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Xantrex Truecharge TC1012 Owner's Manual
Summary of Truecharge TC1012
Page 1
Series battery charger owner’s 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 tc2 series battchg owners guide.Book page i tuesday, july 1, 2008 11:55 pm.
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Tc2 series battchg owners guide.Book page ii tuesday, july 1, 2008 11:55 pm.
Page 3: Truecharge
Truecharge ™ 2 series battery chargers owner’s guide tc2 series battchg owners guide.Book page i tuesday, july 1, 2008 11:55 pm.
Page 4
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 applications in both grid- connected and stand-a...
Page 5: About This Guide
Iii about this guide purpose the purpose of this owner’s guide is to provideexplanations and procedures for operating, maintaining, and troubleshooting the xantrex™ truecharge™ 2 series battery charger. Scope the guide provides safety and operating guidelines as well as information about troubleshoo...
Page 6: Conventions Used
About this guide iv 975-0401-01-01 conventions used the following conventions are used in this guide. This guide contains information for 11 product models of the xantrex™ truecharge™ 2 series battery charger. The 12v models are: tc1012, tc1512, tc2012, tc3012, tc4012, tc5012, and tc6012. When being...
Page 7: Caution: Risk of Injury
V important safety instructions r ead and save this o wner ’ s g uide for future reference . This chapter contains important safety, installation, and operating instructions for the xantrex™ truecharge™ 2 series battery chargers. 1. Before installing and using a truecharge™ 2 battery charger, read a...
Page 8
Safety vi 975-0401-01-01 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 of any attachments not recommended or sold by x...
Page 9: Batteries
Safety 975-0401-01-01 vii 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 unit in the vicinity of the battery, that you read this manual and follow t...
Page 10
Safety viii 975-0401-01-01 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. Never smoke or allow a spark or flame near the en...
Page 11
Safety 975-0401-01-01 ix 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; gases from a battery will corrode and damage the cha...
Page 12: Fcc Information to The User
Safety x 975-0401-01-01 fcc information to the user this equipment has been tested and found to comply with the limits for a class b digital device, pursuant to part 15 of the fcc rules. These limits are designed to provide reasonable protection against harmful interference in a residential installa...
Page 13: Introduction
Xi important safety instructions - - - - - - - - - - - - - - - - - - - - v 1 introduction truecharge™ 2 battery charger - - - - - - - - - - - - - - - - - - - - - 1–1 standard and protection features - - - - - - - - - - - - - - - - - - - - 1–2 truecharge™ 2 battery charger - - - - - - - - - - - - - -...
Page 14: Troubleshooting
Contents xii 975-0401-01-01 3 troubleshooting care and maintenance- - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2 indicator leds on the onboard display panel and optional remote panel - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4 replacing the dc output fuse - - - - - - - - -...
Page 15: Introduction
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 optional remote panel. Truecharge™ 2 battery charger ...
Page 16
Introduction 1–2 975-0401-01-01 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 charging voltage for your batteries when connect...
Page 17
Standard and protection features 975-0401-01-01 1–3 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 protection shutdown • ambient over temperature protec...
Page 18
Introduction 1–4 975-0401-01-01 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 simply onboard display (see “rear panel” on page 1–6 ...
Page 19
Truecharge™ 2 battery charger 975-0401-01-01 1–5 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 wiring compartment, to allow for a trouble free insta...
Page 20: Rear Panel
Introduction 1–6 975-0401-01-01 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 communication port - remote panel port 3 battery posi...
Page 21: Important:
Rear panel 975-0401-01-01 1–7 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 multiple outputs, positive bank 1 must be utilized. Byp...
Page 22: Important:
Introduction 1–8 975-0401-01-01 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 power is not present, the panel’s led control and ...
Page 23
Onboard control and status display panel 975-0401-01-01 1–9 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 numbers below the leds represent the percentage ...
Page 24
Introduction 1–10 975-0401-01-01 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 warning is represented by a thermometer icon. T...
Page 25: Important:
Onboard control and status display panel 975-0401-01-01 1–11 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 truecharge™ 2 battery charger installation guide (d...
Page 26
Introduction 1–12 975-0401-01-01 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 fault (>16.6v) high charger temp warning (>50°c) h...
