01-01 xi This guide for use by qua lified installers only 14. For flooded non-sealed batte ries, add distilled water in each cell until battery acid re aches 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, carefu lly follow ma[...]

Safety xii 975-0402-01-01 This guide for use by qua lified installers only 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 desi gned to provide reasonable protection against harmful interference in a residential insta[...]

xiii This guide for use by qua lified installers only Important Safety Instructions - - - - - - - - - - - - - - - - - - - vii 1 Introduction Truecharge™ 2 Battery Charger - - - - - - - - - - - - - - - - - - - - - 1–1 Standard and Protection Features - - - - - - - - - - - - - - - - - - - - 1–2 Truecharge™ 2 Battery Charger - - - - - - - - - [...]

Contents xiv 975-0402-01-01 This guide for use by qua lified installers only Configuring the Truecharge™ 2 Battery Charger- - - - - - - - - - 2–27 Configuring the Charger Mo de - - - - - - - - - - - - - - - - - - - 2–27 Configuring the Battery Bank Type - - - - - - - - - - - - - - - 2–29 Configuring the Maximum Outp ut Current Percentage - [...]

This guide for use by qua lified installers only 1 Intr oduction Chapter 1 describes the standard features of a T ruecharge™ 2 Battery Ch ar ger, as well as its protection features. It also provides information on the different parts of the T ruechar ge™ 2 Battery Charger. T ruecharge™ 2 Battery Char ger The T ruechar ge™ 2 Battery Char ger[...]

Introduction 1–2 975-0402-01-01 This guide for use by qua lified installers only Standard and Pr otection Featur es The T ruecharge™ 2 Battery Charger provides the following standard features: •t h r e e 1 full current rated outputs • battery monitoring functions while in float mode or rest mode • correct charging voltage for batteries wh[...]

Standard and Protection F eatures 975-0402-01-01 1–3 This guide for use by qua lified installers only • short circuit protectio n for the BTS and communicatio n connector ports including protection from incorrectly inserting the remote panel communication cable plug into the BTS port and vice versa • drip-proof rubber boots for DC terminals f[...]

Introduction 1–4 975-0402-01-01 This guide for use by qua lified installers only T ruecharge™ 2 Battery Char ger This section describes the diff erent parts of the T ruecharge™ 2 Battery Charger. Figure 1-1 T ruecharge™ 2 Battery Charger Item Descri ption 1 Onboard control and status display panel or simp ly onboard disp lay (see “Rear Pa[...]

T ruecharge™ 2 Bat tery Charger 975-0402-01-01 1–5 This guide for use by qua lified installers only 4 Fuse access panel cover provides access to the DC fuse in the event of an accidental reverse battery polarity installation. Disconnect the batteries and AC power before openin g the fuse access panel. 5 AC wiring compartment cover provides the [...]

Introduction 1–6 975-0402-01-01 This guide for use by qua lified installers only Rear P anel This section describes the part s of the rear panel of the T ruecharge™ 2 Battery Charger. Figure 1-2 Tr u e c h a r g e ™ 2 B a t t e r y Char ger Rear P anel Item Descri ption 1 BTS port - battery tem perat ure sensor port 2 Communication port - rem[...]

Rear P anel 975-0402-01-01 1–7 This guide for use by qua lified installers only Please see the T ruecharge™ 2 Batte r y Charger Owner ’ s Guide (doc. p art nu mber: 975- 0401-01-01) for information on the following: 1. Onboard Control and Status Display Pa nel 2. Fault and W arning In dica tors 3. Remote Panel[...]

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This guide for use by qua lified installers only 2 Installation Chapter 2 provides procedures for installing, testing and configuring the T ruecharge™ 2 Battery Char ger. It covers the following major topics: • “Preparing for Installation” on page 2–2. • “Installing the T ruecharge™ 2 Battery Char ger” on page 2–13 • “Instal[...]

Installation 2–2 975-0402-01-01 This guide for use by qua lified installers only Preparing for Installation The T ruecharge™ 2 Battery Ch ar ger is designed to be permanently mounted . Figure 2- 1 shows a typical installati on with three batteries, a battery temperature sensor (BTS) and a remote panel (both optional). It also shows the AC and D[...]

