Xantrex Technology TC40+ manual

Xantrex T ruecharge 20+/40+ Amp Multistage Battery Charger Owner’ s Guide TC20+ TC40+[...]

Owner’s Guide Truecharge 20 +/40 + Amp Multistage Battery Charger[...]

About Xantrex Xantrex T echnology Inc. is a worl d-leadin g supplier of advanced power electroni cs and controls with products from 50 watt mobile units to 1 MW utility -scale system s for wind, solar , batteries, fuel cells, microturbines, and backup power applications in bo th grid-connected and stan dalone systems. Xantr e x products include inv[...]

About This Guide Purpose and scope This guide introduces the Truechar ge + battery chargers, describes their features, explains how they charge batte ries, and provides procedures for their installation and operation. The gui de does not pro vid e detai l s for par ticu lar brands of batteries. Please consult the battery manufacturer for this infor[...]

About This Guide iv Chapter 3, “Operation” provides ba ckground information for char ging batteries with T ruecharge + and procedures for charging and for equalizing b atteries. Chapter 3 a lso explains how to calculate charging times, how generators af fect T ruecharge + and explains how the front panel indicator light s are interpreted. Chapt[...]

v Important Safety Instructions Explosive gas precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–x Precautions When Working With Batteries - - - - - - - - - - - - - - - - - - - - - - - - - 1–x 1I n t r o d u c t i o n Truecharge + Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -[...]

Contents vi Connecting to AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11 Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14 Installing Optional Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14 Battery Temperature Sensor [...]

Contents vii Maintenance Guidelines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2 Preparation for Cleaning Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3 Clothing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3 Tools - - - - - - [...]

viii[...]

ix Important Safety Instructions 1. Before using the charger , read all instructions and cautionary markings on the charger , the batte ries, and all appropriate sections of this guide. 2. Do not expose the charger to rain , snow , spray , or bilge water . T o reduce risk of fire hazard, do no t cover or obstruct the ventilation openings. Do not in[...]

Importa nt Safety Informat ion x 7. Do not disassemble the charger . See Appendix D, “Product an d System Information” for instructions on obtaining service. Attempting to service the unit your self may result in a risk of electrical shock or fire. Internal capacitors remain char ged after all power is disconnected. 8. T o reduce the risk of el[...]

Importa nt Safety Informa tion xi 3. W ear complet e eye protection and clothing protect ion. A void touching your eyes wh ile wo rking near batteries. 4. If battery acid contacts skin or clothing, wash immediately with soap and wa ter . If acid enters yo ur eye, immediately flood it with running cold water for at least twenty minute s and get m ed[...]

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1 Introduction Chapter 1, “Introduction” introduces and describes features of the T ruechar ge + multistage battery chargers.[...]

Introduction 1–2 Truecharge + Features T ruecharge + is an advanc ed battery ch arger designed specifically for high performance, deep-cycle le ad-acid batteri es. It is smaller and lighter than many other chargers and can be installed or stored in small compartments. It has AC to DC isolatio n, a sur ge prot ector , and many other safety feature[...]

T ruecharge + Features 1–3 Selector Switches T ruechar ge + has selector switches for charge mode, battery type, and battery temperature setting. Char ge mode The char ge-mode switch allows you to select three-step charge, two-step charge or 13.5 volt fixed output modes. Refer to Appe ndix B, “Battery Charging” for an explanation of th e char[...]

Introduction 1–4 Fixed Voltage Mode The fixed voltage mode setting is mean t to be used as a power supply or battery eliminator . It is not meant for charging batteries. The battery type, battery temperature, and equaliz e switches are all ignored in fixed voltage mode. The remote battery temperatur e sensor does not compensate the voltage, but t[...]

Indicator Lights and Settings on the Front P anel 1–5 The indicator lights are also used to indicate error codes. See Chapter 4, “Maintenance and T roubleshooting” T a ble 1-1 T ruecharge + front p a nel Pa n e l Item Description 1 Status indicator lights which indi cate that batteries are charged and ready for use or that the batteries are b[...]

Introduction 1–6 How Truecharge + Works T ruechar ge + changes the alternating current (AC) suppl y from the utility to the controlled low-voltage, direct current (DC) required to char ge the battery by using high-frequency , switched-mode power conversion circuits. The high-frequency power conv ersion method is similar to that used in power supp[...]