Page 27
Onboard control and status display panel 975-0401-01-01 1–13 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 fan ac battery fuse charger remote fault f u s ...
Page 28
Introduction 1–14 975-0401-01-01 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 35 45 55 65 70 °c tc2 series battchg owners guid...
Page 29: Important:
Remote panel (sold separately) 975-0401-01-01 1–15 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 communications cable up to 15 m (50 ft) from the tr...
Page 30
Introduction 1–16 975-0401-01-01 • 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 cycle • display faults and warnings • display basi...
Page 31
Remote panel (sold separately) 975-0401-01-01 1–17 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 that batteries are fully charged and in float st...
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1–18 tc2 series battchg owners guide.Book page 18 tuesday, july 1, 2008 11:55 pm.
Page 33: Operation
2 operation chapter 2 describes the operating states and provides procedures for charging a battery and performing an equalization. It covers the following: • “about truecharge™ 2 battery charger” on page 2–2 • “charging batteries” on page 2–8 • “equalizing flooded batteries” on page 2–10 • “transit...
Page 34: Important:
Operation 2–2 975-0401-01-01 about truecharge™ 2 battery charger most truecharge™ 2 battery charger models have three outputs that share the full rated current enabling it to charge three different batteries or battery banks that either have the same chemistry or can tolerate the same charge sequenc...
Page 35: Three-Stage Charging
About truecharge™ 2 battery charger 975-0401-01-01 2–3 three-stage charging the three-stage charging mode employs the following sequence: bulk, absorption, and float. During the bulk stage the batteries are accepting a constant maximum current. In the absorption stage, the battery voltage is held co...
Page 36: Two-Stage Charging
Operation 2–4 975-0401-01-01 two-stage charging the two-stage charging mode employs the following sequence: bulk and absorption. It runs similar to the three- stage sequence except that there is no float stage; after the absorption stage the charger stops providing voltage and current to the battery...
Page 37: Charging Voltage Setpoints
About truecharge™ 2 battery charger 975-0401-01-01 2–5 charging voltage setpoints the truecharge™ 2 battery charger charging process enables the battery or battery banks to reach the following voltage setpoints. Table 2-1 charging maximum voltages for 12 v chargers battery type bulk/ absorption (vol...
Page 38: Charging Overview
Operation 2–6 975-0401-01-01 charging overview the truecharge™ 2 battery charger will perform a battery qualification on each application of ac, to determine if battery banks are present and healthy. To force a battery detection sequence, 1. Turn off ac. 2. Wait approximately 20 seconds or until all...
Page 39: Important:
About truecharge™ 2 battery charger 975-0401-01-01 2–7 temperature considerations xantrex strongly recommends that you purchase and install the optional battery temperature sensor (bts) to protect your battery and improve charging accuracy. Attach the bts to the warmest battery. If no bts is connect...
Page 40: Charging Batteries
Operation 2–8 975-0401-01-01 charging batteries before you start to charge batteries read the “important safety instructions” on page v and follow all safety precautions when working with batteries. To charge your batteries: 1. If possible, disconnect all loads from the battery, by opening disconnec...
Page 41
Charging batteries 975-0401-01-01 2–9 the batteries can be in one of eight different modes which will be indicated on the onboard display in the charger status leds: after charging is complete, the truecharge™ 2 battery charger enters into one of these modes: float mode when the ready and charging i...
Page 42: Equalizing Flooded Batteries
Operation 2–10 975-0401-01-01 equalizing flooded batteries about equalization in the following conditions the truecharge™ 2 battery charger will not enter equalization mode: • the battery type is set to gel or agm • any battery is not fully charged (all three battery banks must be charged to float o...
Page 43: Performing An Equalization
Equalizing flooded batteries 975-0401-01-01 2–11 performing an equalization to equalize your batteries: 1. Check the battery electrolyte level. If necessary, refill with distilled water only. All the cells should have similar electrolyte levels. If the levels are widely different, it will influence ...
Page 44: Important:
Operation 2–12 975-0401-01-01 3. Press and hold for five seconds the charger mode select button and battery temp select button at the same time to put the truecharge™ 2 battery charger into equalization mode. When the charger is performing the equalization, the equalize led illuminates as a solid li...
