TC2 204060 Series BattChg Owners Guide.book Page i Friday, July 8, 2011 11:44 AM
TM
TM
Owner’s Guide
Series Battery Charger
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Trademarks
Product Numbers
Non-IEC Models
IECa Models
Xantrex, Truecharge, and Smart choice for power are trademarks of Schneider
Electric Services International sprl, registered in the U.S. and other countries. Other
trademarks, registered trademarks, and product names are the property of their
respective owners and are used herein for identification purposes only.
804-1220-02,
804-1240-02,
804-1260-02,
804-2410,
804-2420,
804-2430
804-1220-03,
804-1240-03,
804-1260-03
804-2410-01,
804-2420-01,
804-2430-01
Notice of Copyright
Truecharge2 Series Battery Charger Owner’s Guide © August 2011 Xantrex
Technology USA Inc. All rights reserved. No part of this document may be
reproduced in any form or disclosed to third parties without the express written
consent of: Xantrex Technology USA Inc., 541 Roske Drive, Suite A, Elkhart,
Indiana USA 46516. Xantrex Technology USA Inc. reserves the right to revise this
document and to periodically make changes to the content hereof without obligation
or organization of such revisions or changes unless required to do so by prior
arrangement.
a.IEC refers to the international standard from the International
Electrotechnical Commission for "plugs, socket-outlets and cou-
plers for industrial purposes". IEC models have an AC input recep-
tacle that connects with an IEC cable (not provided).
Contact Information
Exclusion for Documentation
Telephone:
1 800 670 0707
1 800 994 7828
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY USA INC. (“XANTREX”)
(A) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY
TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION;
(B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES,
WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE
OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY
AT THE USER’S RISK; AND
Fax:
Web:
(C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH,
ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE
ACCURACY CANNOT BE GUARANTEED. APPROVED XANTREX CONTENT IS CONTAINED WITH THE
ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW.XANTREX.COM.
Date and Revision
August 2011 Rev C
Document Part Number
975-0526-01-02
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About This Guide
Purpose
Conventions Used
The following conventions are used in this guide.
The purpose of this Owner’s Guide is to provide explanations and
procedures for installing, troubleshooting, operating and maintaining the
Truecharge2 Series Battery Charger.
Scope
STATEMENT OF HAZARD
The Guide provides safety and operating guidelines, procedures for
installing the battery charger, as well as information on configuring the
battery charger. It also provides information about troubleshooting the unit.
It does not provide details about particular brands of batteries. You need to
consult individual battery manufacturers for this information.
Contains statements of avoidance or strict compliance.
Failure to follow these instructions will result in death or serious
injury.
Audience
The Guide is intended for users and operators of the Truecharge2 Series
Battery Charger. The Installation section is primarily intended for qualified
installers who need to install and configure any unit model of the
Truecharge2 Series Battery Charger. The installer should have knowledge
and experience in installing electrical equipment, knowledge of the
applicable installation codes, and awareness of the hazards involved in
performing electrical work and how to reduce those hazards. A qualified
technician or electrician has this knowledge and experience.
STATEMENT OF HAZARD
Contains statements of avoidance or strict compliance.
Failure to follow these instructions can result in death or serious
injury.
STATEMENT OF HAZARD
Contains statements of avoidance or strict compliance.
Failure to follow these instructions can result in minor or moderate
injury.
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STATEMENT OF HAZARD
Contains statements of avoidance or strict compliance.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
IMPORTANT: These notes describe things which are important for you to
know, however, they are not as serious as a danger, warning, or caution.
Related Information
You can find more information about Xantrex Technology USA Inc. as well
The product marking on the left when found imprinted on
electrical and electronic units and appliances means that you
are to refer to this guide for cautions and warnings.
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Important Safety Instructions
IMPORTANT: READ AND SAVE THIS OWNER’S GUIDE FOR FUTURE
REFERENCE.
ELECTRICAL SHOCK HAZARD
•
Do not expose the Truecharge2 Battery Charger to rain, snow, spray,
This chapter contains important safety and installation instructions for the
Truecharge2 Series Battery Chargers. Each time, before using the
Truecharge2 Series Battery Charger, READ ALL instructions and
cautionary markings on or provided with the battery charger, the batteries,
and all appropriate sections of this guide.
or bilge water.
•
Do not operate the battery charger if it has received a sharp blow,
been dropped, has cracks or openings in the enclosure including if the
fuse cover has been lost, damaged, or will not close, or otherwise
damaged in any other way.
•
•
Do not disassemble the battery charger. Internal capacitors remain
charged after all power is disconnected.
Disconnect both AC and DC power from the battery charger before
attempting any maintenance or cleaning or working on any circuits
connected to the battery charger. See note below.
Do not operate the battery charger with damaged or substandard
wiring. Make sure that all wiring is in good condition and is not
NOTE: The Truecharge2 Series Battery Charger contains no user-
serviceable parts with the exception of the DC output fuse(s) which are
instructions. For obtaining service other than replacing the fuse, see
•
NOTE: The Truecharge2 Series Battery Charger must be provided with
equipment-grounding conductors connected to the AC input ground and to
the DC chassis ground. See “Step 2: Connecting the DC Chassis Ground
(Earth)” on page 17 for instructions.
Failure to follow these instructions will result in death or serious
injury.
NOTE: Turning off the battery charger using the on/standby button on the
optional remote panel will not reduce an electrical shock hazard.
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FIRE AND BURN HAZARD
PERSONAL INJURY HAZARD
Do not cover or obstruct the air intake vent openings and/or install in a
zero-clearance compartment. See “Location” on page 10 for proper
location requirements.
This battery charger is not intended for use by persons (including
children) with reduced physical, sensory, or mental capabilities or lack of
experience and knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person responsible for
their safety. Children should be supervised to ensure that they do not play
with the battery charger.
Failure to follow these instructions will result in death or serious
injury.
Failure to follow these instructions can result in death or serious
injury.
EXPLOSION HAZARD
•
Charge only properly rated (such as 12 V and 24 V) lead-acid (GEL,
AGM, Flooded, or lead-calcium) rechargeable batteries because other
battery types may explode and burst.
•
Do not work in the vicinity of lead-acid batteries. Batteries generate
explosive gases during normal operation. See note below.
Failure to follow these instructions will result in death or serious
injury.
NOTE: Follow these instructions and those published by the battery
manufacturer and the manufacturer of any equipment you intend to use in
the vicinity of the battery. Review cautionary markings on these products
and on the engine.
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Precautions When Working With Batteries
5. Use extra caution to reduce the risk or dropping a metal tool on the
battery. It could spark or short circuit the battery or other electrical
parts and could cause an explosion.
BURN FROM HIGH SHORT-CIRCUIT CURRENT, FIRE AND EXPLO-
SION FROM VENTED GASES HAZARDS
6. Batteries can produce a short circuit current high enough to weld a ring
or metal bracelet or the like to the battery terminal, causing a severe
burn.
•
Always wear proper, non-absorbent gloves, complete eye protection,
and clothing protection. Avoid touching your eyes and wiping your
forehead while working near batteries. See note #4.
7. When removing a battery, always remove the negative terminal from
the battery first for systems with grounded negative. If it is grounded
positive, remove the positive terminal first. Make sure all loads
connected to the battery and all accessories are off so you don’t cause
an arc.
•
Remove all personal metal items, like rings, bracelets, and watches
when working with batteries. See notes #5 and #6.
•
•
Never smoke or allow a spark or flame near the engine or batteries.
Never charge a frozen battery.
Failure to follow these instructions can result in death or serious
injury.
NOTES:
1. Locate the Truecharge2 Series Battery Charger unit away from
batteries in a well ventilated compartment.
2. Always have someone within range of your voice or close enough to
come to your aid when you work near a lead-acid battery.
3. Always have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing, or eyes.
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.
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Precautions When Preparing to Charge
Precautions When Placing the Battery Charger
RISK OF DAMAGE TO THE BATTERY CHARGER
EXPOSURE TO CHEMICALS AND GASES HAZARD
•
Never allow battery acid to drip on the battery charger when reading
gravity, or filling battery.
•
Make sure the area around the battery is well ventilated.
Make sure the voltage of the batteries matches the output voltage of
the battery charger.
•
•
Never place the Truecharge2 Series Battery Charger unit directly
above batteries; gases from a battery will corrode and damage the
charger.
•
Be careful to keep corrosion from coming into contact with your eyes
and skin when cleaning battery terminals.
•
Do not place a battery on top of the battery charger.
Failure to follow these instructions can result in death or serious
injury.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
NOTES:
NOTE: For North American marine installations, external connections to the
charger shall comply with the United States Coast Guard Electrical
Regulations (33CFR183, Sub Part I).
1. Study and follow all of the battery manufacturer's specific precautions,
such as removing or not removing cell caps while charging, whether
equalization is acceptable for your battery, and recommended rates of
charge.
2. For flooded non-sealed batteries, add distilled water in each cell until
battery acid reaches the level specified by the battery manufacturer.
This helps to purge excessive gas from cells. Do not overfill. For a
battery without removable cell caps, carefully follow manufacturer's
instructions.
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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 installation. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to
radio or television reception, which can be determined by turning the
equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:
•
•
•
Reorient or relocate the receiving antenna.
Increase the separation between the equipment and receiver.
Connect the equipment into an outlet on a circuit different from that to
which the receiver is connected.
•
Consult the dealer or an experienced radio/TV technician for help.
