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Xantrex Truecharge TC1012 Installation Manual

Other manuals for Truecharge TC1012: Owner's Manual, Owner's Manual
Manual is about: TrueCharge2 series

Summary of Truecharge TC1012

  • Page 1

    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 qualified installers only tc2 series battchg install guide.Book page i ...

  • Page 2

    Tc2 series battchg install guide.Book page ii monday, june 30, 2008 3:18 pm.

  • Page 3: Truecharge

    This guide for use by qualified installers only truecharge ™ 2 series battery chargers installation guide tc2 series battchg install guide.Book page i monday, june 30, 2008 3:18 pm.

  • Page 4

    This guide for use by qualified installers only about xantrex xantrex technology inc. Is a world-leading supplier of advanced power electronics and controls with products ranging from small mobile units to utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power ...

  • Page 5: About This Guide

    Iii this guide for use by qualified installers only about this guide purpose the purpose of this installation guide is to provide explanations and procedures for installing and configuring the truecharge™ 2 series battery charger. Scope the guide provides safety guidelines, procedures for installing...

  • Page 6: Conventions Used

    About this guide iv 975-0402-01-01 this guide for use by qualified installers only chapter 2 provides procedures for installing, testing and configuring the truecharge™ 2 battery charger. Appendix a contains physical, electrical performance, and regulatory approval specifications for the truecharge™...

  • Page 7: Caution: Risk of Injury

    V this guide for use by qualified installers only important safety instructions r ead and save this i nstallation g uide for future reference . This chapter contains important safety, installation, and operating instructions for the truecharge™ 2 series battery chargers. 1. Before installing and usi...

  • Page 8

    Safety vi 975-0402-01-01 this guide for use by qualified installers only 4. To avoid a risk of fire and electric shock, make sure that existing wiring is in good condition and that wire is not undersized. Do not operate the truecharge™ 2 battery charger with damaged or substandard wiring. 5. The use...

  • Page 9: Batteries

    Safety 975-0402-01-01 vii this guide for use by qualified installers only 10. Working in the vicinity of lead-acid batteries is dangerous. Batteries generate explosive gases during normal operation. Therefore, it is of utmost importance that each time before servicing the charger in the vicinity of ...

  • Page 10

    Safety viii 975-0402-01-01 this guide for use by qualified installers only 4. 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. 5. N...

  • Page 11

    Safety 975-0402-01-01 ix this guide for use by qualified installers only battery charger location 15. Locate the truecharge™ 2 battery charger unit away from batteries as practical in a well ventilated compartment. 16. Never place the truecharge™ 2 battery charger unit directly above batteries; gase...

  • Page 12: Fcc Information to The User

    Safety x 975-0402-01-01 this guide for use by qualified 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 designed to provide reasonable protection agains...

  • Page 13: Introduction

    Xi this guide for use by qualified installers only important safety instructions - - - - - - - - - - - - - - - - - - - - v 1 introduction truecharge™ 2 battery charger - - - - - - - - - - - - - - - - - - - - - 1–1 standard and protection features - - - - - - - - - - - - - - - - - - - - 1–2 truecharg...

  • Page 14: Specifications

    Contents xii 975-0402-01-01 this guide for use by qualified installers only installing optional accessories- - - - - - - - - - - - - - - - - - - - - -2–24 mounting the optional remote panel - - - - - - - - - - - - - -2–24 installing the optional battery temperature sensor (bts) 2–25 configuring the ...

  • Page 15: Introduction

    This guide for use by qualified installers only 1 introduction chapter 1 describes the standard features of a truecharge™ 2 battery charger, as well as its protection features. It also provides information on the different parts of the truecharge™ 2 battery charger including information on the optio...

  • Page 16

    Introduction 1–2 975-0402-01-01 this guide for use by qualified installers only standard and protection features the truecharge™ 2 battery charger provides the following standard features: • three 1 full current rated outputs • battery monitoring functions while in float mode or rest mode • correct ...

