Xantrex Technology TC2 204060 manual

TM TM Series Battery Charger Owner’ s Guide TC2 204060 Series Batt Chg Owners Guide.book Page i Friday, July 8, 2011 11: 44 AM[...]

TC2 204060 Series Batt Chg Owners Guide.book Pa ge ii Friday, July 8, 2011 11:44 AM[...]

975-0526-01-02 i T ra demarks Xantrex , T ruecharge , and Smart choice for power are trademarks of Schneider Electric Services International sprl, register ed in the U.S. and other countries. Other trademarks, registered trad emarks, and product names are the prop erty of their respective owners and are used herein for identifi cation purposes only[...]

ii T ruecharge2 Se ries Battery Charger Owner’s Guide About This Guide Purpose The purpose of this Owner ’ s Guide is to provide explanations and procedures for installing, troubles hooting, operating a nd maintaining the T ruecharge2 Series Battery Charger. Scope The Guide provides safety and opera ting guidelines, procedures for installing th[...]

975-0526-01-02 iii Related Inform ation Y ou can find more information about Xantrex T echnology US A Inc. as well as its products and services at www .xantrex.com . ST A TEMENT OF HAZA RD Contains state ments of avoi dance or strict compliance. Failure to follow these instructio ns can damage the u nit and/or damage other equipment. IMPORT ANT : T[...]

iv T ruecharge2 Se ries Battery Charger Owner’s Guide Important Safety Instructions IMPOR T ANT : R EAD AND SAVE THIS O WNER ’ S G UIDE FOR FUT URE REFERENCE . This chapter contains important safety a nd installation i nstructions for the T ruecharge2 Series Battery Charge rs. Each time, before using the T ruecharge2 Series Battery Charge r, RE[...]

975-0526-01-02 v NO TE: Follow these instructions a nd 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. FIRE AND BURN HAZARD Do not cover or obstruct the ai r intake vent o penings and/or install in a z[...]

vi T ruecharg e2 Series Battery Ch arger Owner’s Guide Precautions W hen W o rking With Batteries NO TES: 1. Locate the T ruecharge2 Series Battery Char ger unit away from batteries in a we ll ventilated compartment. 2. Always have someone within range of your voice or close enough to come to your aid when you wo rk near a lead-acid battery . 3. [...]

975-0526-01-02 vii Precautions W hen Preparing to Charge NO TES: 1. Study and follow all of the battery manufacturer's specific precautions, such as removing or not removing cell caps while char ging, whether equalization is acceptable for your battery , and recommended rates of charge. 2. For flooded non-sealed batteries, add distilled water [...]

viii T ruecharge2 Se ries Battery Charger Owner’s Guide FCC Information to the User This equipment has been tested and f ound to comply with the limits for a Class B digital device, pur suant t o part 15 of the FCC Rules. These li mits are designed to provide reasonable pr otection against ha rmful interference in a residential insta llation. Thi[...]

Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

TC2 204060 Series Batt Chg Owners Guide.book Pa ge ii Friday, July 8, 2011 11:44 AM[...]

975-0526-01-02 1 Introduction This chapter describes the standard featur es of a T ruecharge2 Battery Charger, as well as its protection feat ures. It also provides information on the different parts of the T ruecharge2 Battery Charger. T ruechar ge2 Battery Charger The T ruecharge2 Battery Charger ships with the following items: • one T ruecharg[...]

2 T ruecharge2 Series Batt ery Charger Own er’ s Gui de Introduction • electronic current limiting provide s protectio n against short circuit conditions on the charger’ s output, • ignition-protected rati ng, enabling insta llati on in engine spaces, • isolated design, • short circuit protection for the BTS and communication connector [...]

975-0526-01-02 3 T ruecharge 2 Battery Char ger Featur es This section describes the differen t parts of the T ruecharge2 Battery Charger. Front P a nel Figure 1 T ruecharge2 Battery Charger F ront P anel 1 2 6 4 3 5 Item Description 1 Onboard control and status display panel or simply onboard display (see “Onboard Control and Status Display Pane[...]