Unauthorized changes or modifications to the equipment could void the
user’s authority to operate the equipment.
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Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Preparing For Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing the Truecharge 2 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Transitioning the Charger to ON, Standby, or Disabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Warranty and Return Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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Introduction
This chapter describes the standard features of a Truecharge2 Battery
Charger, as well as its protection features. It also provides information on
the different parts of the Truecharge2 Battery Charger.
Standard and Protection Features
The Truecharge2 Battery Charger provides the following standard features:
2
•
•
•
up to three full current rated outputs,
battery monitoring functions,
correct charging voltage for batteries when connected to almost any
single phase AC power outlet in the world,
Truecharge2 Battery Charger
The Truecharge2 Battery Charger ships with the following items:
•
•
•
•
•
•
one Truecharge2 Battery Charger unit,
owner’s guide,
rubber boots for DC terminals,
•
•
•
•
•
low electromagnetic interference (EMI),
automatic charge resumption, if required, after AC power interruption,
3
programmable custom charge settings ,
4
nuts and washers (M6) for DC terminals and ground stud,
fully discharged battery charging ,
1
strain relief clamp for AC input cables ,
ability to operate two Truecharge2 Battery Chargers in parallel mode
with the use of the optional remote panel.
1
three crimp connectors for AC wiring .
NOTE: Keep the carton and packing material in case you need to return
the Truecharge2 Battery Charger for servicing.
The Truecharge2 Battery Charger provides the following protection
features:
•
•
•
•
battery reverse polarity protection via user-replaceable output fuse(s),
AC input out-of-range derating and shutdown,
ambient over-temperature derating and shutdown,
battery over-charging protection,
2.Each output can charge different batteries that either have the same chemistry or can
tolerate the same charge sequence and voltage/current ratings.
3.The charger can be programmed with custom charge setpoints using PC interface.
This programming can only be done using a special configuration tool operated by
Xantrex or a designated OEM.
1.Not included with IEC models of Truecharge2 Battery Chargers.
4.The charger can initiate charging a non-damaged but zero voltage battery.
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Introduction
•
electronic current limiting provides protection against short circuit
conditions on the charger’s output,
The optional Battery Temperature Sensor (BTS) provides these protection
features:
•
•
•
ignition-protected rating, enabling installation in engine spaces,
isolated design,
•
•
•
battery under-temperature charging protection preventing battery
charging at -25 °C (-13 °F) or below,
battery over-temperature charging protection preventing battery
charging at 70 °C (158 °F) or higher, and
charging voltage compensation based on the temperature of the battery
the optional BTS is connected to.
short circuit protection for the BTS and communication connector
ports including protection from incorrectly inserting the remote panel
communication cable plug into the BTS port and vice versa,
drip-proof rubber boots for DC terminals for added moisture
protection,
•
•
1
IP-32 drip protection rating ,
The optional Remote Panel provides the following features:
4
•
Can be mounted up to 15 meters (50 feet) away for remote control
and monitoring,
The following optional accessories are available for the Truecharge2
Battery Charger:
•
maximum output current limiting for charging smaller capacity
batteries or to lower the current drawn from the generator or AC
source,
2
•
•
an optional battery temperature sensor (BTS) and
an optional remote panel .
3
•
•
•
ability to enable or disable the charger while AC power is connected,
ability to display individual battery bank levels, and
ability to operate two Truecharge2 Battery Chargers in parallel for
increased output current capacity.
1.In two specific installation orientations–see “Mounting Orientations (Deck and
Horizontal)” on page 11.
2.Part number: 808-0232-01
3.Part number: 808-8040-01
4.Remote panel comes standard with a 7.5-m (25-ft) cable. For longer [15-m (50-ft)]
cable, order part number 31-6262-00
2
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Truecharge 2 Battery Charger Features
This section describes the different parts of the Truecharge2 Battery
Charger.
Item
Description
1
Onboard control and status display panel or simply
onboard display (see “Onboard Control and Status Display
Panel” on page 5 for more information) for controlling the
Truecharge2 Battery Charger settings and for monitoring
charger status and charging current.
Front Panel
1
2
3
Mounting flanges are used to permanently install the product.
DC wiring compartment cover protects the DC terminals, as
well as the communication and BTS ports. Remove and
replace when installing cables.
2
ELECTRICAL SHOCK HAZARD
Disconnect the batteries and AC power before opening the fuse access
panel.
3
5
Failure to follow these instructions will result in death or serious
injury.
4
6
4
Fuse access panel cover provides access to the DC fuse in the
event of an accidental reverse battery polarity installation.
Remove and replace the cover when replacing a fuse or fuses.
Figure 1 Truecharge2 Battery Charger Front Panel
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Truecharge 2 Battery Charger Features
Item
Description
Item
Description
5
AC wiring compartment cover provides the installer with
easy access to the AC wiring compartment, to allow for a
trouble free installation. Remove and replace when installing
the product.
1
2
3
4
5
6
BTS port- battery temperature sensor port
Communication port - remote panel port
Battery positive (+) for bank 3 (6 mm stud)
Battery positive (+) for bank 2 (6 mm stud)
Battery positive (+) for bank 1 (6 mm stud)
6
DC ground stud for connecting the charger’s chassis to
ground.
Battery negative (–), common for all three banks (6 mm
stud)
Rear Panel
This section describes the parts of the rear panel of the Truecharge2 Battery
Charger.
7
8
9
Air vents - located inside is the fan assembly
AC wiring compartment
40 A model (TC4012)
shown. Other models
AC pigtail wiring - line, neutral, and ground input wires
3
4
7
may vary.
8
9
5
2
6
1
Figure 2 Truecharge2 Battery Charger Rear Panel
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Truecharge 2 Battery Charger Features
To reduce current draw from the connected battery when AC power is not
present, the panel’s LED control and status lights are automatically turned
off and the buttons are disabled.
Onboard Control and Status Display Panel
This section describes the parts of the onboard control and status display
panel of the Truecharge2 Battery Charger. See “Reading Onboard Display
LEDs” on page 41 for more information.
However, to temporarily check the status of the connected battery when AC
power is not present, press the Status button on the optional remote panel.
IMPORTANT: To prevent any unintentional changes in the setting, Select
panel buttons must be pressed and held down for three seconds to advance
to the next selection.
To set and cancel an equalization program, press and hold for five seconds
both the Charger Mode and Battery Temp. Select panel buttons.
Item Description
1
Charging Output (%) LEDs
•
The LEDs illuminate like a bar graph displaying the present
total output charge current as a percentage of the maximum
rated charge current. For example, unit model TC4012 has a
maximum rated charge current of 40 A so at 60% the
charger’s current output is 24 A. The numbers below the
LEDs represent the percentage values. See “Reading
1
2
3
NOTE: When the maximum Charge Output current is
limited via the optional remote panel, the LEDs will still
display the total charge output current as a percentage of the
maximum rated charge current and NOT as a percentage of
the limited charge current.
4
5
6
•
One or two LEDs may flash intermittently in combination
with a solid Fault LED (indicating a fault) or with a
flashing Fault LED (indicating a warning). The icons
above the LEDs represent the various types of fault and
warning conditions. See “Reading Onboard Display LEDs”
Figure 3 Onboard Control and Status Display Panel
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Truecharge 2 Battery Charger Features
Item Description
Item Description
4 Charger Mode Select button
2
Fault LED
The LED may illuminate a solid light (indicating a fault) or
flash intermittently (indicating a warning) in combination with
flashing Charging Output (%) LEDs. See “Interpreting Fault
and Warning Indicators” on page 43 for details.
•
Press and hold the button for three seconds to select one of
two settings. An indicator LED corresponds to each setting.
Each setting optimizes the charging sequence differently in
charging the batteries by stages.
•
Three-stage - Bulk, Absorption, and Float;
default setting
Two-stage - Bulk and Absorption only
3
Charger Status LEDs
Displays the current status of the charger.
•
•
•
•
•
Ready - a solid light indicates batteries are fully charged
and the charger is in rest stage.
Ready and Charging - solid lights indicate batteries are
fully charged and the charger is in float stage.
Charging - a solid light indicates charger is performing a
normal charge cycle.
•
When setting or cancelling an Equalization program: Press
and hold for five seconds both the Charger Mode and
Battery Temp. Select buttons.
5
Battery Type Select button
Press and hold the button for three seconds to select one of five
settings. An indicator LED corresponds to each setting.
NOTE: The fifth setting is a custom battery type setting and is
indicated when all four LEDs illuminate. See “Custom” below.
Equalize - a solid light indicates that the charger is
performing an equalization cycle.
- a flashing light indicates that the equalization
cycle will begin after the absorption stage is
done.
Each setting maximizes charger performance for its
corresponding battery type.
•
•
•
•
•
AGM - Absorbent Glass Mat lead-acid battery
Flooded - Lead-acid battery; default setting
GEL - Gel-type lead-acid battery
Lead Calc. - Lead-calcium battery
Custom - Only available if a custom algorithm has been
programmed by Xantrex or a designated OEM.
6
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Truecharge 2 Battery Charger Features
Item Description
Item Description
6
Battery Temp. Select button
6
•
•
•
Cold - for battery temperature below 5 °C (41 °F); raises
the charging voltage to compensate
Warm - for battery temperature between
5 and 30 °C (41 and 86 °F); default setting
Hot - for battery temperature above 30 °C (86 °F);
lowers charging voltage to compensate
•
Press and hold the button for three seconds to select one of
three settings. An indicator LED corresponds to each
setting.
continued
If an optional BTS is connected, the indicator LEDs
represent real-time battery temperature.