Preparing for Installation 975-0402-01-01 2–3 This guide for use by qua lified installers only Figure 2-1 T ypical T r uecharge™ 2 Battery Charger System Installation 1 AC mains source protected by correct size and type of branch rated circuit breaker 2 AC input wiring compartment 3 DC negative cab le 4 DC positive cables 5 DC circuit breakers [...]

Installation 2–4 975-0402-01-01 This guide for use by qua lified installers only T ools and Materials T o mount and connect th e T ruecharge™ 2 Battery Charger you nee d the following tools : • 10 mm socket wrench and exte nsion for the DC terminals and ground stud • Phillips screwdriver for removi ng and re-securing the AC and DC wiring co[...]

Preparing for Installation 975-0402-01-01 2–5 This guide for use by qua lified installers only Location Install the T ruecharge™ 2 Battery Charger in a location that meets the following requirements: C ondition Re quirement Dry The T ruecharge™ 2 Battery Char ger must be installed in a dry location not subject to mo isture especially rain, sp[...]

Installation 2–6 975-0402-01-01 This guide for use by qua lified installers only When planning to install the T ruecharge™ 2 Battery Char ger, be sure that you conside r the location and orientation carefully . The T ruecharge™ 2 Battery Charger is considered to have an IP rating of IP-32, if installed in either of two specific orientations [[...]

Preparing for Installation 975-0402-01-01 2–7 This guide for use by qua lified installers only Figure 2-2 T ruecharge™ 2 Battery Char ger Mounting Orientations Figure 2-3 V entilation Clearance Deck Mount - this orientation meets IP-32 requirements and is drip-proo f. Vertical Wall Mount (Rear panel facing down or up) - this orientation is allo[...]

Installation 2–8 975-0402-01-01 This guide for use by qua lified installers only Wi r i ng R e q u i re m e n t s DC Wiring The following two tables show some typical wire sizes for various cable length runs, b ased on 3% voltage dro p on DC cables, 75 °C (167 °F) rated wire with wiring being inside the engine compartment – assumed ambient of[...]

Preparing for Installation 975-0402-01-01 2–9 This guide for use by qua lified installers only Over -current protection discon nect Electrical codes require the DC circuit from each battery to the char ger to be equipped w ith a disconnect and an over- current protection device, usual ly within 7 inches (17. 8 cm) of each battery 1 . The devices [...]

Installation 2–10 975-0402-01-01 This guide for use by qua lified installers only The DC chassis ground (earth) wire should also be size d correctly to provide proper protection. Refer to the local electrical codes for your spec ific installation to determine the correct gauge. The ABYC standards require this DC chassis ground wire to be the same[...]

Preparing for Installation 975-0402-01-01 2–11 This guide for use by qua lified installers only a minimum of 75C, and si zed based on the AC in put current to the char ger (see Appendix A) and on the value o f overcurrent protection provi ded. For example, in US NEC, you may use a 14 A WG wire with a 15 A breaker for up to 12 A continuous current[...]

Installation 2–12 975-0402-01-01 This guide for use by qua lified installers only Battery Bank Size Requirements The T ruechar ge™ 2 Battery Charge r is designed to work with a minimum battery bank size. Each bank sho uld meet the minimum Ah rating shown in T able 2-4. Note: If the battery manufacturer has specified the maximum charge current, [...]

Installing the T ruecharge™ 2 Battery Charger 975-0402-01-01 2–13 This guide for use by qua lified installers only Installing the T ruecharge™ 2 Battery Charger Installation Sequence T o make charger installation quick and easy , Xantrex recommends that the installatio n tasks be performed in the following sequence: 1. Mount the char ger in p[...]

Installation 2–14 975-0402-01-01 This guide for use by qua lified installers only Mounting the T ruecharge™ 2 Battery Char ger Mount the T ruecharge™ 2 Battery Charger using all four mounting slots and hol es which are provided . Mounting orientations a) and b) in Figure 2-2 meet IP-32 a nd drip-proof requirements that are needed to ensure sa[...]

Installing the T ruecharge™ 2 Battery Charger 975-0402-01-01 2–15 This guide for use by qua lified installers only Connecting the DC Chas sis Ground (Earth) The T ruecharge™ 2 Battery Charger Battery Charger must be connected to a grou nded, m etal, permanent wiring system, or an equipment-ground ing conductor should be run with the circuit c[...]