4 T ruecharge2 Series Batt ery Charger Own er’ s Gui de T ruecharge 2 Battery Charger Features Rear P anel This section describes the parts of the rear panel of the Truechar ge2 Battery Charger. Item Descri ption 5 AC wiring compartment cover provides the installer with easy access to the AC wiring compartm ent, to allow for a trouble free instal[...]

975-0526-01-02 5 T ruecharge 2 Battery Charger Features Onboard Contr ol and Status Display P anel This section describes the parts of the onboard control and status display panel of the T ruecharge2 Battery Ch ar ger. See “Reading Onboard Display LEDs” on page 41 for more information. T o reduce current draw from the conne cted battery when AC[...]

6 T ruecharge2 Series Batt ery Charger Own er’ s Gui de T ruecharge 2 Battery Charger Features 2F a u l t L E D The LED may il luminate a solid light (indicating a fault) or flash intermittently (indicating a warning) in combination with flashing Char ging Output (%) LE Ds. See “Interpreting Fault and W arning Indicators” on page 43 for detai[...]

975-0526-01-02 7 T ruecharge 2 Battery Charger Features 6 Battery T emp. Sele ct button • Press and hold the button for th ree seconds to select one of three settings. An indicato r LED corresponds to each setting. If an optional BTS is conne cted, the indicator LEDs represent real -time battery temperature. • When the optional BTS is not used,[...]

8 T ruecharge2 Series Batt ery Charger Own er’ s Gui de Preparing F or Installation NO TE: The Truechar ge2 Battery Char ger is designed to be permanently mounted. Figure 4 shows a typical instal lation with three ba tteries, a battery temperature sensor (BTS) and a remote panel (both optional). It also shows the AC and DC wiring and protecti on [...]

975-0526-01-02 9 Preparing F or Installation T ools and Materials T o mount and conn ect the T ruechar ge2 Battery Charger you need the following tools: • 10 mm socket wrench and extension for the DC terminals and ground stud, • Phillips screwdriver for remov ing and re-securing the AC and DC wiring compartment covers, • power drill/screwdriv[...]

10 T ruecharge2 Se ries Battery Charger Owner’s Guide Preparing F or I nstallation Location Install the T ruecharge2 Batt ery Charger in a loc ation that meets the following requirements: NO TES: When planning to install the T ruecharge 2 Battery Char ger, be sure that you consider the location and orientation carefully . The Truechar ge2 Battery[...]

975-0526-01-02 11 Preparing F or Installation panel covers are att ached and secured. This rating means that it meets standards to prevent dripping wate r from entering the enclosure, and causing shock hazard and damage to equipment. The other possible mounti ng orientations [shown in Figure 6 (c) and (d)] will not prevent the entry of dripping wat[...]

12 T ruecharge2 Se ries Battery Charger Owner’s Guide Preparing F or I nstallation W iring Requirements NO TES: • W iring and fuse sizes are governed by electrical codes and standards. Different requirements apply in different countries and to dif ferent types of installations, for ex ampl e, boat, home or R V . It is the responsibil ity of the[...]

975-0526-01-02 13 Preparing F or Installation DC Wiring The following tables show some typica l wire sizes for va rious 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). NO TE : In the event of a conflict between the voltage [...]

14 T ruecharge2 Se ries Battery Charger Owner’s Guide Preparing F or I nstallation current and be rated to withstand the short circuit current available from the connected battery bank. Do not subs titute devices rated only for AC voltage; they may not operate prop erly . The current rating of the DC fuses must be correctly matched to the size of[...]

975-0526-01-02 15 Preparing F or Installation Note that every j urisdiction will hav e differ ent requirements as will ea ch application, so research the regula tions for your local jurisdiction to determine which wire si ze and type is correct based on the maximum AC input current marked on the chargers and given in “AC Input Specifications” o[...]