2 Installing Truecharge + Chapter 2, “Installing T ruechar ge +” lists the materials you receive, provides site recommendations for installing T ruechar ge +, and provides the materials and procedures for its installation. The chapter also makes reference to the installation codes that may be applicable in your application, for example, the US [...]

Installing T ruecharge + 2–2 Materials List Contents The unit is packed wi th the following materials: • Owner ’ s Guide • W iring cover with 2 blunt-ti p screws and two lock washers • AC cable clamp • Three twist-on wire nuts • Three crimp-on butt-splices Recording information After unpacking the unit, record th e serial number and o[...]

Preparing for Installation 2–3 Location Install T ruechar ge + in a location that meets the requirements set out in Ta b l e 2 - 1 . Circuits T ruechar ge + is designed to operate from a 15 amp, 120 V AC (nominal) branch circuit. The circuit must be protected by a 15 amp circuit breaker . Any switch in the circuit should be rated for a minimum of[...]

Installing T ruecharge + 2–4 Figure 2-2 T ruecharge + system 1 3 .8 /1 3 .4 C o ld W a rm H o t 14 .4 /1 3 .5 14 .0 /1 3 .1 14 .2 /1 3 .8 O u tp u t V o lts A bs or p tio n / F lo a t B a tte ry T yp e F lo o de d G e l E q u a liz e C h a rg in g R e a d y B u lk /A b so rp tio n /F lo a t 1 3 .5 V (fix e d ) 1 4 .6 /1 4 .2 T M 1 4 .0 /1 3 .1 14[...]

Preparing for Installation 2–5 Wiring Requirements Figure 2-2 depicts a typical configuration system for the T ruecharge + showing the AC and DC wiring and protection devices required for a successful installation. DC Wiring The DC wiring must meet the following requirements : • Length and size Use the largest recommended size ra ther than the [...]

Installing T ruecharge + 2–6 AC Wiring Be sure that your AC wiring meets the following requirements before you install the T ruechar ge +: • Input wiring The AC input wiring fo r T ruechar ge + should be three-conductor cable, providing a line, neutral, an d g round conductor in an ou ter jacket. The conductors must be No. 14 A WG or larger . F[...]

Preparing for Installation 2–7 Tools T o mount and c onnect T ruechar ge + you need: p a slot screwdriver with a maximum 3/16 in wide blade for the DC terminals p a No. 1 Phillips screwdriver for securing the AC wiring compartment cover p a wire stripper p the manufacturer's recommended cr imp tool for any crimp terminals that are be ing use[...]

Installing T ruecharge + 2–8 Installing Truecharge + Installation steps T ruechar ge + is installed in three steps. The unit is 1. mounted ( page 2–8 ) 2. connected to the batteries ( page 2 –9 ) 3. connected to its AC power source ( page 2–1 1 ) Mounting Mount the T ruechar ge + on a vertical surface such as a bulkhead, using the mounting [...]

Installing T ruecharge + 2–9 Connecting DC Wiring For A Single Battery Or Multiple Batteries The procedure for installing the DC wiri ng applies to a single battery or multiple batteries or battery banks. Figure 2-3 shows the connectio n order . Figure 2-3 DC wiring connection order WARNING T ruechar ge + cannot be set to deliver dif ferent char [...]

Installing T ruecharge + 2–10 T o install the DC wiring: 1. Plan the route the DC wires will fo llow trying to make it as short as possible. Meas ure th e requi red wire length, and cut the cables. Allow some extra length for connections and to provide slack in the wires. It is possible that the co nn ection to the battery negative circuit may no[...]

Installing T ruecharge + 2–11 8. Before proceeding, carefully check the wiring polarity – make sure the positive on th e char ger is going to the positive on the batteries (fuse or breaker) and make sure the negative on the charger is going to the battery nega tive terminal (or engine negativ e bu s or DC negative bus). Do not reverse the c onn[...]

Installing T ruecharge + 2–12 3. Route the wiring without connectin g it to the AC source or to the charger yet. 4. Install the supplied cable clamp in the knock-out of yo ur choice on the AC wiring compartment on the top end of the charger and tighten the locknut. Run the AC wiring th rough the cable clamp and about 6 inches into the wiring comp[...]

Installing T ruecharge + 2–13 T o connect AC wires with the crimp-on butt-splice connector: 1. Using a wire stripper , carefully strip 5/16” (8mm) from the ends of the two wires being connected. 2. Insert one wire into one end o f the butt-splice, insert the butt-splice into the crimping tool, and crimp firmly . The proper location for the crim[...]