Page 45: Warning: Shock Hazard
Transitioning the truecharge™ 2 battery charger to on, standby, or disabled 975-0401-01-01 2–13 transitioning the truecharge™ 2 battery charger to on, standby, or disabled there are two ways to turn on the truecharge™ 2 battery charger: • connect the batteries to the charger (i.E., charger is on sta...
Page 46
Operation 2–14 975-0401-01-01 accessing charger information the truecharge™ 2 battery charger provides a lot of information about the status of the charger and the batteries. Reading remote panel and onboard display leds the remote panel and onboard display panel show what is happening during the ch...
Page 47
Accessing charger information 975-0401-01-01 2–15 reporting without ac power or while on standby if ac power has been disconnected or if you have used the optional remote panel to place the truecharge™ 2 battery charger on standby mode, the onboard display (and the optional remote panel, if installe...
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2–16 tc2 series battchg owners guide.Book page 16 tuesday, july 1, 2008 11:55 pm.
Page 49: Troubleshooting
3 troubleshooting chapter 3 contains information and procedures for troubleshooting your truecharge™ 2 battery charger. Tc2 series battchg owners guide.Book page 1 tuesday, july 1, 2008 11:55 pm.
Page 50: Care And Maintenance
Troubleshooting 3–2 975-0401-01-01 care and maintenance the truecharge™ 2 battery charger contains solid-state electronic components that require no maintenance. The best care you can give the charger is to protect it from contact with liquids, spray, or fumes which may cause corrosion and by keepin...
Page 51: Caution: Battery Damage
Care and maintenance 975-0401-01-01 3–3 4. To remove any stubborn residue, sprinkle baking soda directly on the area, scrub with a wet toothbrush (or other soft-bristle brush), add water as required, and then rinse. 5. Reconnect the positive battery cable terminals to the battery lugs and tighten. 6...
Page 52
Troubleshooting 3–4 975-0401-01-01 indicator leds on the onboard display panel and optional remote panel all indicator leds on the onboard display panel (and the optional remote panel, if installed) will illuminate for one second when ac (or dc) power is supplied to the truecharge™ 2 battery charger...
Page 53
Indicator leds on the onboard display panel and optional remote panel 975-0401-01-01 3–5 table 3-1 interpreting fault and warning indicators fault or warning condition temp fan ac battery fuse charger remote fault solution high battery temp warning (>50°c) • check the batteries. Do not charge a batt...
Page 54
Troubleshooting 3–6 975-0401-01-01 high battery temp fault (>70°c) • check the batteries. Do not charge a battery that is rated other than 12 v nominal for all 12 v chargers or 24 v nominal for all 24 v chargers. Check that the battery type and temperature settings match the actual battery and its c...
Page 55
Indicator leds on the onboard display panel and optional remote panel 975-0401-01-01 3–7 low battery temp fault ( • check the batteries. Do not charge a frozen battery. Charging a frozen battery may present a risk of explosion. Check that the battery type and temperature settings match the actual ba...
Page 56
Troubleshooting 3–8 975-0401-01-01 high battery voltage fault (>16.6v) • discontinue or disconnect ac power source from supplying power to the charger. • disconnect voltage sensitive dc loads from dc supply to prevent damage. • if the dc bus voltage is still measuring high after ac power has been di...
Page 57
Indicator leds on the onboard display panel and optional remote panel 975-0401-01-01 3–9 locked fan fault • check for anything impeding the fan located between the dc output terminals and ac wiring cavity. Safely remove any obstructions when the charger is off. • no further action required. The fan ...
Page 58
Troubleshooting 3–10 975-0401-01-01 table 3-2 charger status led sequences on the truecharge™ 2 battery charger charger status led activity charger status ready led illuminates solid the charger is in rest mode of two- stage charging. All batteries have been fully charged. Ready and charging leds il...
Page 59: Replacing The Dc Output Fuse
Replacing the dc output fuse 975-0401-01-01 3–11 replacing the dc output fuse to replace the dc output fuse: 1. Disconnect all ac and dc sources to the charger. 2. Locate the fuse cover on the charger’s top panel (see figure 1-1, “truecharge™ 2 battery charger” on page 1–4). 3. Loosen the screw on t...
