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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 2.
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This guide for use by qualified installers only Truecharge ™ 2 Series Battery Chargers Installation Guide.
This guide for use by qualified installers only About Xantrex Xantrex T echnology Inc. is a world-leading supplie r of advanced power electronics and controls with products ranging from small mobile u.
iii This guide for use by qualified installers only About This Guide Purpose The purpose of this Instal lation Guide is to provide explanations and procedu res for installing and configuring the T r ue charge™ 2 Series Battery Charger.
About T his Guide iv 975-0402-01-01 This guide for use by qualified installers only Organization This Guide is organized into two chapters and one appendix. Chapter 1 describes the standard features of a T ruecharge™ 2 Battery Charger , as well as its protection features.
About T his Guide 975-0402-01-01 v This guide for use by qualified installers only The 24 Vdc models are: TC1524, TC2024, TC3 024, and TC5024. When bein g referred to individually , the produc t will be referred to by its model name. When all models are being referre d to, they will be referred to as T ruechar ge™ 2 Battery Char gers.
vi This guide for use by qualified installers only.
vii This guide for use by qua lified installers only Important Safety Instructions R EAD AND SAVE THIS I NSTALLATION G UIDE FOR FUTURE REFERENCE . This chapter contains import ant safety , installatio n, and operating instructio n s for the T ruecharge™ 2 Series Battery Chargers.
Safety viii 975-0402-01-01 This guide for use by qua lified installers only 4. T o avoid a risk of fire and electric shock, make sure that all wiring is in good condition and is not un dersized. Do not operate the T ruecharge™ 2 Battery Charger with damaged or substandard wiri ng.
Safety 975-0402-01-01 ix This guide for use by qua lified installers only 9. W orking in the vicinity of lead-acid batteries is dangerous. Batteries ge nerate explosive gase s du ring normal operation. Therefo re, it is of utmost importance that you read this manual and follow the instructions exactly each time you use the charger .
Safety x 975-0402-01-01 This guide for use by qua lified installers only 4. If battery acid contacts skin or clothing, wash immediately with soap and wate r . If acid enters your ey e, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately .
Safety 975-0402-01-01 xi This guide for use by qua lified installers only 14. For flooded non-sealed batte ries, add distilled water in each cell until battery acid re aches the level specified by the battery manufacturer . This helps to purge excessive gas from cells.
Safety xii 975-0402-01-01 This guide for use by qua lified installers only FCC Information to the User This equipment has been tested and found to comply with the limits for a Class B digital device , pursuant to part 15 of the FCC Rules.
xiii This guide for use by qua lified installers only Important Safety Instructions - - - - - - - - - - - - - - - - - - - vii 1 Introduction Truecharge™ 2 Battery Charger - - - - - - - - - - - - - -.
Contents xiv 975-0402-01-01 This guide for use by qua lified installers only Configuring the Truecharge™ 2 Battery Charger- - - - - - - - - - 2–27 Configuring the Charger Mo de - - - - - - - - - -.
This guide for use by qua lified installers only 1 Intr oduction Chapter 1 describes the standard features of a T ruecharge™ 2 Battery Ch ar ger, as well as its protection features. It also provides information on the different parts of the T ruechar ge™ 2 Battery Charger.
Introduction 1–2 975-0402-01-01 This guide for use by qua lified installers only Standard and Pr otection Featur es The T ruecharge™ 2 Battery Charger provides the following standard features: •.
Standard and Protection F eatures 975-0402-01-01 1–3 This guide for use by qua lified installers only • short circuit protectio n for the BTS and communicatio n connector ports including protectio.
Introduction 1–4 975-0402-01-01 This guide for use by qua lified installers only T ruecharge™ 2 Battery Char ger This section describes the diff erent parts of the T ruecharge™ 2 Battery Charger.
T ruecharge™ 2 Bat tery Charger 975-0402-01-01 1–5 This guide for use by qua lified installers only 4 Fuse access panel cover provides access to the DC fuse in the event of an accidental reverse battery polarity installation. Disconnect the batteries and AC power before openin g the fuse access panel.
Introduction 1–6 975-0402-01-01 This guide for use by qua lified installers only Rear P anel This section describes the part s of the rear panel of the T ruecharge™ 2 Battery Charger.
Rear P anel 975-0402-01-01 1–7 This guide for use by qua lified installers only Please see the T ruecharge™ 2 Batte r y Charger Owner ’ s Guide (doc. p art nu mber: 975- 0401-01-01) for information on the following: 1. Onboard Control and Status Display Pa nel 2.
1–8 This guide for use by qua lified installers only.
This guide for use by qua lified installers only 2 Installation Chapter 2 provides procedures for installing, testing and configuring the T ruecharge™ 2 Battery Char ger. It covers the following major topics: • “Preparing for Installation” on page 2–2.