•
When the optional BTS is not used, this selection changes
the charger's output voltage settings to compensate for the
battery temperature selected. The Cold setting raises the
voltages, and the Hot setting lowers the voltages. See
“Battery Temperature Compensation Levels” on page 32.
•
When setting or cancelling an Equalization program: Press
and hold for five seconds both the Charger Mode and
Battery Temp. Select buttons.
RISK OF BATTERY DAMAGE
Be sure the appropriate setting is selected before charging. For varying
conditions, use the Warm setting.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
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Preparing For Installation
11
NOTE: Not to scale. For illustration purposes only.
IMPROPER INSTALLATION BY AN UNQUALIFIED INSTALLER
The battery charger must be installed by a qualified installer in
accordance with all applicable local or national installation codes.
Examples of such codes are the US National Electrical Code (NFPA 70),
the American Boat & Yacht Council standards E-11 and A-31, and the
US Coast Guard Electrical Regulations (33CFR183).
1
2
L
N
G
3
10
Failure to follow these instructions can damage the unit and/or
damage other equipment.
9
8
L
N
G
4
NOTE: In some jurisdictions a
double-pole breaker may be
required.
NOTE: The Truecharge2 Battery Charger is designed to be permanently
mounted. Figure 4 shows a typical installation with three batteries, a battery
temperature sensor (BTS) and a remote panel (both optional). It also shows
the AC and DC wiring and protection devices required for a typical
installation. Means of over-current protection and disconnection must be
incorporated into the fixed wiring, in accordance with the electrical code
that governs each installation.
6
5
6
7
6
Figure 4 Configuration for Normal Loads
1
2
AC input wiring compartment
AC mains source protected by correct size and type of branch
rated circuit breaker
3
DC negative cable
8
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Preparing For Installation
You need the following materials:
4
5
6
7
DC positive cables
•
3 conductor AC input wiring
DC circuit breakers or DC fused disconnects
Battery or battery bank
your local electrical codes to determine the correct wire and breaker or
fuse.
Battery Temp. Sensor
(optional accessory part number: 808-0232-01)
•
•
AC cable strain relief (if the one included is not compliant with your
local electrical code requirements).
appropriately sized DC cables for each battery, with suitable
connectors at the battery end
8
Engine ground bus or DC negative bus
Ground bus
9
10
11
DC chassis ground (earth)
electrical codes to determine the correct wire and breaker or fuse.
appropriately sized DC chassis ground (earth) cable with suitable
connectors,
ring terminals to fit 6 mm (1/4 in.) studs at the charger end (Marine
grade hardware is recommended),
DC fused disconnect or properly rated circuit breaker for each battery
bank,
mounting screws, M3 or #6 marine grade, corrosion resistant
(4 pieces) (Length dependent on mounting surface).
Remote panel
(optional accessory part number: 808-8040-01)
•
•
•
•
Tools and Materials
To mount and connect the Truecharge2 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-securing the AC and DC
wiring compartment covers,
•
•
•
power drill/screwdriver,
drill bit set for pilot holes for mounting screws (if using #6 mounting
screws, use 1/16 drill),
•
•
wire stripper,
manufacturer's recommended crimp tool for any crimp terminals that
are being used.
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Preparing For Installation
Location
Condition Requirement
Close to
batteries
The Truecharge2 Battery Charger should be installed as
Install the Truecharge2 Battery Charger in a location that meets the
following requirements:
close as possible to the batteries, but not in the same
compartment to prevent corrosion. Avoid excessive cable
lengths and use the recommended wire sizes. Xantrex
recommends installing with cables sized to achieve less
than 3% voltage drop on battery cables under full load.
This will maximize the performance of the charger.
Condition Requirement
Dry
The Truecharge2 Battery Charger must be installed in a
dry location not subject to moisture especially rain, spray,
or splashing bilge water.
a.Applicable to Non-IEC models only. See “Product Numbers” on page i.
Clean
The Truecharge2 Battery Charger should not be exposed
to metal filings or any other form of contamination.
Cool
The ambient air temperature should be between
0 – 50 °C (32 – 122 °F) for best performance.
Ventilated
There must be at least 10 cm (4 in.) of clearance on the top
and bottom ends of the Truecharge2 Battery Charger for
air flow and at least 6 cm (2.5 in.) of clearance on either
side (see Figure 7). Ventilation openings on the charger
must not be obstructed. If the charger is mounted in a tight
fitting compartment, the compartment must be ventilated
with cut-outs to prevent the charger from overheating.
EXPLOSION HAZARD FOR IEC MODELS ONLY
Do not place the battery charger in machinery space or in areas
containing gasoline tanks or fittings in which ignition-protected
equipment is required.
Failure to follow these instructions will result in death or serious
injury.
a
b
Safe
This battery charger (except IEC models ) is ignition-
NOTES:
protected equipment, so it can be installed in areas
containing gasoline tanks or fittings which require
ignition-protected equipment. Nevertheless, Xantrex
recommends that it is safest not to install any kind of
electrical equipment including the Truecharge2 Battery
Charger in these areas.
When planning to install the Truecharge2 Battery Charger, be sure that you
consider the location and orientation carefully. The Truecharge2 Battery
Charger is considered to have an IP rating of IP-32, if installed in either of
two specific orientations [shown in Figure 5 (a) and (b)] and only if all
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Preparing For Installation
panel covers are attached and secured. This rating means that it meets
standards to prevent dripping water from entering the enclosure, and
causing shock hazard and damage to equipment.
(a)
The other possible mounting orientations [shown in Figure 6 (c) and (d)]
will not prevent the entry of dripping water, and are not suitable for marine
or other moist environments without the installation of additional drip
protection. They are only acceptable for use in locations that are always dry.
Deck Mount - this orientation
meets IP-32 requirements and is
drip-proof.
The environment, therefore, will determine the mounting orientations that
are suitable for each installation. Is the installation environment one that
will always be dry or will moisture or condensation sometimes enter the
area?
(b)
Horizontal Wall Mount (with AC
wiring higher than DC terminals
only) - this orientation meets IP-
32 requirements and is drip-
proof.
AC
ELECTRICAL SHOCK HAZARD
DC
In marine environments, there is a likelihood that condensation will be
present, and may drip on to the charger. Use the appropriate mounting
orientations as shown in Figure 5 and Figure 6.
Figure 5 Mounting Orientations (Deck and Horizontal)
Failure to follow these instructions will result in death or serious
injury.
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Preparing For Installation
Wiring Requirements
Vertical Wall Mount
(Rear panel facing
down or up) - this
orientation is allowed
in locations that are
always dry but is
approved for marine
installations only with
additional drip
ELECTRICAL SHOCK AND FIRE HAZARD
Do not operate the battery charger with damaged or substandard wiring.
Make sure that all wiring is in good condition and is not undersized. See
notes below.
protection.
Failure to follow these instructions will result in death or serious
injury.
(c)
(d)
NOTES:
Figure 6 Mounting Orientations (Vertical)
•
Wiring and fuse sizes are governed by electrical codes and standards.
Different requirements apply in different countries and to different
types of installations, for example, boat, home or RV. It is the
responsibility of the installer to ensure that each installation complies
with all applicable codes and standards.
•
Ensure that wires and fuses or breakered disconnects are correctly
sized. Maximum continuous DC current available from the charger
may be an additional 6–10% above the nominal current rating of the
charger.
10 cm.
(4 in.)
6 cm.
(2.5 in.)
Figure 7 Ventilation Clearance
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Preparing For Installation
DC Wiring
a
Table 2 DC Wiring Examples for 24 V chargers
The following tables show some typical wire sizes for various cable length
runs, based on 3% voltage drop on DC cables, 75 °C (167 °F) rated wire
with wiring being inside the engine compartment – assumed ambient of
50 °C (122 °F).
Wire Length
(max length one way)
Wire Size (AWG and mm2)
feet
meters
1.5
TC1024
No. 16
TC2024
No. 10
TC3024
No. 10
5
a
Table 1 DC Wiring Examples for 12 V chargers
2
2
2
(1.3 mm )
No. 16
(5.3 mm )
No. 10
(5.3 mm )
No. 10
7.5
20
2.25
6
Wire Length
Wire Size (AWG and mm2)
2
2
2
(1.3 mm )
(5.3 mm )
(5.3 mm )
(max length one way)
No. 10
No. 8
No. 6
feet
meters
1.5
TC2012
No. 10
TC4012
No. 8
TC6012
No. 6
2
2
2
(5.3 mm )
(8.4 mm )
(13.3 mm )
5
a.Values based on American Boat & Yacht Council E-11 2008
Table VI-A and Table IX.
2
2
2
(5.3 mm )
(8.4 mm )
(13.3 mm )
7.5
20
2.25
6
No. 10
No. 6
No. 4
NOTE: In the event of a conflict between the voltage drop table (Table IX)
and the ampacity table (Table VI-A) use the larger wire size.
2
2
2
(5.3 mm )
(13.3 mm )
(21.2 mm )
No. 6
No. 2
No. 1
Over-current Protection Disconnect
2
2
2
(13.3 mm )
(33.6 mm )
(42.4 mm )
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 (17.8 cm) of each battery . The devices are usually
a.Values based on American Boat & Yacht Council E-11 2008
Table VI-A and Table IX.