  • Page 17

    Standard and protection features 975-0402-01-01 1–3 this guide for use by qualified installers only the truecharge™ 2 battery charger provides the following protec- tion features: • reverse polarity protection via an output fuse to guard against reverse battery polarity • ac input out-of-range prote...

  • Page 18

    Introduction 1–4 975-0402-01-01 this guide for use by qualified installers only truecharge™ 2 battery charger this section describes the different parts of the truecharge™ 2 battery charger. Figure 1-1 truecharge™ 2 battery charger item description 1 onboard control and status display panel or simpl...

  • Page 19

    Truecharge™ 2 battery charger 975-0402-01-01 1–5 this guide for use by qualified installers only 4 fuse access panel cover provides access to the dc fuse in the event of an accidental reverse polarity installation. 5 ac wiring compartment cover provides the installer with easy access to the ac wirin...

  • Page 20: Rear Panel

    Introduction 1–6 975-0402-01-01 this guide for use by qualified installers only rear panel this section describes the parts of the rear panel of the truecharge™ 2 battery charger. Figure 1-2 truecharge™ 2 battery charger rear panel item description 1 bts port - battery temperature sensor port 2 comm...

  • Page 21: Important:

    Rear panel 975-0402-01-01 1–7 this guide for use by qualified installers only 7 air intake vent - located inside is the fan assembly 8 ac wiring - line, neutral, and ground input wires important: when installing only a single bank (or one battery) for truecharge™ 2 battery chargers that have multipl...

  • Page 22: Important:

    Introduction 1–8 975-0402-01-01 this guide for use by qualified installers only onboard control and status display panel this section describes the parts of the onboard control and status display panel of the truecharge™ 2 battery charger. To reduce current draw from the connected battery when ac po...

  • Page 23

    Onboard control and status display panel 975-0402-01-01 1–9 this guide for use by qualified installers only item description 1 charging output (%) leds • the leds illuminate like a progress bar displaying the present total output charge current as a percentage of the set maximum charge current. The ...

  • Page 24

    Introduction 1–10 975-0402-01-01 this guide for use by qualified installers only the fault led works in conjunction with the charging current (%) leds. The icons at the top row above the charging current (%) leds represent the various types of fault and warning conditions. For example, a temperature...

  • Page 25: Important:

    Onboard control and status display panel 975-0402-01-01 1–11 this guide for use by qualified installers only table 1-1 on page 1–11 summarizes the various fault conditions that might occur during the operation of the charger. For suggestions in what to do after a fault condition is detected, see tru...

  • Page 26

    Introduction 1–12 975-0402-01-01 this guide for use by qualified installers only low battery temp fault ( see figure 1-6. Ac input out of range warning ( >90v) or (255v) see figure 1-5. Ac input out of range fault (265v) see figure 1-5. Ac frequency out of range fault (65 hz) high battery voltage fa...

  • Page 27

    Onboard control and status display panel 975-0402-01-01 1–13 this guide for use by qualified installers only reverse polarity fuse fault internal fault flashing led solid led figure 1-5 input voltage operating and de-rating curve table 1-1 fault and warning indicators fault or warning condition temp...

  • Page 28

    Introduction 1–14 975-0402-01-01 this guide for use by qualified installers only figure 1-6 battery and charger temperature thresholds ambient temperature derating to 80% imax. Charger alarm set charger fault set charger alarm reset charger fault reset -25 -20 -15 -10 -5 0 5 10 20 30 40 50 60 15 25 ...

  • Page 29: Important:

    Remote panel (sold separately) 975-0402-01-01 1–15 this guide for use by qualified installers only remote panel (sold separately) this section describes the parts of the optional remote panel (part number: 808-8040-00) of the truecharge™ 2 battery charger. The remote panel can be mounted using a com...

  • Page 30

    Introduction 1–16 975-0402-01-01 this guide for use by qualified installers only • limit the maximum charger output current (20, 40, 60, 80, and 100% of charger rating) to lower the current drawn from the generator or ac source • set the charger to on or on standby • set or cancel an equalization cy...