Installing T ruecharge + 2–14 Grounding T ruechar ge + must be grounded to redu ce the risk of electrical shock. The AC input ground wire must be properly connected to grou nd in accordance with all applicable elec tric al codes. Meeting electrical codes is achieved by connectin g the ground conductor of the AC input cable to a properly grounded [...]

Installing Optional Access ories 2–15 Effect on charging W ith the BTS, the charging setpoint s are temperature-compensated up to 140 °F (60 °C). If the battery temperature exceeds 140 °F the charger stops charging. The BTS also provides more accurate compensation over a wider range of temperatures than th e front panel temperature settings. F[...]

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3 Operation Chapter 3, “Operation” provides background information for charging batteries with T ruechar ge + and procedur es for char ging and for equalizing batteries. Chapter 3 also explains how to calculate char ging times, how generators af fect T ruechar ge + and explains how the front panel indicator lights are interpreted.[...]

Operation 3–2 About Charging This section provid es information about • calculating the charging time • effect of battery temperature on charging • indicator light activity during the char ging process • using a generat or to run T ruecharge + Charging Time Formula Charging time will depe nd on the capacity of your battery and on how deep[...]

About Charging 3–3 Battery Temperature T emperature switch Selecting the correct temperature sett ing selects the appropriate charging voltage to compensate for battery temperature. Effect of temperature Cold battery temperatur e If you choose the Cold setting, T ruechar ge + delivers, for example, 14.8 volts in absorption mode and 13.9 volts in [...]

Operation 3–4 Using A Generator As Source Power The T ruecharge + can be run from a regular power sour ce or from an alternate power source such as a generator . Refer to Appendix A, “Specifications” for AC input draw to determ ine the size of generator you need. Many generators prov ide output voltage that is modified si ne wa ve (MSW) rathe[...]

Charging batteries 3–5 Charging batteries Before you start Before you start to char ge batteries read the “Important Safety Instructions” on page ix and take all safety pr ecautions when working with batteries. T o charge your batteries: 1. If possible, disconnect all loads fro m the battery , by removing battery cables, by opening a disconne[...]

Operation 3–6 2. Set the Battery T ype selector sw itch according to the table below . 3. Set the Battery T emperature selector switch for the te mperature of your battery as follows: If temperatures fluctuate near the batteries, set this switch each time you char ge the batteries. If your batteries are in different lo cations with dif ferent tem[...]

Equalizing Flooded Batteries 3–7 light on T ruecharge 40 +) will light for most of the char ging cycle. Near the end of the cycle, the char ging current de creases and the oth er indicator lights illuminate in sequence. The charger pauses every 15 mi nutes for approximately 10 seconds to measure the battery voltage and to check for new or disconn[...]

Operation 3–8 Battery type T ruechar ge + equalizes only flood ed lead-acid batteries. It does not equalize sealed lea d-acid batteries si nce they can be damaged by this process. If the battery type selector is set for Gel or AGM, and you try to equalize them, th e in dicator lights on the front pa nel flash but T ruechar ge + does not enter equ[...]

Equalizing Flooded Batteries 3–9 Important T urn off or disconnect all loads on the battery during eq ualization. The voltage applied to the battery during equalization may be above the safe levels for some loads. Be sure to check battery electrolyte before and after equalization. Fill only with distilled water . T o equalize your batteries: 1. U[...]

3–10[...]

4 Maintenance and Troubleshooting Chapter 4, “Maintenance and T roubleshooting” provides information for maintaining and troubleshooting T ruechar ge +.[...]

Maintenance and T roubleshooting 4–2 Care and Maintenance Cleaning Truechar ge + conta ins solid-state electronic components that require no maintenance. The best care you can give the unit is to protect it from contact with liquids, spray , or fumes which may cause corrosion. Disconnect all AC and DC power and clean the outside of the case and w[...]

Tr o u b l e s h o o t i n g 4–3 Middle charging current indicator light blinks, all others are o ff T ruechar ge + is in over-temperature shutdown due to excessive battery temperature. This sh utdown only occurs if the BTS is installed . T able 4-1 Indicator light sequence s on T ruecharge + Display Condition[...]