16 T ruecharge2 Se ries Battery Charger Owner’s Guide Installing the T ruecharge 2 Battery Char ger Be sure to read the safet y guidelines a nd pay attent ion to all ca utions and warnings throughout the installation proc edure. The installer is responsible for ensuring compliance with the in stallation codes for your particular application. See [...]

975-0526-01-02 17 Installing the T ruecharge 2 Battery Char ger Step 2: Connecting the DC Chassis Ground (Earth) NO TE: Have an electrician install a prop erly grounded circuit if one is not available. The T ruecharge2 Battery Charger must be connected to a grounded, metal, permanent wiring system, or an e quipment-grounding conductor should be run[...]

18 T ruecharge2 Se ries Battery Charger Owner’s Guide Installing the T ruecharge 2 Battery Charger Step 3: Installing DC W iring The procedure for installing the DC wi ring applies to a single battery , as well as multiple batteries or battery banks. 1. Remove the DC compartment cove r . See “Front Panel” on page 3. 2. Plan the route that the[...]

975-0526-01-02 19 Installing the T ruecharge 2 Battery Char ger 7. Install crimp lugs on the charger end of the DC battery cables using the crimp manufac turer ’ s in structions and tool. NO TE: Make sure the positive termi nals of the T ruecharge2 Battery Char ger will be conn ected to th e correct term inals of the battery (fuse s or breakers) [...]

20 T ruecharge2 Se ries Battery Charger Owner’s Guide Installing the T ruecharge 2 Battery Charger NO TE: If you are using more than one batt ery , you will need to connect the negative cable from each of the batteries to the negative ground bar or bus. The negative ground bar or b us will then have a single negative cable connecting to the negat[...]

975-0526-01-02 21 Installing the T ruecharge 2 Battery Char ger Step 4: Installing A C Wiring Before connecting AC wiring, make sure the AC sour ce circuit is protected by a breaker switch of the correct si ze and type, to comply with the electrical code for your location and application. The current rating of the input breaker should not be lar ge[...]

22 T ruecharge2 Se ries Battery Charger Owner’s Guide Installing the T ruecharge 2 Battery Charger 7. Feed the AC supply wiring through th e wider end of strain relief and out the tapered end. 8. Slide the strain relie f on the jacket of the wir ing (not on the individual conductors) approximately 25 mm (1 in.) from the end of the jacket. 9. Conn[...]

975-0526-01-02 23 Installing the T ruecharge 2 Battery Char ger c) Insert one wire into one end of the butt-splice, until the insulation hits the internal me tal crimp section, inse rt the butt-splice into t he crimper 1 , and crimp firmly . The proper location for the crimp is approximately 1.6 mm (1/16 in.) pa st whe re the butt- splice insu- lat[...]

24 T ruecharge2 Se ries Battery Charger Owner’s Guide Installing the T ruecharge 2 Battery Charger Step 5: P owering Up Make one last check th at all connections are correct and secure. The T ruecharge2 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 . I[...]

975-0526-01-02 25 Installing a P arallel Configur ation A parallel configuration is when tw o T ruecharge2 Battery Chargers are coupled together to increase the out put capacity . For example, a 40-amp T ruecharge2 Battery Charger can be connected with anoth er 40-amp T ruecharge2 Battery Charger for a comb ined 80-amp capacity ch arger . This conf[...]

26 T ruecharge2 Se ries Battery Charger Owner’s Guide Installing a P arallel Configuratio n Powering up after installing a parallel configuration: 1. Follow the procedures in “S tep 5: Powering Up” on page 24. 2. Observe that the Para llel LED on the remote panel lights up to indicate that two ch arger s are in para lle l configuratio n charg[...]

975-0526-01-02 27 Installing Batteries Battery installation should always be treated like a brand new installation. This means, that all safe ty and precautionary gu idelines that were foll owed prior and during the installation of th e battery charger , must again be followed in order to avoid risks of electrical shock, injury , or death. T o repl[...]