  • Page 31

    Remote panel (sold separately) 975-0402-01-01 1–17 this guide for use by qualified installers only 3 charger status leds displays the present status of the charger. • ready - a solid light indicates that all batteries are fully charged and in rest stage. • ready and charging - solid lights indicate ...

  • Page 32

    1–18 this guide for use by qualified installers only tc2 series battchg install guide.Book page 18 monday, june 30, 2008 3:18 pm.

  • Page 33: Installation

    This guide for use by qualified installers only 2 installation chapter 2 provides procedures for installing, testing and configuring the truecharge™ 2 battery charger. It covers the following major topics: • “preparing for installation” on page 2–2. • “installing the truecharge™ 2 battery charger” o...

  • Page 34: Preparing For Installation

    Installation 2–2 975-0402-01-01 this guide for use by qualified installers only preparing for installation the truecharge™ 2 battery charger is designed to be permanently mounted. Figure 2-1 shows a typical installation with three batteries, a battery temperature sensor (bts) and a remote panel (bot...

  • Page 35

    Preparing for installation 975-0402-01-01 2–3 this guide for use by qualified installers only 1 ac mains source protected by correct size and type of branch rated circuit breaker 2 ac input wiring compartment 3 dc negative cable 4 dc positive cables 5 dc circuit breakers or dc fused disconnects 6 ba...

  • Page 36: Tools and Materials

    Installation 2–4 975-0402-01-01 this guide for use by qualified installers only tools and materials to mount and connect the truecharge™ 2 battery charger you need the following tools: • 10 mm socket wrench and extension for the dc terminals and ground stud • phillips screwdriver for removing and re...

  • Page 37: Location

    Preparing for installation 975-0402-01-01 2–5 this guide for use by qualified installers only location install the truecharge™ 2 battery charger in a location that meets the following requirements: when planning to install the truecharge™ 2 battery charger, be sure that you consider the location and...

  • Page 38: Important:

    Installation 2–6 975-0402-01-01 this guide for use by qualified installers only rating means that it meets european and u.S. Standards in preventing dripping water from entering the enclosure, and causing shock hazard and damage to equipment. The other possible mounting orientations will not prevent...

  • Page 39

    Preparing for installation 975-0402-01-01 2–7 this guide for use by qualified installers only figure 2-2 truecharge™ 2 battery charger mounting orientations figure 2-3 ventilation clearance deck mount - this orientation meets ip-32 marine requirements and is drip-proof. Vertical wall mount (rear pan...

  • Page 40: Wiring Requirements

    Installation 2–8 975-0402-01-01 this guide for use by qualified installers only wiring requirements dc wiring the following two tables show some typical wire sizes, based on 3% voltage drop on dc cables, 75 °c (167 °f) rated wire and wiring being inside the engine compartment – assumed ambient of 50...

  • Page 41

    Preparing for installation 975-0402-01-01 2–9 this guide for use by qualified installers only over-current protection 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 (...

  • Page 42: Ac Wiring

    Installation 2–10 975-0402-01-01 this guide for use by qualified installers only ac wiring the ac wiring must meet be of sufficient size, and it must be protected by the appropriate size and type of input breaker, based on the jurisdiction and application. Some basic examples are given below. The ac...

  • Page 43: Note:

    Preparing for installation 975-0402-01-01 2–11 this guide for use by qualified installers only battery bank size requirements the truecharge™ 2 battery charger is designed to work with a minimum battery bank size. Each bank should meet the minimum ah rating shown in table 2-3. Note: if the battery m...

  • Page 44: Charger

    Installation 2–12 975-0402-01-01 this guide for use by qualified installers only installing the truecharge™ 2 battery charger installation sequence to make charger installation quick and easy, xantrex recommends that the installation tasks be performed in the following sequence: 1. Select charger mo...

  • Page 45: Planning Dc Wiring

    Installing the truecharge™ 2 battery charger 975-0402-01-01 2–13 this guide for use by qualified installers only planning dc wiring the procedure for installing the dc wiring applies to a single battery, as well as multiple batteries or battery banks. 1. Identify the battery or bank that most freque...