Maintenance and T roubleshooting 4–4 Typical Proble ms This section lists typical problems yo u may have with the T ruecharge +, suggests their causes, then offers po ssible solutions to the problems. Symptom Indicator lights do not turn on, or remai n on, when char ger is connected to an AC receptacle. Symptom Indicator lights co ntinue to blink[...]

Tr o u b l e s h o o t i n g 4–5 Symptom Charging light blinks but does not come on steadily . Other indicator lights are o ff. Symptom The 20 amp indicator light blinks on T ruecha rge 20 +, or the 40 amp light blinks on T ruecharge 40 +. Other indicator lights are of f (only when temperature sensor is installed). Symptom T ruechar ge + appears [...]

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A Specifications Appendix A “Specifications” contains the T ruechar ge + physical, electrical, AC input, and protection feature specifications.[...]

Specifications A–2 Physical Specifications Electrical Specifications Dimensions 15 1/8 in x 6 3/4 in x 2 3/4 in 385 mm x 172 mm x 70 mm W eight T ruecharg e 20 + 6.9 lbs (3 .1 kg) T ruechar ge 40 + 7.4 lbs (3.3 kg) AC input connections Three co lor -code d No. 16 A WG wires (L, N, G) minimum 6 inches long in a separate AC wiring enclosure with pr[...]

Electrical Specifications A–3 Absorption voltage Hot Warm Cold Flooded 14.0 14.4 14.8 VDC Gel 13.8 14.2 14.6 VDC AGM 14.0 14.3 14.6 VDC Float voltage at no load Hot Warm Cold F looded 13.1 13.5 13.9 VDC Gel 13.4 13.8 14.2 VDC AGM 13.1 13.4 13.7 VDC Equalize mode current T ruecharge 2 0 + 5 ADC T r uecharge 40 + 10 ADC Equalize mode—maximum outp[...]

Specifications A–4 AC Input Specifications Protection Features T ruecharge 20 + T ruecharge 40 + AC input voltage range 90 – 135 V AC, 50/60 Hz Maximum AC input current at 90 V AC 6.5 A rms 12 A rms T ypical AC input current at 120 V AC 4.6 A rms 8.5 A rms No-load AC power draw (without remote panel) less than 3 watts less than 3 watts Power fa[...]

Approv als A–5 Approvals Over-temperature Internal ch ar ger tempera ture is me asured. Uni t shuts do wn and restarts as follows: • Over -temperature shutdown at 62 °C • Over-temperature restart at 61 °C Current derating in ambient temp eratures— automatic output T ruechar ge 20+ 20 A at 30 °C to 10 A at 50 °C T r uecharge 4 0+ 40 A at[...]

A–6[...]

B Battery Charging Appendix B “Battery Charging” describes the T ruechar ge + multistage char ging algorithm.[...]

Battery Chargi ng B–2 Charging Algorithms Battery Type T ruechar ge + char ges lead-acid floode d, gel, and AGM (ab sorbed glass mat) batteries. Flooded “Flooded” batteries have removable battery caps for refilling with distilled water and testing the electrolyte. Gel The sealed gel battery has its electrolyt e is in the form of a gel rather [...]

Charging Algorithms B–3 Bulk Charge In the first stage, known as th e bulk charge, T ruecharge + delivers its full- rated output current.This constant curre nt is delivered to the batteries until the battery voltage approaches its absorption voltage—typically around 14.4 volts for 12 volt batteries. The bu lk char ge stage res to res about 75% [...]

Battery Chargi ng B–4 Figure B-1 Three-st age charging profile Equalization Charge The equalization charge must be ma nually initiated because it is not required each time the battery is rech ar ged. Equalization is a deliberate overcharge designed to return each cell to optimum condition by reducing sulfation and stratificatio n in the battery .[...]

C Battery Maintenance Appendix C “Battery Maintenance” contains procedures for maintaining the battery enclosure, battery terminals and lugs , and battery cables. It also provides a list of the clothing, tools, equipment, and supplies you should have before you begin battery maintenance.[...]

Battery Main te nance C–2 Maintenance Guidelines Electrolyte At a minimum, check the level of the electrolyte in each battery cell once a month (for flooded batteries). It sh ould be above the top of th e plates, but not completely full. Most batteries have a plastic cup that just touches the electrolyte when the cell is full . Don’t overfill t[...]

Prepar ation for Cleaning Bat teries C–3 Preparation for Cl eaning Batteries The appropriate clothing, tools, equipm ent, and supplies are listed below . Gather what you need before b egin ning. Clothing Appropriate clothin g could include old clot hes, rubber boots, or old shoes. Battery acid is highly corro sive, so wear something you can live [...]