1
NOTE: In the event of a conflict between the voltage drop table (Table IX)
DC-rated circuit breakers, fused disconnects, or a separate fuse and
and the ampacity table (Table VI-A) use the larger wire size.
disconnect for each circuit. These devices must be rated for DC voltage and
1.Per American Boat & Yacht Council E-11.
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Preparing For Installation
current and be rated to withstand the short circuit current available from the
connected battery bank. Do not substitute devices rated only for AC
voltage; they may not operate properly.
AC Wiring
The current rating of the DC fuses must be correctly matched to the size of
the DC wiring used, in accordance with the applicable codes. This helps to
protect the installation against fire in case of any overcurrent or short circuit
fault.
FIRE HAZARD
Use only on circuits provided with 20A maximum branch circuit
protection in accordance with National Electrical Code, NFPA 70.
Table 3 Fuse Sizes versus Wire Sizes Based on ABYC Regulations
Failure to follow these instructions will result in death or serious
injury.
AWG
14
12
10
8
Max. Fuse/Breaker
15 A
20 A
30 A
50 A
The AC wiring must 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.
6
4
2
1
80 A
The AC input wiring for the Truecharge2 Battery Charger should be three-
conductor cable, providing a line, neutral, and ground conductor (or L, N,
GND) in an outer jacket, rated a minimum of 75C, and sized based on the
AC input current to the charger (see “AC Input Specifications” on page 54)
and on the value of overcurrent protection provided.
100 A
125 A
150 A
DC Chassis Ground
For example:
The DC chassis ground (earth) wire should also be sized correctly to
provide proper protection. Refer to the local electrical codes for your
specific installation to determine the correct gauge. The ABYC standards
require this DC chassis ground wire to be the same size as the largest DC +
and – conductors connected to the charger, or no more than one wire size
17 for instructions.
•
in US NEC, you may use a 14 AWG wire with a 15 A breaker for up to
12 A continuous current (or 12 AWG for a 20 A breaker for up to 16 A
continuous current) or
for 230 Vac application, you may be able to use either a 2.5mm2 wire
with a 16 A breaker or use 1.5 mm2 wire with a 10 A breaker.
•
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Preparing For Installation
Note that every jurisdiction will have different requirements as will each
application, so research the regulations for your local jurisdiction to
determine which wire size and type is correct based on the maximum AC
input current marked on the chargers and given in “AC Input
Battery Bank Size Requirements
The Truecharge2 Battery Charger is designed to work with a minimum
battery bank size. Each bank should meet the minimum Ah rating shown in
Table 4. These minimum values are based on twice the charger’s rated
maximum charging current. For example, a 20-amp charger will charge a
minimum 40 Ah battery. If you are considering new batteries, please
consult the battery’s manufacturer for their recommendation based on the
maximum charging current of your charger.
Other examples of AC wiring requirements:
•
For marine applications, the American Boat & Yacht Council (ABYC)
requires stranded wire, which is more robust than solid wire when
exposed to vibration.
IMPORTANT: If the battery manufacturer has specified the maximum
charge current, please follow their recommendation.
•
For RV applications, the United States National Electrical Code (NEC)
allows solid wire in multi-conductor cable, however, stranded wire is
also acceptable which will withstand vibration better.
Table 4 Minimum Battery Bank Size
The AC wiring supplying the Truecharge2 Battery Charger must be
protected by the correct size and type of branch-circuit rated fuse or breaker
to meet the applicable installation codes. If a fuse is used instead of a
breaker, a correctly rated disconnect switch is required ahead of the fuse so
that power can be turned off, allowing fuse replacement and safe
maintenance of other equipment on the mains circuit.
Minimum Battery Bank Size (Ah)
12 Vdc Models
TC2012
TC4012
TC6012
40
80
120
Minimum Battery Bank Size (Ah)
24 Vdc Models
TC1024
TC2024
TC3024
20
40
60
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Installing the Truecharge 2 Battery Charger
Be sure to read the safety guidelines and pay attention to all cautions and
Step 1: Mounting the Battery Charger
warnings throughout the installation procedure. The installer is responsible
for ensuring compliance with the installation codes for your particular
application. See CAUTION statement under “Preparing For Installation” on
Mount the Truecharge2 Battery Charger using all four mounting slots and
holes which are provided. Mounting orientations a) and b) in Figure 5 meet
IP-32 and drip-proof requirements that are needed to ensure safety in the
presence of condensation. The other possible mounting orientations c) and
d) shown in Figure 6 will not prevent the entry of dripping water, and are
not suitable for use in marine installations or other moist environments
without the installation of additional drip protection. They are only
acceptable for use in locations that are always dry.
ELECTRICAL SHOCK HAZARD
Disconnect all sources of AC and DC power before proceeding.
Failure to follow these instructions will result in death or serious
injury.
To mount the Truecharge2 Battery Charger:
1. Select a mounting surface that is flat and allows for a minimum of 10
cm (4 in.) of clearance on the top and bottom ends for air flow and at
least 6 cm (2.5 in.) of clearance on either sides (see Figure 7,
“Ventilation Clearance” on page 12).
Installation Sequence
To make charger installation quick and easy, Xantrex recommends that the
installation tasks be performed in the following sequence:
2. Drill the four pilot holes for the mounting screws, taking care that
there is nothing behind the surface that can be damaged by the drill.
1. Mount the charger in position.
2. Connect the DC ground.
3. Mount the Truecharge2 Battery Charger using corrosion resistant, #6
(3 mm) round, pan head (or similar) screws.
The top two keyhole-style mounting holes can be used to hold the
Truecharge2 Battery Charger in place while fastening the bottom two
screws. For secure, permanent mounting, use the holes in all four
mounting flanges and fasten all four screws. Do not rely on screws
only in the keyhole slots for the installation of the charger.
3. Install DC wiring including installing required disconnects, fuses, or
breakers.
4. Install AC wiring including earth grounds.
5. Power up the charger.
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Installing the Truecharge 2 Battery Charger
Step 2: Connecting the DC Chassis Ground (Earth)
To connect the DC chassis ground (earth):
1. Locate the ground stud on the Truecharge2 Battery Charger.
2. Connect the DC chassis ground (earth) from the ground stud to the
ground bus. See Figure 4, “Configuration for Normal Loads” on page
8.
ELECTRICAL SHOCK HAZARD
Improper connection can result in risk of electric shock. See note below.
Failure to follow these instructions can result in death or serious
injury.
Use a flat washer, a lock washer and a nut (included in the installation
kit) to secure the connection.
3. Tighten the nuts to 2.3 N-m (20 lb-in.) torque and test that the wire is
secure. Do not over-tighten as this may result in damage to the charger.
NOTE: Have an electrician install a properly grounded circuit if one is not
available.
The Truecharge2 Battery Charger must be connected to a grounded, metal,
permanent wiring system, or an equipment-grounding conductor should be
run with the circuit conductors and connected to the equipment-grounding
lead on the charger. Connections to the battery charger must comply with
all local and application-specific codes and ordinances.
Xantrex recommends that you install a DC chassis ground (earth) wire from
the ground stud on the Truecharge2 Battery Charger to the engine bus or
DC ground bus. The DC chassis ground (earth) wire should be sized
correctly with the power conductors, and both must be sized for the battery
fuses that are used to protect the DC wiring. Refer to your local electrical
codes to verify the requirements in your jurisdiction for your application.
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Installing the Truecharge 2 Battery Charger
4. Install a DC circuit breaker or fused disconnect in each positive cable
that is as close to the battery positive terminal as possible.
Step 3: Installing DC Wiring
Consult your local electrical codes regarding the distance allowed
between the battery and the fuse or breaker. For example, for most
situations ABYC standard E-11 requires no more than 7 inches
(17.8 cm). Be sure the breaker or fused disconnect is open.
The procedure for installing the DC wiring applies to a single battery, as
well as multiple batteries or battery banks.
5. Route the wiring to the batteries and to the Truecharge2 Battery
Charger. Avoid routing wiring through an electrical distribution panel,
battery isolator, or other device that will add voltage drops.
ACCIDENTAL SHORT OR SPARK HAZARD
Leave the DC disconnects or breakers in the Off position or DC fuses
removed from their fuse holders until installation is complete.
Failure to follow these instructions can result in death or serious
injury.
SHOCK HAZARD
The rubber boots must be installed over the Truecharge2 Battery Charger
DC terminals to keep water off of live parts and to maintain the chargers'
IP-32 and drip-proof ratings.
1. Remove the DC compartment cover. See “Front Panel” on page 3.
2. Plan the route that the DC wires will follow, keeping it as short as
possible. Measure and cut the required wire length, after allowing
some extra length for connections and to provide slack in the wires for
strain relief.
Failure to follow these instructions can result in death or serious
injury.
3. Identify the positive wires, by using color-coded wire, or by marking
both ends of the wire with colored tape, or similar kind of marking.
Repeat with a different color for the negative. Most installation codes
recommend coloring the positive red and the negative black.
6. Insert and slide the rubber boot(s) over the charger end of the DC
battery cables.
IMPORTANT: You may find it helpful to label each cable, associating it
with the battery bank it is connected to. For example, bank 1 (–), bank 1
(+), bank 2 (–), and so on.
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Installing the Truecharge 2 Battery Charger
7. Install crimp lugs on the charger end of the DC battery cables using the For one battery or bank
crimp manufacturer’s instructions and tool.