  • Page 46

    Installation 2–14 975-0402-01-01 this guide for use by qualified installers only 4. Install a dc circuit breaker or fused disconnect in each positive cable within 7 inches (17.8 cm) of each battery. Consult your local electrical codes regarding the distance between the battery and the disconnect dev...

  • Page 47: Planning Ac Wiring

    Installing the truecharge™ 2 battery charger 975-0402-01-01 2–15 this guide for use by qualified installers only planning ac 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 ...

  • Page 48

    Installation 2–16 975-0402-01-01 this guide for use by qualified installers only 6. Remove the ac (l, n, gnd ) wires from the ac wiring compartment of the charger. 7. Feed the source ac wire through the included strain relief. Position approximately 1" from end of jacketed portion of the ac wiring. ...

  • Page 49: Important:

    Installing the truecharge™ 2 battery charger 975-0402-01-01 2–17 this guide for use by qualified installers only to connect ac wires with the crimp-on butt-splice connector: a) using a wire stripper, carefully strip 8 mm (5/16 in.) from the ends of the two wires being connected. B) insert one wire i...

  • Page 50: Important:

    Installation 2–18 975-0402-01-01 this guide for use by qualified installers only mounting the truecharge™ 2 battery charger mount the truecharge™ 2 battery charger using all four mounting slots and holes which are provided. For marine only installations, the mounting orientations a) and b) in figure...

  • Page 51: Make The Final Connections

    Installing the truecharge™ 2 battery charger 975-0402-01-01 2–19 this guide for use by qualified installers only make the final connections after planning the dc and ac connections and mounting the charger, the last procedures, including installing the dc terminal rubber boots for drip protection, w...

  • Page 52: Final Dc Connections

    Installation 2–20 975-0402-01-01 this guide for use by qualified installers only installing the drip protection rubber boots xantrex recommends that you install the supplied rubber boots over the truecharge™ 2 battery charger dc terminals to provide drip and short circuit protection. To install rubb...

  • Page 53

    Installing the truecharge™ 2 battery charger 975-0402-01-01 2–21 this guide for use by qualified installers only the truecharge™ 2 battery charger (figure 2-4, item 1). Use a flat washer, a lock washer and a nut (5 included in the installation kit) to secure the connection. Tighten the nuts to 2.3 n...

  • Page 54: Final Ac Connections

    Installation 2–22 975-0402-01-01 this guide for use by qualified installers only 5. Install the dc chassis ground (earth) from the ground stud on the truecharge™ 2 battery charger to the engine bus or dc ground bus (figure 2-4, item 15). Use a flat washer, a lock washer and a nut (included in the in...

  • Page 55: Grounding Instructions

    Installing the truecharge™ 2 battery charger 975-0402-01-01 2–23 this guide for use by qualified installers only grounding instructions the truecharge™ 2 battery charger battery charger must be connected to a grounded, metal permanent wiring system, or an equipment-grounding conductor should be run ...

  • Page 56

    Installation 2–24 975-0402-01-01 this guide for use by qualified installers only installing optional accessories optional accessories are available for purchase at xantrex. Call customer service to order the accessories below: • remote panel (part number: 808-8040-00) • battery temperature sensor (p...

  • Page 57: (Bts)

    Installing optional accessories 975-0402-01-01 2–25 this guide for use by qualified installers only installing the optional battery temperature sensor (bts) xantrex strongly recommends that you install the optional battery temperature sensor (bts) to protect your battery and improve charging accurac...

  • Page 58: Charger

    Installation 2–26 975-0402-01-01 this guide for use by qualified installers only configuring the truecharge™ 2 battery charger once the charger is connected to a battery on bank 1 or to ac, it is live and it may be configured. The indicator leds on the onboard display will illuminate for a second (p...

  • Page 59: Configuring The Charger Mode

    Configuring the truecharge™ 2 battery charger 975-0402-01-01 2–27 this guide for use by qualified installers only configuring the charger mode using the onboard display panel to configure the charger mode: note: by default, the charger mode is set to three-stage. 1. Press and hold the charger mode s...