Battery Main te nance C–4 Maintaining and Cleaning Follow these procedures to maintain the • battery enclosure • battery terminal and lugs • cables Battery Enclosur e and Batteries Mix four ounces of baking soda with a gallon of fresh wat er and fill a spray bottle. Spray the so lution on all exposed surfaces of the battery compartment, and[...]

Maintaining and Cleaning C–5 Reconnect t he battery cabl e terminals to the battery lugs and tighten t o approximately 10–15 foot-pou nds using the torque wren ch. If yo u do not have a torque wren c h, use an appr opriate tool to ti ghten the bolts reasonably snug. Do not ov er-tighten. After tightening the cables, evenly coat all the exposed [...]

C–6[...]

D Product and System Information Appendix D “Product and System Information” contains the Xantrex warranty for your product and return instructions. It also contains a place for you to record the serial number and date of purchase and other details of your battery charger .[...]

Product and System Inf ormation D–2 Warranty What does thi s warranty cover? This Limited W arranty is provided by Xantrex T echnology , Inc. ("Xa ntrex") and covers defects in workmanship and materials in yo ur Xantrex T ruecharge 20+ and T ruechar ge 40+. This warranty lasts for a W arranty Period of 12 months from the date of purchas[...]

Wa r r a n ty D–3 Direct returns may be performed according to the Xantrex Return Material Authorization Policy describ ed in your product manual. For some products, Xantrex ma intains a network of regional Autho rized Service Centers. Call Xantrex or check our website to see if yo ur p rod uct can be repaired at one of these facilities. In any w[...]

Product and System Inf ormation D–4 DISCLAIMER Product THIS LIMI T ED W ARRANTY IS TH E SOLE AND EX CLUSIVE W ARRANTY PROVIDED BY XANTREX IN CONNECTIO N WITH YOUR XANTREX PRODU CT AND IS, WHERE PERMITTED BY LA W , I N LIEU OF ALL OTHER W ARRANTIES, COND ITIONS, GUARANTEES, REPRESENT A TIONS, OBLIGA TIONS AND LIABILITIES, EXPRESS OR IMPLIED, ST A [...]

Return Material Authorization P olicy D–5 Return Material Authorization Policy Before returning a produc t directly to Xantrex you must obtain a Return Material Authorization (RMA) number and the correct factory "Ship T o" address. Products must also be ship ped prepaid. Product shipment s will be refused and returned at your expens e i[...]

Product and System Inf ormation D–6 If you are r eturning a product to a Xantr ex Authorized Service Center (ASC) A Xantrex return material authorization (RMA) number is not required. However , you must co ntact the ASC prior to returning the product or presenting the unit to verify an y return procedures that may apply to that particular facilit[...]

Information about your T ruecharge + D–7 Information about your Truecharge + Please record the following inform ation when you unpa ck your T ruechar ge +unit. : If you need to contact Customer Serv ice, please gather the following information before ca lling.The information will assist the service representative in providing you with better serv[...]

Product and System Inf ormation D–8[...]

A absorption charge, battery activity during B–3 AC input specifications A–4 AC wiring requirements 2–6 AGM (absorbed glass mat) batteries B–2 AGM batteries, selector switch for 1–3 anti-corrosion grease C–2 B baking soda C–3 batteries AGM (absorbed glass mat) B–2 first aid when working with 1–x maintenance guidelines C–2 precau[...]

Index Index–2 equalization charge B–4 equalization of batteries, understand ing 3–7 equalizing, procedure 3–9 F failure to operate 4–4 fan speed, change in speed of 3–7 fax number for Customer Service D–2 features 1–2 first aid 1–xi fixed voltage mode 1–4 float charge, battery activities during B–3 flooded batteries equalizing[...]

Index– 3 Index T telephone number for Customer Servic e D–2 temperature switch description of 1–3 setting for charging 3–3 temperature, effec t of in charging 3–3 terminals and lugs, maintenance of C–4 three-battery charging 1–2 three-stage charging algorithm explanation B–2 three-stage charging profile (diagram) B–4 tools, requir[...]

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Xantrex T echnology Inc. T oll free 1 800 670 0707 Direct 1 360 925 5097 F ax 1 360 925 5143 CustomerService@xantrex.com www .xantrex.com[...]