Installation 2–16 975-0402-01-01 This guide for use by qua lified installers only Installing DC Wiring The procedure for installing the DC wiring applies to a single battery , as well as multiple batteries or battery banks. 1. Plan the route that the DC wires will follow , keeping it as short as possible. Measure and cut the required wire length,[...]

Installing the T ruecharge™ 2 Battery Charger 975-0402-01-01 2–17 This guide for use by qua lified installers only 5. Insert and slide the rubber bo ot(s) over the charger end of the DC battery cables. 6. Install crimp lugs on the ch arger end of the DC battery cables using the crimp manu facturer ’ s instructions and tool. W ARNING: Shock ha[...]

Installation 2–18 975-0402-01-01 This guide for use by qua lified installers only 7. Connect the negative cable to the negative DC terminal. See Figure 2-1, “T ypical Truechar ge™ 2 Battery Charger System Installation” on page 2–3. For one battery or bank ◆ Connect the negativ e cable fro m the negative terminal on the battery to the ne[...]

Installing the T ruecharge™ 2 Battery Charger 975-0402-01-01 2–19 This guide for use by qua lified installers only 13. Secure cables in place usin g tie-wraps or cable straps according to electrical codes. 14. Slide the rubber bo ots to cover the DC terminals. 15. If available, route the optional battery temperature sensor (BTS) from the batter[...]

Installation 2–20 975-0402-01-01 This guide for use by qua lified installers only Installing A C Wiring Before connecting AC wiring, make sure the AC source circuit is protected by a breaker switch of the correct size and type, to comply with the electrical code for your location and application. The current ratin g of the input breaker should no[...]

Installing the T ruecharge™ 2 Battery Charger 975-0402-01-01 2–21 This guide for use by qua lified installers only 5. Carefully remove 50 – 75 mm (2 – 3 in.) of the outer jacket from the AC supply wi ring, being careful not to cut or nick the insulation on the individual cond uctors. 6. Extend the charger ’ s AC (L, N, GND ) pigtail leads[...]

Installation 2–22 975-0402-01-01 This guide for use by qua lified installers only T o connect AC wires with the provided crimp-on butt-splice connecto r: a) Make the connections using the provided crimp-on connectors 1 or with other approv ed connectors required by your code, an d suitable for your installation. For example, the ABYC Standards an[...]

Installing the T ruecharge™ 2 Battery Charger 975-0402-01-01 2–23 This guide for use by qua lified installers only 10. When all conne ctions are comp leted, push the wiring and connectors inside the AC wiring compartment. 1 1. Place the strain relief on the AC wiring access hole. 12. Install the wiring compartmen t cover to fasten the strain re[...]

Installation 2–24 975-0402-01-01 This guide for use by qua lified installers only Po w e r i n g U p Make one last check that all connections are correct and connectors are secure. The T r ue charge™ 2 Battery Charger charger may now be powered up. 1. Close the DC disconnect switch or breaker . 2. Switch the AC power on at the source breaker . [...]

Installing Optional Accessories 975-0402-01-01 2–25 This guide for use by qua lified installers only Installing Optional Accessories Optional accessories are available for purchase at Xantrex. Call Customer Service to order the accessories below: • Battery T emperature Sensor (Part number: 80 8-0232-01) • Remote Panel (Part number: 808-80 40-[...]

Installation 2–26 975-0402-01-01 This guide for use by qua lified installers only Mounting the Optional Remote P anel T o mount the remote panel: 1. Choose a location for the remo te panel that is within 15 m (50 ft.) from the charger . Use only the six-conductor commun ications cable (RJ-12) that came with the remote panel. 2. Use the mounting t[...]

Configuring the T ruecharge™ 2 Bat tery Charger 975-0402-01-01 2–27 This guide for use by qua lified installers only Configuring the T r uecharge™ 2 Battery Charger Once the charger is connected to a battery on bank 1 or to AC, it is live and it may be c onfigured . The indicator LEDs on the onboard display will illumi nate for a second (powe[...]