28 T ruecharge2 Se ries Battery Charger Owner’s Guide Installing Batteries Multi-Stage Charging Most T ruecharge2 Battery Charger mo dels have three ou tputs that share the full rated current enabling it t o charge three different batteries or battery banks that either have th e same chemist ry or can tolerate the same char ge sequence and thresh[...]

975-0526-01-02 29 Installing Batteries Three-Stage Charging The three-st age char ging mode employs the following sequence: Bulk, Absorption, and Float . During the Bulk stage the batteries are ac cepting a constant maximum current. In th e Absorption stage, the battery volta ge is held constant and the current decl ines. A battery will “gas” ([...]

30 T ruecharge2 Se ries Battery Charger Owner’s Guide Installing Batteries T wo-Stage Charging The two-stage charging mode employs the following sequence: Bulk and Absorption . It runs similar to the three-stage sequence exce pt that there is no float stage; after the absorption stage the charger stops providing current to the battery and the cha[...]

975-0526-01-02 31 Installing Batteries Charging V oltage Setpoints The T ruecharge2 Battery Charger ch argi ng process is designed to make the battery or battery ba nks reach the followi ng voltage setpoints. Battery Qualification The T ruecharge2 Battery Char ger wi ll perform a battery qualification on each applicati on of AC (or DC > 9 V [for[...]

32 T ruecharge2 Se ries Battery Charger Owner’s Guide Installing Batteries Setting the Battery T emper ature without a BTS NO TE: Always be aware of the temperat ure setting, observe the battery’ s actual temperature and adju st the Batt ery T emperature setting accordingly . For varying conditions, use the W arm setting. T o configur e the bat[...]

975-0526-01-02 33 Installing Batteries Operating DC Loads When the T ruecharge™ 2 Battery Char ger is operating, DC loads su ch as fans and lights may vary in speed or intensity . This is normal. The T ruecharge™ 2 Battery Charger will not harm any load connected to it as long as the load can withsta nd the following maximum voltages: • 16 V [...]

34 T ruecharge2 Se ries Battery Charger Owner’s Guide Configuring the T ruecharge2 Battery Char ger Once the charger is connected to at le ast one battery bank and to AC, it is live and it may be configured. The indicator LEDs on the onboard display will illuminate for a se cond (power on test) before reportin g charging and battery status inform[...]

975-0526-01-02 35 Charging Batteries Before you start to charge batteries re ad the “Importa nt Safety Instructions” on page iv and follow all safety prec autions when working with batteries. T o charge your batteries: 1. If possible, disconnect any heavy loads on the batteries being charged, by opening disconnect switches or by switching the l[...]

36 T ruecharge2 Se ries Battery Charger Owner’s Guide Charging Batteries After charging is complete, the T ruechar ge2 Battery Charger enters into one of these modes: Float mode When the ready and char ging indicator LEDs both illuminate, all batteries are fully char ged and ready for use. If you selected the three-sta ge char ging mode, the T ru[...]

975-0526-01-02 37 Equalizing Flooded Batteries The T ruecharge2 Battery Charger cannot automatically determine when to stop the equalization of a battery . Th e 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 suf ficiently short to pr[...]

38 T ruecharge2 Se ries Battery Charger Owner’s Guide Equalizing Flooded Batteries P erforming An Equalization NO TE: The voltage applied to the batter y during equalization may be above safe levels for some loads but the absolute maximum is 16 V for 12-volt chargers and 32 V for 24-volt char gers within opera tional tempe rature range. NO TE: If[...]

975-0526-01-02 39 Equalizing F looded Batterie s 3. Press and hold for five seconds th e Charger Mode Select button and Battery T emp Select button at the same time to put the T ruecharge2 Battery Char ger into equalization mode. When the charger is performing the e qualization, th e Equalize L ED illuminates as a so lid light. It will flash inter [...]

40 T ruecharge2 Se ries Battery Charger Owner’s Guide T ransitioning the Char ger to ON , Standby , or Disabled There ar e two ways to turn ON the T ruecharge2 Battery Charger: • Connect the batteries to the charg e r (i.e., charger is on standby) then connect AC power at the source. If the batteries are not fully charged then charging begins i[...]