Page 60: Troubleshooting
Troubleshooting 3–12 975-0401-01-01 troubleshooting in the event that you have a problem with your truecharge™ 2 battery charger, the following tables will help you to identify the problem and offer possible solutions to the problem. Symptom indicator leds do not illuminate when charger is connected...
Page 61
Troubleshooting 975-0401-01-01 3–13 symptom fault indicator led illuminates. Temp and battery indicator leds flash. Symptom truecharge™ 2 battery charger completes a charging cycle, but the battery voltage seems too low. Possible cause solution battery temperature is either too hot or too cold for s...
Page 62
Troubleshooting 3–14 975-0401-01-01 symptom the truecharge™ 2 battery charger appears to be taking too long to charge battery. Ready indicator led does not illuminate after 24 hours of charging. Symptom the truecharge™ 2 battery charger appears to have quickly charged the battery. Ready indicator le...
Page 63
Troubleshooting 975-0401-01-01 3–15 symptom the truecharge™ 2 battery charger will not transition to equalization mode. Possible cause solution battery is the wrong type, or set to the wrong type to equalize. Not all batteries are fully charged. An active fault is present on the bank you are attempt...
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3–16 tc2 series battchg owners guide.Book page 16 tuesday, july 1, 2008 11:55 pm.
Page 65: Specifications
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 owners guide.Book page 1 tuesday, july 1, 2008 11:55 pm.
Page 66: Physical Specifications
Specifications a–2 975-0401-01-01 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 (13.78 × 6.70 × 2.76 in.) tc1524, tc2024: 250 × 170 ×...
Page 67: Electrical Specifications
Electrical specifications 975-0401-01-01 a–3 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 nominal battery voltage 12 v units:12 vdc 24 v units...
Page 68
Specifications a–4 975-0401-01-01 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 ±6% equalize mode— maximum output voltage 12 v un...
Page 69: Ac Input Specifications
Ac input specifications 975-0401-01-01 a–5 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 vac tc1012: 2.5 a tc1012: 1.5 a tc1512: 3.5 a tc15...
Page 70: Dc Output Specifications
Specifications a–6 975-0401-01-01 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 units: 16 vdc 24 v units: 32 vdc voltage accuracy...
Page 71: Protection Features
Protection features 975-0401-01-01 a–7 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. Output current limit tc1012: 10 ±10% a tc1512:...
Page 72: Approvals
Specifications a–8 975-0401-01-01 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 battery chargers, including australian deviations i...
Page 73: Warranty and Return
975-0401-01-01 wa–1 warranty and return information warranty what does this warranty cover and how long does it last? This limited warranty is provided by xantrex technology inc. ("xantrex") and covers defects in workmanship and materials in your xantrex™ truecharge™ 2 series battery charger. This w...
Page 74
Warranty and return wa–2 975-0401-01-01 xantrex covers both parts and labor necessary to repair the product, and return shipment to the customer via a xantrex-selected non-expedited surface freight within the contiguous united states and canada. Alaska, hawaii and outside of the united states and ca...
Page 75: Disclaimer
Warranty and return 975-0401-01-01 wa–3 b) the product if it has been subjected to fire, water, generalized corrosion, biological infestations, or input voltage that creates operating conditions beyond the maximum or minimum limits listed in the xantrex product specifications including, but not limi...
Page 76: Return Procedure
Warranty and return wa–4 975-0401-01-01 warranty directive 1999/44/ ec and as such directive has been implemented in the e uropean u nion member state where you purchased the product . F urther , while this limited warranty gives you specific legal rights , you may have other rights which may vary f...
Page 77: Out of Warranty Service
Warranty and return 975-0401-01-01 wa–5 if you are returning a product to a xantrex authorized service center (asc) a xantrex return material authorization (rma) number is not required. However, you must contact the asc prior to returning the product or presenting the unit to verify any return proce...
Page 78
Warranty and return wa–6 975-0401-01-01 information about your system as soon as you open your xantrex™ truecharge™ 2 series battery charger package, record the following information and be sure to keep your proof of purchase. If you need to contact customer service, please record the following deta...
Page 79
Tc2 series battchg owners guide.Book page 7 tuesday, july 1, 2008 11:55 pm.
Page 80: 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 975-0401-01-01 printed in china tc2 series battchg owners guide.Book page 8 tuesday, july 1, 200...