◆
Connect the negative cable from the negative terminal on the battery to
the negative DC terminal on the Truecharge2 Battery Charger.
Use a flat washer, a lock washer and a nut (five of each included in the
installation kit) to secure the connection.
To charger
For more than one battery or bank
◆
Connect the negative cable from the negative terminal on the negative
ground bar or bus to the negative DC terminal on the Truecharge2
Battery Charger.
Use a flat washer, a lock washer and a nut (five of each included in the
installation kit) to secure the connection.
9. Tighten the nuts to 2.3 N-m (20 lb-in.) torque and test that the wire is
secure. Do not over-tighten as this may result in damage to the charger.
REVERSE POLARITY DAMAGE
Before proceeding to the next step, carefully check the wiring polarity.
Do not reverse the connections. See note below.
10. Connect each positive cable to the correct positive DC terminal on the
Truecharge2 Battery Charger.
Use a flat washer, a lock washer and a nut (five of each included in the
installation kit) to secure the connection.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
11. Tighten the nuts to 2.3 N-m (20 lb-in.) torque and test that the wire is
secure.
NOTE: Make sure the positive terminals of the Truecharge2 Battery Charger
will be connected to the correct terminals of the battery (fuses or breakers)
and from there to the positive terminals of the battery. Make sure the
negative terminal of the Truecharge2 Battery Charger will be connected to
the battery negative terminal (or DC negative bus).
12. Connect the free end of each positive cable assembly to the correct
positive terminal of the battery, using sufficient torque as
recommended by your battery manufacturer.
13. Connect the free end of the negative cable to the negative terminal on
the battery, using sufficient torque as recommended by your battery
manufacturer.
8. Connect the negative cable to the negative DC terminal on the charger.
See Figure 4, “Configuration for Normal Loads” on page 8.
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Installing the Truecharge 2 Battery Charger
NOTE: If you are using more than one battery, you will need to connect
the negative cable from each of the batteries to the negative ground bar
or bus. The negative ground bar or bus will then have a single negative
cable connecting to the negative charger terminal.
14. Secure cables in place using tie-wraps or cable straps according to
electrical codes.
15. Slide the rubber boots to cover the DC terminals.
16. If available, route the optional battery temperature sensor (BTS) from
the battery (one which is located in the warmest ambient temperature)
to the charger location.
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Installing the Truecharge 2 Battery Charger
Step 4: Installing AC Wiring
Before connecting AC wiring, make sure the AC source circuit is protected 4. Unscrew the wiring compartment cover from the left rear of the
by a breaker switch of the correct size and type, to comply with the
electrical code for your location and application. The current rating of the
input breaker should not be larger than 20 A for 120 Vac applications and
16 A for 230 Vac applications, but may be required to be lower depending
on the wire size used.
Truecharge2 Battery Charger to expose the AC wiring access hole and
charger’s AC pigtail leads.
wiringcompartment
cover
ELECTRICAL SHOCK HAZARD
Disconnect the AC source by turning off the breaker feeding the circuit,
unplugging from shore power and disconnecting any other power sources
(such as a generator).
Failure to follow these instructions will result in death or serious
injury.
AC wiring access hole
AC pigtail leads
5. Carefully remove 50 – 75 mm (2 – 3 in.) of the outer jacket from the
AC supply wiring, being careful not to cut or nick the insulation on the
individual conductors.
1. Plan the route that the AC supply wiring will follow from the source
(usually an AC distribution panel) to the Truecharge2 Battery Charger.
2. Measure and cut the required length of three-conductor (L, N, GND)
cable allowing some extra length for connections and providing some
slack.
6. Extend the charger’s AC (L, N, GND) pigtail leads (wires) from the AC
wiring compartment of the charger.
3. Route the AC supply wiring from the charger (in its mounted position)
to the source.
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Installing the Truecharge 2 Battery Charger
7. Feed the AC supply wiring through the wider end of strain relief and
out the tapered end.
To connect AC wires with the provided crimp-on butt-splice connector:
1
a) Make the connections using the provided crimp-on connectors
or with other approved connectors required by your code, and
suitable for your installation.
tapered end
of strain relief
For example, the ABYC Standards and Recommended Practices for Small
Craft prohibit twist-on connectors for AC connections on a boat. For other
types of installation, refer to your applicable code.
AC supply wiring
FIRE HAZARD
Improperly connected wires may overheat. Exercise care when using any
crimp connector, use the tool specified by the crimp connector
manufacturer, and follow all crimping instructions.
8. Slide the strain relief on the jacket of the wiring (not on the individual
conductors) approximately 25 mm (1 in.) from the end of the jacket.
9. Connect the AC supply wires to the Truecharge2 Battery Charger
pigtail wires.
Failure to follow these instructions will result in death or serious
injury.
NOTE: Connect the line conductor to the AC line, the neutral to the AC
neutral, and the ground to the AC ground. The wires are color coded as
follows:
b) Using a wire stripper, carefully strip 8 mm (5/16 in.) from the
ends of the two wires being connected.
Conductor Charger Pigtail
Color Code
AC Supply Wire
Color Code
Line
Black
White
Black (or brown)
White (or blue)
Neutral
Ground
Green with yellow stripe Green with yellow stripe
1.Provided butt-splice connector (catalog number BNYF2) is available
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Installing the Truecharge 2 Battery Charger
c) Insert one wire into one end of the butt-splice, until the insulation
hits the internal metal crimp section, insert the butt-splice into the
screw to secure the
wiring compartment
cover
1
crimper , and crimp firmly. The proper location for the crimp is
approximately 1.6 mm (1/16 in.) past where the butt-splice insu-
lation tapers down as shown.
1/16 “
CRIMP TOOL
STRIP 5/16”
AC wiring access hole
with strain relief
d) Repeat Step c for the other end of the butt-splice.
10. When all connections are completed, push the wiring and connectors
inside the AC wiring compartment.
13. If applicable, install the optional remote panel.
14. Connect the AC supply wiring from the charger to the AC panel
feeding the charger.
11. Place the strain relief on the AC wiring access hole.
12. Install the wiring compartment cover to fasten the strain relief and
tighten the screw on top to secure the cover. Do not over-tighten.
15. Connect the line conductor to the breaker, the neutral to the neutral
bus, and the ground to the ground bus.
16. Secure cables in place using tie-wraps or cable straps according to
electrical codes.
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Installing the Truecharge 2 Battery Charger
Step 5: Powering Up
Make one last check that all connections are correct and secure.
The Truecharge2 Battery Charger charger may now be powered up.
1. Close the DC disconnect switch or breaker.
EXPLOSION AND/OR FIRE HAZARD
The final connection of the DC battery circuit will generate an arc.
Ensure all areas of the system, including batteries and engine
compartments, are well ventilated prior to making this connection.
Failure to follow these instructions will result in death or serious
injury.
2. Switch the AC power on at the source breaker. It is normal to see a
seven to ten second delay while the charger powers up. During this
time, the indicator LEDs on the onboard display and the remote panel
will illuminate for a second (power on test) before reporting charging
and battery status information.
NOTE: Battery qualification may not be correctly performed if AC
power is switched on first.
NOTE: The onboard display LEDs will also illuminate momentarily
with DC power alone when DC power is applied and the minimum
battery voltage (i.e., the connected batteries) is above 9 V.
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Installing a Parallel Configuration
A parallel configuration is when two Truecharge2 Battery Chargers are
coupled together to increase the output capacity. For example, a 40-amp
Truecharge2 Battery Charger can be connected with another 40-amp
Truecharge2 Battery Charger for a combined 80-amp capacity charger. This
configuration is possible only with the use of the optional remote panel.
Installing a parallel configuration:
1. Follow the installation sequence (from steps 1 through 4) for a single
AC input lines come from the same circuit branch, that is, both AC
input lines should have a common circuit breaker.
3. Designate a primary charger and a secondary charger between the two
chargers. Remember that only the primary charger or remote panel can
be used to configure and operate the parallel system.
DAMAGE TO THE BATTERY CHARGER
Do not parallel Truecharge2 Battery Chargers together without a
Truecharge2 Remote Panel (part number: 808-8040-01).
4. Connect the primary charger’s battery bank 1 to the secondary
charger’s battery bank 1. Do the same for battery banks 2 and 3.
NOTE: A maximum of three battery banks can be connected to a
parallel-configured charger system.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
5. Leave any unused DC output/s unconnected.
Parallel configuration can only be done when the following conditions are
met:
6. Connect the remote panel’s communications cable to the primary
charger’s remote port and to the remote panel’s primary port. Do the
same for the secondary charger.
•
Two Truecharge2 Battery Chargers must have the same output
voltage rating. Never parallel a 24-volt charger with a 12-volt
charger.
7. Connect the BTS (or battery temperature sensor’s) cable plug to the
primary charger’s BTS port. Then connect the BTS’s sensor to the
battery.
•
•
Both Truecharge2 Battery Chargers must connect to a
Truecharge2 Remote Panel.
NOTE: If you have two BTSs, you may connect the two separate cable
plugs to each of the battery chargers’ BTS ports. You may then
connect each of the sensors to two separate batteries. However, during
operation, the BTS that is detecting a higher temperature will be used
for battery temperature compensation.
Both Truecharge2 Battery Chargers must be correctly installed.
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Installing a Parallel Configuration
Fault and Warning Conditions
Powering up after installing a parallel configuration:
•
When one charger encounters a fault condition, the other charger
remains charging but the remote panel will stop synchronizing the two
chargers’ settings at this point. The remote panel will display the fault
condition via Fault/Warning LED the same way as the “faulty” charger
displays it on its onboard display.
