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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.
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.
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.
v Important Safety Instructions Explosive gas precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–x Precautions When Working With Batteries - - - - - - - - - - - .
Contents vi Connecting to AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11 Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -.
Contents vii Maintenance Guidelines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2 Preparation for Cleaning Batteries - - - - - - - - - - - - - - - - - - - - - - - -.
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 .
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.
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.
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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.
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.
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.
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 + fron.
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.
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.
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 ca.
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 .
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 .
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.
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.
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.
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.
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.
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.
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).
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.
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 .
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.
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.
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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 gin.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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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.
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.
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.
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 resta.
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.
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.
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 .
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 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.
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.
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+.
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.
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 PERM.
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 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.
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.
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-cor.
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 Cust.
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, mainten.
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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.
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