975-0526-01-02 41 Accessing Charger Information The T ruecharge2 Battery Charger provides a lot of information about the status of the charger and the batteries. Reading Onboard Display LEDs The Fault LED works in conjunction with the Char ging Current (%) LEDs. The icons at the top row above the Charging Current (%) LEDs represent the various type[...]

42 T ruecharge2 Se ries Battery Charger Owner’s Guide Accessing Charger Information Reporting W ithout A C P ower or W hile on Standby If AC power has been disconnected or if you have used the optional remote panel to place the T ruecharge2 Ba ttery Char ger on St andby mode, the onboard display (and the optional remote panel, if installe d) LEDs[...]

975-0526-01-02 43 Accessing Charger Information T able 9 Interpreting F ault and W arning Indicators Fa u l t o r Wa r n i n g Condition T emp Fan AC Battery Fuse Charger Remot e F ault Solution AC input out of range fault (<85 V or >265 V) • Check AC connections. Cha nge to a more stable AC power source and check that the voltage and volta[...]

44 T ruecharge2 Se ries Battery Charger Owner’s Guide Accessing Charger Information Low Battery T emp fault (< -25°C) • Check the batteries. Do not cha rge a froze n battery . Charging a fr ozen battery may present a risk of explosion. Check that the battery type and temperature settings mat ch the actual battery . • Allow the battery (or[...]

975-0526-01-02 45 Accessing Charger Information Reverse Polarity Fuse fault • Check for reverse battery polarity (negative connected to negative, posi tive connected to positive is correct) a t battery and charger output terminals. • Disconnect AC and DC sour ces before replacing the fuse(s) on the charger . See “Replacing the DC Output Fuse?[...]

46 T ruecharge2 Se ries Battery Charger Owner’s Guide Using A Generator As Sour ce P ower The T ruecharge2 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 d etermine the size of generator you need. Many [...]

975-0526-01-02 47 Maintaining the Charger NO TE: The Truecharge2 Series Batte ry Charger contains no user- serviceable parts with the exception of the DC output fuse(s) which are user-replaceable. See “Repla cing th e DC Output Fuse” on page 48 for instructions. For obtaining service ot her than replacing th e fuse, see “W arranty and Return [...]

48 T ruecharge2 Se ries Battery Charger Owner’s Guide Replacing the DC Output Fuse T o replace the DC Outp ut Fuse: 1. Locate the fuse cover on the char ger ’ s top panel (see “Front Panel” on page 3). 2. Loosen the screw on the fuse c over using a Philli ps screwdriver . NO TE: The screw will not se parate from the cover . 3. Pull out the [...]

975-0526-01-02 49 Replacing the DC Output Fuse Fuse Replacement Ratings RISK OF EQUIPMENT DAMA GE For continued protection, re place only with Littelfuse ® type 257 (or equivalent) with rating s as shown below . Failure to follow these instructio ns can damage the u nit and/or damage other equipment. Model Amper age V oltage TC2012 30 A (green) 32[...]

50 T ruecharge2 Se ries Battery Charger Owner’s Guide T roubleshooting In the event that you have a prob lem with your T ruecharge2 Battery Charger, the following tables will help you to identify the problem and of fer possible solutions to the problem. Symptom Indicator LEDs do not illuminate when c harger is con nected to an AC power source. Sy[...]

975-0526-01-02 51 T roubleshooti ng Symptom Fault indicator LED illum inates. T emp a nd Battery indicator LEDs flash. Symptom T ruecharge2 Battery Charger completes a char ging cycle, but the battery voltage seem s too low . EXPLOSION HAZARD Never charge a frozen battery . Failure to follow these instructions can result in death or seri ous injury[...]