2. Observe that the Parallel LED on the remote panel lights up to indicate
that two chargers are in parallel configuration charging mode.
During Charging
•
Remote panel’s Fault/Warning LED only clears when fault or warning
conditions at both chargers are cleared. The remote panel will resume
synchronizing the two chargers’ settings at this point.
The two Truecharge2 Battery Chargers’ output currents are synchronized
during most of the charging cycle. When a battery is approaching a fully
charged state, it is normal to see one charger’s output current drop down
earlier than the other charger. The output current displayed via the remote
panel lights is the sum of both chargers’ output currents divided by the total
maximum current ratings of both chargers.
Exiting parallel operation:
Once the remote panel enters parallel operation, the only way to exit out of
it is to completely power down the remote panel by unplugging both of the
communication cables.
When Configuring the Battery Chargers
The secondary charger’s configurations are automatically synchronized
with the primary charger. The configuration can be performed from either
the remote panel or the primary charger’s onboard display. Follow the
exact same procedures as a single charger when configuring the paralleled
chargers.
When Equalizing Batteries
Equalization can be programmed and cancelled through the remote panel.
Equalization can be cancelled through both charger’s onboard display.
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Installing Batteries
Battery installation should always be treated like a brand new installation.
This means, that all safety and precautionary guidelines that were followed
prior and during the installation of the battery charger, must again be
followed in order to avoid risks of electrical shock, injury, or death.
5. Reconnect the battery cables to the new battery.
NOTE: For Negative chassis systems, reconnect the positive cable first,
then the negative cable.
For Positive chassis systems, reconnect the negative cable first, then
the positive cable.
IMPORTANT: If the new battery is different from the old one in chemistry,
temperature, or size, remember to re-configure the battery settings
accordingly. See “Setting the Battery Temperature without a BTS” on page
ELECTRICAL SHOCK HAZARD
Disconnect both AC and DC power from the battery charger before
attempting before replacing old or defective batteries and even installing
new batteries.
Failure to follow these instructions will result in death or serious
injury.
Input Voltage Operating and Derating
To replace an old battery:
When AC input is within the lower range between 90–108 Vac, the
Truecharge2 Battery Charger derates to 80% of maximum current.
1. Turn off the AC source by disconnecting the AC line and/or opening
the AC source disconnect.
However, when AC input increases above 108 Vac up to 265 Vac,
maximum current returns to 100% capacity. Furthermore, the Truecharge2
Battery Charger will continue to operate at 100% of maximum current.
2. Switch off all devices operating from currently installed batteries.
3. Disconnect the battery cables from the old battery.
NOTE: For Negative chassis systems, disconnect the negative cable
first, then the positive cable.
For Positive chassis systems, disconnect the positive cable first, then
the negative cable.
Inspect all AC and DC cables for damage and repair, if necessary.
4. Replace the old battery with the new battery.
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Installing Batteries
Multi-Stage Charging
Remote panel
(optional)
NOTE: Not to scale. For illustration purposes only.
Most Truecharge2 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
sequence and thresholds. The Truecharge2 Battery Charger can perform
either three-stage charging (Bulk, Absorption, and Float) or two-stage
charging (Bulk and Absorption).
AC source
L
N
G
IMPORTANT: The battery banks are not galvanically isolated from each
other. They share a common negative as shown in the diagram below.
The negative bus to chassis connection as shown below may not be suitable
in some applications.
L
N
G
BTS
(optional)
NOTE: In some jurisdictions a
double-pole breaker may be
required.
Negative bus
Battery banks
Figure 8 Typical Three-Battery Installation
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Installing Batteries
Three-Stage Charging
Vbat = Vabs
for 1 minute
lout < 10% lrating
for 1 minute
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 constant and the current declines. A battery will “gas” (produce
hydrogen and oxygen) when its voltage exceeds the “gassing” voltage.
Finally, in the Float stage, the charger continues to provide voltage at a
lower level to maintain the battery in a fully charged state. If there is no
load on the battery, it will typically draw very little current. The charger,
however, is able to provide current to its full rating to power auxiliary DC
loads on the battery.
Battery Voltage
Vbat = Vgas
for 1 minute
Vbat < 12.5 V
for 15 minutes
Vgas voltage
Charge
start
ABS
CC
ABS
CV
BULK
FLOAT
The charger will restart the charging cycle in the Bulk stage if the lowest
battery voltage of the three banks drops below 12.5 V (12 Vdc chargers) or
25 V (24 Vdc chargers) for 15 minutes. After seven days, the charger will
automatically restart charging in order to refresh the batteries.
Time
ABS CV timeout
max 5 hrs
FLOAT timeout
max 7 days
Start of
charging cycle
Total ABS timeout
max 8 hrs
Figure 9 Three-Stage Charging Process
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Installing Batteries
Two-Stage Charging
Vbat = Vabs
for 1 minute
lout < 10% lrating
for 1 minute
Battery Voltage
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 current
to the battery and the charger output drops to 9 V (12 Vdc chargers) or 18V
(24 Vdc chargers). In this manner, DC loads draw power supplied by
batteries and the charger enters a “rest or standby stage.” Like the three-
stage sequence, the charger will restart the charging cycle in the Bulk stage
if the lowest battery voltage of the three banks drops below 12.5 V (12 Vdc
chargers) or 25 V (24 Vdc chargers) for 15 minutes. After seven days, the
charger will automatically restart charging in order to refresh the batteries.
Vbat = Vgas
for 1 minute
Vgas voltage
GO TO BULK when
Vbat < 12.5 V for
15 minutes
Charge
start
ABS
CC
ABS
CV
REST
(Standby)
BULK
Time
ABS CV timeout
max 5 hrs
REST (Standby)
timeout max 7 days
Start of
charging cycle
Total ABS timeout
max 8 hrs
Figure 10 Two-Stage Charging Process
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Installing Batteries
Battery Qualification
Charging Voltage Setpoints
The Truecharge2 Battery Charger will perform a battery qualification on
each application of AC (or DC > 9 V [for 12-volt batteries]; DC > 18 V [for
24-volt batteries]), to determine if battery banks are present and healthy.
The Truecharge2 Battery Charger charging process is designed to make the
battery or battery banks reach the following voltage setpoints.
Table 5 Charging Maximum Voltages for 12-volt chargers
To force a battery detection sequence,
Battery
Type
Absorption
(Volts)
Float (Volts) Equalization
(Volts)
1. Turn off AC and DC.
2. Wait approximately 20 seconds or until all lights on the charger or
remote have gone out.
Flooded
GEL
14.4
14.2
14.3
15.5
13.5
13.8
13.4
13.5
16.0
3. Turn on DC.
not applicable
not applicable
16.0
4. Turn on AC.
AGM
The charger will then perform a battery detection.
Lead-Calcium
The Truecharge2 Battery Charger charges all banks at the same time but the
bank in most need of charging is the one that receives the most charge. For
example, if Bank 1 and Bank 2 are both charged, but Bank 1 has a load and
Bank 2 does not, then the charger may rarely charge Bank 2.
Table 6 Charging Maximum Voltages for 24-volt chargers
Battery
Type
Absorption
(Volts)
Float (Volts) Equalization
(Volts)
Flooded
GEL
28.8
28.4
28.6
31.0
27.0
27.6
26.8
27.0
32.0
Temperature Considerations
not applicable
not applicable
32.0
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.
AGM
Lead-Calcium
If no BTS is connected, the charger defaults to the Battery Temp. selection
on the onboard display as well as on the optional remote panel.
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Installing Batteries
Setting the Battery Temperature without a BTS
NOTE: Cold is for battery temperature below 5 °C (41 °F). Warm
(default setting) is for battery temperature between 5 and 30 °C (41
and 86 °F). Hot is for battery temperature above 30 °C (86 °F). See
Table 7, “Battery Temperature Compensation Levels” on page 32 to
see how output voltage is offset by varying the temperature selection.
RISK OF BATTERY DAMAGE
Do not set a battery temperature that is lower than the actual temperature
in the absence of a BTS as this may cause the battery to be overcharged.
Similarly, do not set a battery temperature that is higher than the actual
temperature in the absence of a BTS as this may result in under-charging
the battery.
Table 7 Battery Temperature Compensation Levels
Recommended
Temperature
Selection
for battery
Voltage added for temperature
Failure to follow these instructions can damage the unit and/or
damage other equipment.
temperature of: compensation offset from 25 °C
Cold
Warm
Hot
below 5 °C
(41 °F)
Flooded/PbCa/
Gel
0.675
NOTE: Always be aware of the temperature setting, observe the battery’s
actual temperature and adjust the Battery Temperature setting accordingly.
For varying conditions, use the Warm setting.
AGM
0.525
0
between
5 and 30 °C
(41 and 86 °F)
Flooded/PbCa/
Gel
To configure the battery temperature:
NOTE: By default, the Battery Temp. is set to Warm.
AGM
0
1. Press and hold the Battery Temp. Select button for three seconds to
advance to the next setting.
above 30 °C
(86 °F)
Flooded/PbCa/
Gel
-0.27
2. Select the appropriate battery temperature setting.
The LEDs will indicate which of the three types is being selected:
Warm, Hot, or Cold.