  • Page 60

    Installation 2–28 975-0402-01-01 this guide for use by qualified installers only using the remote panel to configure the charger mode: note: by default, the charger mode is set to three-stage. 1. Press and hold the status button for three seconds to enter the setup mode. Entering the setup mode will...

  • Page 61

    Configuring the truecharge™ 2 battery charger 975-0402-01-01 2–29 this guide for use by qualified installers only configuring the battery bank type using the onboard display panel to configure the battery bank type: note: by default, the battery type is set to flooded. 1. Press and hold the battery ...

  • Page 62: Bts

    Installation 2–30 975-0402-01-01 this guide for use by qualified installers only configuring the battery temperature without the bts using the onboard display panel to configure the battery temperature: note: by default, the battery temp. Is set to warm. 1. Press and hold the battery temperature sel...

  • Page 63: Percentage

    Configuring the truecharge™ 2 battery charger 975-0402-01-01 2–31 this guide for use by qualified installers only configuring the maximum output current percentage using only the remote panel to configure the maximum output current: note: by default, the max. Output % is set to 100. Press the set ma...

  • Page 64: Installing Batteries

    Installation 2–32 975-0402-01-01 this guide for use by qualified installers only installing batteries replacing old or defective batteries (even installing new batteries) require that you disconnect all ac and dc sources prior to installation. To replace an old battery: 1. Turn off the ac source by ...

  • Page 65: Specifications

    This guide for use by qualified installers only a specifications appendix a contains physical, electrical performance, and regulatory approval specifications for the truecharge™ 2 battery charger. Note: specifications are subject to change without notice. Tc2 series battchg install guide.Book page 1...

  • Page 66: Physical Specifications

    Specifications a–2 975-0402-01-01 this guide for use by qualified installers only physical specifications base unit 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 (13.7...

  • Page 67: Electrical Specifications

    Electrical specifications 975-0402-01-01 a–3 this guide for use by qualified installers only electrical 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 nomi...

  • Page 68

    Specifications a–4 975-0402-01-01 this guide for use by qualified installers only float voltage: ±0.1 v for 12 v units ±0.2 v for 24 v units 12 v units 24 v units 25 °c (77 °f) 25 °c (77 °f) flooded 13.5 27.0 gel 13.8 27.6 agm 13.4 26.8 lead-calcium 13.5 27.0 equalize mode current 50% rated output ±...

  • Page 69: Ac Input Specifications

    Ac input specifications 975-0402-01-01 a–5 this guide for use by qualified installers only ac input specifications ac input voltage range nominal: 120 vac, 230 vac, 240 vac full performance: 105 – 265 vac ±4 vac automatic derating to 80%: 90 – 104 ±4 vac maximum ac input current at 104 vac at 208 va...

  • Page 70: Dc Output Specifications

    Specifications a–6 975-0402-01-01 this guide for use by qualified installers only dc output specifications temperature specifications dc output voltage range including dead battery charging voltage 12 v units: 0 – 15.5 vdc 24 v units: 0 – 31 vdc maximum equalization voltage (no bts installed) 12 v u...

  • Page 71: Protection Features

    Protection features 975-0402-01-01 a–7 this guide for use by qualified installers only protection features battery reverse polarity protected by a replaceable dc output fuse over-voltage limits the truecharge™ 2 battery charger will stop charging any bank if the output voltage is above 16.6 ±0.5 vdc...

  • Page 72: Approvals

    Specifications a–8 975-0402-01-01 this guide for use by qualified installers only approvals safety nrtl approved to csa e60335-2-29 and ul1236, including the marine supplement, ignition protection, and ul1564 ce marked, complying with low voltage directive 2006-95-ec, complying with en60335-2-29 bat...

  • Page 73

    Tc2 series battchg install guide.Book page 9 monday, june 30, 2008 3:18 pm.

  • Page 74: Xantrex Technology Inc.

    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 tc2 series battchg install guide.Book page 10 monday, june 30, 2...