52 T ruecharge2 Se ries Battery Charger Owner’s Guide T roubleshooting Symptom The T ruecharge2 Battery Charger appear s to be taking too long to charge battery . Ready i ndicator LED does not illuminate a fter 24 hours of charging. Symptom The T ruecharge2 Battery Char ger appe ars to have quickly charged the battery . Ready i ndicator LED illu [...]

975-0526-01-02 53 T roubleshooti ng Symptom The T ruecharge2 Battery Charger will not perform equalization. P ossib le Cause Solution Battery is the wrong type, or set to the wrong type to equalize. Not all batte ries are full y charged. An active fault is present o n the bank you are attempting to equalize. Determine if the battery type i s set to[...]

54 T ruecharge2 Se ries Battery Charger Owner’s Guide Specifications NO TE: Specifications are subject to change without prior notice. Physical Spec ificatio ns Base Unit Dimensions : L × W × H TC2012, TC4012 250×170×70 mm (9.84×6.70×2.76 in.) TC1024, TC2024 250×170×70 mm (9.84×6.70×2.76 in.) TC6012, TC3024 340×170×90 mm (13.38×6.70?[...]

975-0526-01-02 55 Specifications DC Output Specifica tions Number of isol ated battery bank outputs 3 separated outputs DC output voltage range including dead battery charging voltage 12-volt units: 24-volt units: 0 – 16 Vdc 0 – 32 Vdc Maximum equalization voltage 12-volt units: 24-volt units: 16 Vdc 32 Vdc V oltage accuracy (no load) 12-volt u[...]

56 T ruecharge2 Se ries Battery Charger Owner’s Guide Specifications Float voltage: Flooded GEL AGM Lead-calcium 12-volt units 24-volt units 25 °C (77 °F) 25 °C (77 °F) 13.5 ±0.1 27.0 ±0.2 13.8 ±0.1 27.6 ±0.2 13.4 ±0.1 26.8 ±0.2 13.5 ±0.1 27.0 ±0.2 Equalize m ode curr ent 50% rated output ±6% Equalize mode—maximum output voltage 12[...]

975-0526-01-02 57 Specifications Protection Features Battery reverse polarity Protect ed by replaceable DC output fuses Over -voltage limits T he T ruecharge2 Battery Char ger will stop charging if the output voltage is above 16.6 ±0.5 Vdc for 12 Vdc units, 33.2 ±0.1 Vdc for 24 Vdc units. Output current limit TC2012: TC4012: TC6012: TC1024: TC202[...]

58 T ruecharge2 Se ries Battery Charger Owner’s Guide W arranty and Return Information W arranty What does this warranty cover and h ow long does it last ? This Limited W arranty is provided by Xantrex T echnology USA Inc. (“Xantrex”) and covers defects in workmanship and materials in your T ruecharge2 Series Battery Charger. This warranty pe[...]

975-0526-01-02 59 W arr anty and Return Inform ation What proof of pur chase is required? In any war ranty claim, dated proof of purchase must accompany the pr oduct and the product must not have been disassembled or modified without prior written authorizatio n by Xantrex. Proof of purchase may be in any one of the following forms: • The dated p[...]

60 T ruecharge2 Se ries Battery Charger Owner’s Guide W arranty and Return Information Disclaimer Product T HIS 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 [...]

975-0526-01-02 61 W arr anty and Return Inform ation Return Material Authorization P olicy For those products that are not being repaired in the field and are being returned to Xantrex, before return ing a product direct ly to Xantrex you must obtain a Return Material Authorization (RMA) nu mber and the correct factory “Sh ip T o” address. Prod[...]

62 T ruecharge2 Se ries Battery Charger Owner’s Guide W arranty and Return Information Information About Y our System As soon as you open your T ruecharge2 Series Battery C harger package, record the following in formation and be sure to keep your proof of purchase. If you need to contact Customer Service, please r ecord the following details bef[...]

TC2 204060 Series Batt Chg Owners Guide.book Page i 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. TC2 204060 Series Batt Chg Owners Guide.book Pa ge ii Friday, July 8, 2011 11:44 AM[...]