AGM
-0.21
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Installing Batteries
Operating DC Loads
When the Truecharge™ 2 Battery Charger is operating, DC loads such as
fans and lights may vary in speed or intensity. This is normal. The
Truecharge™ 2 Battery Charger will not harm any load connected to it as
long as the load can withstand the following maximum voltages:
•
•
16 V for 12-volt chargers,
32 V for 24-volt chargers.
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Configuring the Truecharge2 Battery Charger
Once the charger is connected to at least one battery bank and to AC, it is
live and it may be configured. The indicator LEDs on the onboard display
will illuminate for a second (power on test) before reporting charging and
battery status information.
Configuring the Charger Mode
NOTE: By default, the Charger Mode is set to 3-Stage.
1. Press and hold the Charger Mode Select button for three seconds to
advance to the next setting.
2. Select the proper charger mode.
The LEDs will indicate which of the two modes is being selected:
three-stage (default) or two-stage.
Configuring the Battery Bank Type
Figure 11 Onboard Display Panel
NOTE: By default, the battery type is set to Flooded.
1. Press and hold the Battery Type Select button for three seconds to
advance to the next setting.
2. Select the proper battery type.
The LEDs will indicate which of the five types is being selected:
Flooded (default), GEL, Lead Calc., AGM, and Custom. The Custom
setting is indicated when all four battery type LEDs are illuminated.
This setting should only be used if a custom algorithm has been
programmed by Xantrex or a designated OEM.
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Charging Batteries
Before you start to charge batteries read the “Important Safety Instructions” The charger can be in one of eight different situations which will be
on page iv and follow all safety precautions when working with batteries.
indicated on the onboard display in the Charger Status LEDs:
To charge your batteries:
Mode
Charger Status LED—ON
1. If possible, disconnect any heavy loads on the batteries being charged,
by opening disconnect switches or by switching the loads off.
Bulk
Charging
Charging
2. Connect the batteries to the charger by closing the DC disconnect
switches.
Absorption
NOTE: The onboard display LEDs will light up for a second.
Standby or Rest (two-stage charging) Ready
3. Ventilate the area around the battery thoroughly during charging.
Review the charging instructions supplied by the manufacturer of your
batteries and follow all safety precautions and the required steps.
Float (three-stage charging)
Equalize (in progress)
Ready and Charging
Equalize (solid light)
Equalize (flashing)
4. Apply AC power to the Truecharge2 Battery Charger by:
Equalize
•
•
closing the AC breaker or
turning the generator on.
(waiting for absorption to end)
a
Fault
Fault (solid light)
All onboard display indicator LEDs will illuminate for one second
(power on test) as the initialization sequence runs.
a
Warning
Fault (flashing)
After initialization, the indicator LEDs will display present status and
settings. At this point, changes in Battery Type, Battery Temperature,
and/or Charger Mode can then be applied.
a.In combination with one or more flashing Charging Output % LEDs.
These settings are stored in memory (even when all power sources are
disconnected) and need not be entered after every initialization.
During charging, the Charging Output (%) LEDs will show the total
current being delivered to the battery bank as well as any DC load
applied. The charger fan may activate as well.
5. After charging is completed, reconnect all loads to the battery.
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Charging Batteries
After charging is complete, the Truecharge2 Battery Charger enters into one
of these modes:
Float mode When the ready and charging indicator LEDs both
illuminate, all batteries are fully charged and ready for use. If you selected
the three-stage charging mode, the Truecharge2 Battery Charger is in float
mode and will maintain the batteries’ charge.
Standby mode Or Rest mode. If you selected the two-stage charging
mode, the ready indicator LED shows the charger is now in rest mode and is
continuously checking battery voltage.
With either charging mode, the Truecharge2 Battery Charger will begin a
charging cycle:
•
•
seven days after the last completed cycle, or
when the minimum battery terminal voltage drops to below 12.5 V
(12 V chargers) or 25 V (24 V chargers) for 15 minutes, or
when AC is disconnected for more than 15 minutes and then
reconnected.
•
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Equalizing Flooded Batteries
In the following conditions the Truecharge2 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 or rest stage before equalization can be activated on
RISK OF BATTERY DAMAGE
The Truecharge2 Battery Charger will only equalize flooded lead-acid or
lead-calcium batteries. It does not enter equalization when the battery
type is set to sealed lead-acid batteries (GEL or AGM) since they will be
damaged by this process. Use the correct settings for your battery types.
1
any bank)
•
there is an active fault on the battery you are trying to charge
Xantrex recommends that you run a complete normal charge cycle on the
batteries before you equalize them.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
EXPLOSION HAZARD
•
The battery generates explosive gases during equalization. Follow all
of the battery safety precautions listed in this guide.
Ventilate the area around the battery thoroughly using ventilators
with brushless motors and ensure that there are no sources of flame or
sparks in the vicinity.
RISK OF BATTERY DAMAGE
You must monitor the battery specific gravity throughout equalization to
•
determine the end of the equalize cycle.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
Failure to follow these instructions will result in death or serious
injury.
The Truecharge2 Battery Charger cannot automatically determine when to
stop the equalization of a battery. The one hour time-out is intended as a
safety feature to require the user to continually re-activate it as necessary
after checking batteries manually, but may not be sufficiently short to
prevent battery damage.
1.In this case an equalization cycle can be programmed to start once the charge cycle
is done.
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Equalizing Flooded Batteries
NOTE: 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.
Performing An Equalization
To equalize your batteries:
RISK OF EQUIPMENT DAMAGE
•
Turn off or disconnect all DC loads on the battery during
IMPORTANT: Remember that all connected batteries will undergo the
equalization. If only one bank is intended to undergo equalization then the
other banks must be disconnected prior to equalization.
equalization.
•
Do not equalize if the level of equalization voltage (see note below)
does not comply with the battery manufacturer’s recommendation
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 the relative concentration
of acid, thereby affecting the specific gravity measurements. If
distilled water is added, batteries must undergo a complete charge
cycle.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
NOTE: The voltage applied to the battery during equalization may be above
safe levels for some loads but the absolute maximum is 16 V for 12-volt
chargers and 32 V for 24-volt chargers within operational temperature
range.
2. Program or initiate an equalize cycle. Equalization will begin if all
banks are in either float or rest mode.
IMPORTANT: If equalization is programmed prior to float or rest mode,
the Equalize LED will flash and equalization will start prior to reaching
float or rest mode.
EXPLOSION, FIRE, AND BURN HAZARDS
Always wear proper, non-absorbent gloves, complete eye protection, and
clothing protection. Avoid touching your eyes and wiping your forehead
while working near batteries. See following note.
Failure to follow these instructions can result in death or serious
injury.
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Equalizing Flooded Batteries
3. Press and hold for five seconds the Charger Mode Select button and
Battery Temp Select button at the same time to put the Truecharge2
Battery Charger into equalization mode.
IMPORTANT: The onboard display and remote panel buttons will not
allow selection of equalization for AGM and GEL batteries.
When the charger is performing the equalization, the Equalize LED
illuminates as a solid light. It will flash intermittently when
programmed prior to reaching float or rest mode.
4. Monitor the specific gravity of each cell of the battery during
equalization with a battery hydrometer.
NOTE: The equalization cycle is preset to last for one hour. It is not
possible to program another equalization cycle when the present cycle
has not ended yet.
Carefully check the specific gravity of each cell and repeat the
equalization cycle until they all meet the battery manufacturer’s
specifications for specific gravity or until the specific gravity stabilizes
relative to each other for an hour.
The charger automatically exits equalization to float mode or rest
mode after one cycle. To manually exit equalization mode early, repeat
Step 3.
5. Check the battery electrolyte level. If necessary, refill with distilled
water only and repeat a normal charge cycle.
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Transitioning the Charger to ON, Standby, or Disabled
There are two ways to turn ON the Truecharge2 Battery Charger:
•
Connect the batteries to the charger (i.e., charger is on standby) then
connect AC power at the source. If the batteries are not fully charged
then charging begins immediately. If the batteries are fully charged
then charging will go to either standby (two-stage) or float (three-
stage).
ELECTRICAL SHOCK HAZARD
•
Do not disassemble the battery charger. Internal capacitors remain
charged for five minutes after all power is disconnected.
Disconnect both AC and DC power from the battery charger before
attempting any maintenance or cleaning or working on any circuits
connected to the battery charger. See note below.
•
Or,
•
Press ON/STANDBY on the optional remote panel while batteries and
AC power are both connected to the charger (from Standby).
The charger begins to charge the batteries from Standby.
Failure to follow these instructions will result in death or serious
injury.
There is only ONE way to safely turn the Truecharge2 Battery Charger
off (Disable):
There are two ways to put the Truecharge2 Battery Charger in
Standby (see Warning below):
◆
Disconnect the AC power at the source and disconnect all DC
batteries.
•
•
Disconnect AC power at the source (i.e., only the batteries are
connected) or
Press ON/STANDBY on the optional remote panel while batteries and
AC power are both connected to the charger (from ON).
The charger stops charging but continues to monitor the batteries.
This is the only state where the Truecharge2 Battery Charger is completely
de-energized.
When the Truecharge2 Battery Charger is disabled, the optional remote
panel is inactive.
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Accessing Charger Information
The Truecharge2 Battery Charger provides a lot of information about the
status of the charger and the batteries.
C
h
g
r
R
e
Type of fault and warning
Charging Output (%) LEDs
Charging Output (%) values
Fault LED
F
u
s
e
m
Charging Output (%)
Reading Onboard Display LEDs
<5
5
10 20 40 60 80 100
Fault
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.