Installation 2–2 975-0402-01-01 This guide for use by qua lified installers only Preparing for Installation The T ruecharge™ 2 Battery Ch ar ger is designed to be permanently mounted . Figure 2- 1 shows a typical installati on with three batteries, a battery temperature sensor (BTS) and a remote panel (both optional).
Preparing for Installation 975-0402-01-01 2–3 This guide for use by qua lified installers only Figure 2-1 T ypical T r uecharge™ 2 Battery Charger System Installation 1 AC mains source protected b.
Installation 2–4 975-0402-01-01 This guide for use by qua lified installers only T ools and Materials T o mount and connect th e T ruecharge™ 2 Battery Charger you nee d the following tools : • .
Preparing for Installation 975-0402-01-01 2–5 This guide for use by qua lified installers only Location Install the T ruecharge™ 2 Battery Charger in a location that meets the following requiremen.
Installation 2–6 975-0402-01-01 This guide for use by qua lified installers only When planning to install the T ruecharge™ 2 Battery Char ger, be sure that you conside r the location and orientation carefully .
Preparing for Installation 975-0402-01-01 2–7 This guide for use by qua lified installers only Figure 2-2 T ruecharge™ 2 Battery Char ger Mounting Orientations Figure 2-3 V entilation Clearance Deck Mount - this orientation meets IP-32 requirements and is drip-proo f.
Installation 2–8 975-0402-01-01 This guide for use by qua lified installers only Wi r i ng R e q u i re m e n t s DC Wiring The following two tables show some typical wire sizes for various cable le.
Preparing for Installation 975-0402-01-01 2–9 This guide for use by qua lified installers only Over -current protection discon nect Electrical codes require the DC circuit from each battery to the char ger to be equipped w ith a disconnect and an over- current protection device, usual ly within 7 inches (17.
Installation 2–10 975-0402-01-01 This guide for use by qua lified installers only The DC chassis ground (earth) wire should also be size d correctly to provide proper protection. Refer to the local electrical codes for your spec ific installation to determine the correct gauge.
Preparing for Installation 975-0402-01-01 2–11 This guide for use by qua lified installers only a minimum of 75C, and si zed based on the AC in put current to the char ger (see Appendix A) and on the value o f overcurrent protection provi ded.
Installation 2–12 975-0402-01-01 This guide for use by qua lified installers only Battery Bank Size Requirements The T ruechar ge™ 2 Battery Charge r is designed to work with a minimum battery bank size. Each bank sho uld meet the minimum Ah rating shown in T able 2-4.
Installing the T ruecharge™ 2 Battery Charger 975-0402-01-01 2–13 This guide for use by qua lified installers only Installing the T ruecharge™ 2 Battery Charger Installation Sequence T o make charger installation quick and easy , Xantrex recommends that the installatio n tasks be performed in the following sequence: 1.
Installation 2–14 975-0402-01-01 This guide for use by qua lified installers only Mounting the T ruecharge™ 2 Battery Char ger Mount the T ruecharge™ 2 Battery Charger using all four mounting slots and hol es which are provided .
Installing the T ruecharge™ 2 Battery Charger 975-0402-01-01 2–15 This guide for use by qua lified installers only Connecting the DC Chas sis Ground (Earth) The T ruecharge™ 2 Battery Charger Ba.
Installation 2–16 975-0402-01-01 This guide for use by qua lified installers only Installing DC Wiring The procedure for installing the DC wiring applies to a single battery , as well as multiple batteries or battery banks. 1. Plan the route that the DC wires will follow , keeping it as short as possible.
Installing the T ruecharge™ 2 Battery Charger 975-0402-01-01 2–17 This guide for use by qua lified installers only 5. Insert and slide the rubber bo ot(s) over the charger end of the DC battery cables. 6. Install crimp lugs on the ch arger end of the DC battery cables using the crimp manu facturer ’ s instructions and tool.
Installation 2–18 975-0402-01-01 This guide for use by qua lified installers only 7. Connect the negative cable to the negative DC terminal. See Figure 2-1, “T ypical Truechar ge™ 2 Battery Charger System Installation” on page 2–3.
Installing the T ruecharge™ 2 Battery Charger 975-0402-01-01 2–19 This guide for use by qua lified installers only 13. Secure cables in place usin g tie-wraps or cable straps according to electrical codes. 14. Slide the rubber bo ots to cover the DC terminals.
Installation 2–20 975-0402-01-01 This guide for use by qua lified installers only Installing A C Wiring Before connecting AC wiring, make sure the AC source circuit is protected by a breaker switch of the correct size and type, to comply with the electrical code for your location and application.