Installation 2–28 975-0402-01-01 This guide for use by qua lified installers only Using the Remote Panel T o configure the ch arger mode: Note: By defau lt, the Cha rger Mode is set to three-stage. 1. Press and hold the Status butto n for five seconds to e nter the Setup mode. Entering the Setup mode will enable you to select the charger mode. 2.[...]

Configuring the T ruecharge™ 2 Bat tery Charger 975-0402-01-01 2–29 This guide for use by qua lified installers only Configuring the Battery Bank T ype Using the Onboard Display Panel T o configure the battery bank type: Note: By default, the battery ty pe is set to Flooded. 1. Press and hold the Battery T y pe Select button for three seconds t[...]

Installation 2–30 975-0402-01-01 This guide for use by qua lified installers only Configuring the Maximum Output Current Pe r c e n t a g e Advantages of Current Limiting Feature: • Gives the user flexibility to custom char ge according to the battery manufact urer ’ s instructions. • Allows batteries with a lower current rating to be charg[...]

Installing Batteries 975-0402-01-01 2–31 This guide for use by qua lified installers only Installing Batteries Replacing old or defective batteries (even in stalling new batteries) requires that you disc onne ct all AC and DC sources prior to installation. T o replace an old battery: 1. T urn off the AC source by disconnecting the AC line and/or [...]

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This guide for use by qua lified installers only A Specifications Appendix A contains physical , electrical performance, and regulatory approval specifications for the T ruecharge™ 2 Battery Char ger. Note: Specifications are subject to change without notice.[...]

Specifications A–2 975-0402-01-01 This guide for use by qua lified installers only Physical Specifications Base Un it Dimensions: L × W × H TC1012, TC1512: 200 × 170 × 70mm (7.87 × 6.70 × 2.76 in.) TC2012, TC3012, TC4012: 250 × 170 × 70mm (9.84 × 6.70 × 2.76 in.) TC5012, TC6012: 350 × 170 × 70mm (13.78 × 6.70 × 2.76 in.) TC1524, TC2[...]

Electrical Specifications 975-0402-01-01 A–3 This guide for use by qua lified installers only Electrical Specifications A C Input Specifications AC input voltage range Nominal: 120 V ac, 230 V ac, 240 V ac Full Performance: 104 – 265 V ac ±4 V ac Automatic derating to 80% outpu t: 90 – 10 8 ±4 V ac Maximum A C input current at 104 V ac at 2[...]

Specifications A–4 975-0402-01-01 This guide for use by qua lified installers only DC Output Specifications Number of isolated battery bank outputs TC1012 : 1 output TC1512: 2 separated outputs TC2012, TC3012, TC4012, TC5012 , TC6012, TC1524, TC2024, TC3024, TC5024 : 3 separated outputs DC output voltage range including dead bat t ery charging vo[...]

Environmental Specifications 975-0402-01-01 A–5 This guide for use by qua lified installers only Environmental Specifications Absorption voltage: ±0.1 V for 12 Vdc units ±0.2 V for 24 Vdc units 12 Vdc un its 24 V dc units 2 5° C ( 7 7° F ) 2 5° C ( 7 7° F ) Flooded 14.4 28.8 GEL 14.2 28.4 AGM 14.3 28.6 Lead-calcium 15.5 31.0 Float voltage: [...]

Specifications A–6 975-0402-01-01 This guide for use by qua lified installers only Protection F eatures Battery reverse polarity Protected by replaceable DC output fuses Over-voltage limits The T ruecharge™ 2 Battery Charger will stop charging if the output voltage is above 16.6 ±0.5 Vd c. Output current limit TC1012: 10 +10% A TC1512: 15 +10%[...]

Approvals 975-0402-01-01 A–7 This guide for use by qua lified installers only Approvals Safety NR TL approved to CSA E60335-2-29, UL1236, including the marine supplement, ignit ion protection, and UL1564 CE marked f or the Low V olt age Directive 2006-95-EC, (complying with EN60335 -2-29 Batt ery Chargers) Designed to IEC60335-2-29 including Aust[...]

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Xantrex Technology Inc. 1 800 670 0707 Tel toll free NA 1 408 987 6030 Tel direct +34 93 470 5330 Europe 1 800 994 7828 Fax toll free NA +34 93 473 6093 Europe customerservice@xantrex.com www.xantrex.com 975-0402-01-01 Printed in China[...]