Installing the T ruecharge™ 2 Battery Charger 975-0402-01-01 2–21 This guide for use by qua lified installers only 5. Carefully remove 50 – 75 mm (2 – 3 in.) of the outer jacket from the AC supply wi ring, being careful not to cut or nick the insulation on the individual cond uctors.
Installation 2–22 975-0402-01-01 This guide for use by qua lified installers only T o connect AC wires with the provided crimp-on butt-splice connecto r: a) Make the connections using the provided crimp-on connectors 1 or with other approv ed connectors required by your code, an d suitable for your installation.
Installing the T ruecharge™ 2 Battery Charger 975-0402-01-01 2–23 This guide for use by qua lified installers only 10. When all conne ctions are comp leted, push the wiring and connectors inside the AC wiring compartment. 1 1. Place the strain relief on the AC wiring access hole.
Installation 2–24 975-0402-01-01 This guide for use by qua lified installers only Po w e r i n g U p Make one last check that all connections are correct and connectors are secure. The T r ue charge™ 2 Battery Charger charger may now be powered up.
Installing Optional Accessories 975-0402-01-01 2–25 This guide for use by qua lified installers only Installing Optional Accessories Optional accessories are available for purchase at Xantrex.
Installation 2–26 975-0402-01-01 This guide for use by qua lified installers only Mounting the Optional Remote P anel T o mount the remote panel: 1. Choose a location for the remo te panel that is within 15 m (50 ft.) from the charger . Use only the six-conductor commun ications cable (RJ-12) that came with the remote panel.
Configuring the T ruecharge™ 2 Bat tery Charger 975-0402-01-01 2–27 This guide for use by qua lified installers only Configuring the T r uecharge™ 2 Battery Charger Once the charger is connected to a battery on bank 1 or to AC, it is live and it may be c onfigured .
Installation 2–28 975-0402-01-01 This guide for use by qua lified installers only Using the Remote Panel T o configure the ch arger mode: Note: By defau lt, the Cha rger Mode is set to three-stage. 1. Press and hold the Status butto n for five seconds to e nter the Setup mode.
Configuring the T ruecharge™ 2 Bat tery Charger 975-0402-01-01 2–29 This guide for use by qua lified installers only Configuring the Battery Bank T ype Using the Onboard Display Panel T o configure the battery bank type: Note: By default, the battery ty pe is set to Flooded.
Installation 2–30 975-0402-01-01 This guide for use by qua lified installers only Configuring the Maximum Output Current Pe r c e n t a g e Advantages of Current Limiting Feature: • Gives the user flexibility to custom char ge according to the battery manufact urer ’ s instructions.
Installing Batteries 975-0402-01-01 2–31 This guide for use by qua lified installers only Installing Batteries Replacing old or defective batteries (even in stalling new batteries) requires that you disc onne ct all AC and DC sources prior to installation.
2–32 This guide for use by qua lified installers only.
This guide for use by qua lified installers only A Specifications Appendix A contains physical , electrical performance, and regulatory approval specifications for the T ruecharge™ 2 Battery Char ger. Note: Specifications are subject to change without notice.
Specifications A–2 975-0402-01-01 This guide for use by qua lified installers only Physical Specifications Base Un it Dimensions: L × W × H TC1012, TC1512: 200 × 170 × 70mm (7.87 × 6.70 × 2.76 in.) TC2012, TC3012, TC4012: 250 × 170 × 70mm (9.
Electrical Specifications 975-0402-01-01 A–3 This guide for use by qua lified installers only Electrical Specifications A C Input Specifications AC input voltage range Nominal: 120 V ac, 230 V ac, 2.
Specifications A–4 975-0402-01-01 This guide for use by qua lified installers only DC Output Specifications Number of isolated battery bank outputs TC1012 : 1 output TC1512: 2 separated outputs TC20.
Environmental Specifications 975-0402-01-01 A–5 This guide for use by qua lified installers only Environmental Specifications Absorption voltage: ±0.1 V for 12 Vdc units ±0.2 V for 24 Vdc units 12 Vdc un its 24 V dc units 2 5° C ( 7 7° F ) 2 5° C ( 7 7° F ) Flooded 14.
Specifications A–6 975-0402-01-01 This guide for use by qua lified installers only Protection F eatures Battery reverse polarity Protected by replaceable DC output fuses Over-voltage limits The T ruecharge™ 2 Battery Charger will stop charging if the output voltage is above 16.
Approvals 975-0402-01-01 A–7 This guide for use by qua lified installers only Approvals Safety NR TL approved to CSA E60335-2-29, UL1236, including the marine supplement, ignit ion protection, and U.
A–8 This guide for use by qua lified installers only.
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Xantrex Technology Inc. 1 800 670 0707 Tel toll free NA 1 408 987 6030 Tel direct +34 93 470 5330 Europe 1 800 994 7828 Fax toll free NA +34 93 473 6093 Europe customerservice@xantrex.
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