Figure 12 Charging Output (%) and Fault LEDs
summarizes the various fault conditions that might occur during the
operation of the charger.
The Charging Current (%) LEDs will normally illuminate as a solid
progress bar when they are indicating the amount of output charging
current. If any of the LEDs start to flash intermittently at the same time that
the Fault LED is either solid or flashing, a fault or warning condition is
indicated.
Reporting While Charging or Equalizing
After configuring the charger and during charging, the onboard display
panel (and the optional remote panel, if installed) will show the following
information about the charger and the battery:
IMPORTANT: A warning condition notifies the user of an impending
problem and will not stop the charger from charging, while a fault
condition will stop the charger from charging the battery.
•
•
•
Charging Output Current
Charger Status
Battery Status (available on the optional remote panel only)
If there is a fault or warning related to one of the banks, the fault or warning
information will display in the form of illuminating or flashing Fault
indicator LEDs. Charging for all banks will stop and will only resume once
the fault condition is cleared. However, charging will continue during
warning conditions.
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Accessing Charger Information
Reporting Without AC Power or While on
Standby
To interrupt or cease the charging process, disconnect the AC power source
from the charger. If you have the optional remote panel, you can put the
charger in Standby mode by pressing the ON/STANDBY button to interrupt
the charging process.
If AC power has been disconnected or if you have used the optional remote
panel to place the Truecharge2 Battery Charger on Standby mode, the
onboard display (and the optional remote panel, if installed) LEDs will be
turned off to conserve battery power. However, present settings and battery
status can be viewed momentarily by pressing the Status button on the
optional remote panel to initialize a view cycle that will show the status of
the batteries.
Table 8 Charger Status LED Sequences
Charger Status LED
Activity
Charger status
Ready LED
illuminates solid
The charger is in standby (or rest) mode of two-
stage charging. All batteries have been fully
charged.
The remote panel LEDs will turn off after 30 seconds of inactivity.
Ready and Charging The charger is in float mode of three-stage
LEDs illuminate
solid
charging. All batteries have been fully charged.
Indicator LEDs on the Onboard Display 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 Truecharge2 Battery Charger or when the charger is turned
on using the ON/STANDBY button on the remote panel. A “power on” test
indicates that the charger is now receiving AC power, and all LEDs are
functioning.
Charging LED
illuminates solid
The charger is charging in bulk or absorption
mode
Equalize LED flashes The charger will perform an equalization cycle
after the absorption stage.
Equalize LED
illuminates solid
The charger is currently implementing an
equalization cycle for all batteries.
The Truecharge2 Battery Charger will recover from fault conditions
automatically when the cause of the fault or warning has disappeared.
Under fault conditions, the charging process will be stopped, allowing
either the charger or the battery or both to return within acceptable
normal operating ranges.
Fault LED flashes
A warning condition. See “Interpreting Fault and
Fault LED
illuminates solid
A fault condition. See “Interpreting Fault and
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Accessing Charger Information
Table 9 Interpreting Fault and Warning Indicators
Temp
Fan
AC
Battery
Fuse
Charger
Remote
Fault
Fault or Warning
Condition
Solution
C
h
g
r
R
e
m
F
u
s
e
AC input out of range
fault (<85 V or >265 V)
•
Check AC connections. Change to a more stable AC
power source and check that the voltage and voltage
frequency are within acceptable operating range. See
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-volt chargers
or 24 V nominal for all 24-volt chargers. Check that
the battery type and temperature settings match the
actual battery and its conditions.
•
•
Disconnect or turn off other charging sources such as
an alternator or the charger on a generator with an
electric start.
Allow the battery (or batteries) to cool to normal
operating temperature. See “Specifications” on page
Flashing LED
Solid LED
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Accessing Charger Information
Table 9 Interpreting Fault and Warning Indicators
Temp
Fan
AC
Battery
Fuse
Charger
Remote
Fault
Fault or Warning
Condition
Solution
C
h
g
r
R
e
m
F
u
s
e
Low Battery Temp fault
(< -25°C)
•
•
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 battery.
Allow the battery (or batteries) to warm up to a
temperature that is above freezing before charging.
High Battery voltage
fault
(>16.5V for 12-volt
chargers)
(>33V for 24-volt
chargers)
•
•
•
Discontinue charging 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 disconnected, call a qualified and
certified electrician.
High Charger Temp
fault
•
•
Allow the Truecharge2 Battery Charger to cool while
the AC is connected so the fan stays on.
Improve ventilation or install the charger in a cooler
location.
Loss of Remote
Connection warning
•
Reconnect the communication cable to the port. It
takes about 15 seconds to re-establish
communication.
Flashing LED
Solid LED
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Accessing Charger Information
Table 9 Interpreting Fault and Warning Indicators
Temp
Fan
AC
Battery
Fuse
Charger
Remote
Fault
Fault or Warning
Condition
Solution
C
h
g
r
R
e
m
F
u
s
e
Reverse Polarity Fuse
fault
•
•
Check for reverse battery polarity (negative
connected to negative, positive connected to positive
is correct) at battery and charger output terminals.
Disconnect AC and DC sources before replacing the
fuse(s) on the charger. See “Replacing the DC Output
Internal fault
Flashing LED
•
Call Xantrex for support.
Solid LED
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Using A Generator As Source Power
The Truecharge2 Battery Charger can be run from a regular AC power
source or from an alternate power source such as a generator. Refer to “AC
Input Specifications” on page 54 for AC input current draw to determine
the size of generator you need. Many generators provide output voltage that
is modified sine wave or modified square wave (MSW) rather than the true
sine wave (TSW) that your utility provides.
If a generator needs to run on full load capacity to supply charging current
to the battery via the battery charger, its output frequency and amplitude
may become unstable. This scenario can cause the battery charger to
1
shutdown. Using the current limiting feature from the remote panel can
help avoid this scenario.
The Truecharge2 Battery Charger may be used with MSW generators but
its lifetime may be reduced somewhat depending on the severity of any
peak voltage overshoots, and the severity of waveshape rise times.
1.See “Configuring the Maximum Output Current Percentage of the Charger” on the
Truecharge2 Remote Panel Owner’s Guide.
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Maintaining the Charger
Periodically, disconnect all AC and DC sources and check all DC and AC
wiring connections to be sure they have not loosened or deteriorated. Also
check all cable clamps to ensure they are tightly fastened.
ELECTRICAL SHOCK HAZARD
Loose battery terminals and lugs exposed to open air corrode rapidly. The
corrosion appears as a white powder or granular foam on the terminals and
any nearby exposed metal parts. If it contacts your skin, it will cause burns
unless you rinse it off immediately.
Do not disassemble the battery charger. See note below.
Failure to follow these instructions will result in death or serious
injury.
To clean battery terminals, follow the recommendations and procedures of
the battery manufacturer.
NOTE: The Truecharge2 Series Battery Charger contains no user-
serviceable parts with the exception of the DC output fuse(s) which are
instructions. For obtaining service other than replacing the fuse, see
The Truecharge2 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 keeping the air intake vent clean and free from any
obstructions.
Disconnect all AC and DC power and clean the outside of the case and
wiring with a damp cloth. Wear protective gloves, if you suspect it has
come in contact with battery fluid, salt water, gasoline or oil, or other
corrosive material. Do not operate if the charger contains moisture of any
kind.
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Replacing the DC Output Fuse
3. Pull out the blown fuse(s) gently, using the provided fuse puller.
NOTE: The fuse puller is located on the inside of the fuse cover.
4. Install a brand new fuse(s) with same type and rating as the old one.
IMPROPER INSTALLATION BY AN UNQUALIFIED INSTALLER
Xantrex recommends that the installer should have knowledge and
experience in installing electrical equipment, knowledge of the applicable
installation codes, and awareness of the hazards involved in performing
electrical work and how to reduce those hazards.
5. Replace the fuse cover making sure that it aligns and fits perfectly,
leaving no space for moisture or small debris to enter the
compartment.
6. Tighten the screw on the fuse cover but do not over-tighten.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
7. Fix the reverse polarity fault which caused the fuse to blow prior to
reconnecting all AC and DC sources to the charger.
8. Reconnect all AC and DC sources to the charger.
ELECTRICAL SHOCK HAZARD
Disconnect all AC and DC sources to the charger and wait five minutes
for internal voltage and energy levels to reduce to safe levels.
Failure to follow these instructions will result in death or serious
injury.
To replace the DC Output Fuse:
1. Locate the fuse cover on the charger’s top panel (see “Front Panel” on
page 3).
2. Loosen the screw on the fuse cover using a Phillips screwdriver.
NOTE: The screw will not separate from the cover.
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Replacing the DC Output Fuse
Fuse Replacement Ratings
RISK OF EQUIPMENT DAMAGE
For continued protection, replace only with Littelfuse type 257 (or
®
equivalent) with ratings as shown below.
Failure to follow these instructions can damage the unit and/or
damage other equipment.
Model
Amperage
Voltage
TC2012
TC4012
TC6012
TC1024
TC2024
TC3024
30 A (green)
2×30 A (green)
3×30 A (green)
30 A (green)
15 A (blue)
32 Vdc
32 Vdc
32 Vdc
32 Vdc
32 Vdc
32 Vdc
40 A (amber)
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Troubleshooting
In the event that you have a problem with your Truecharge2 Battery
Charger, the following tables will help you to identify the problem and offer
possible solutions to the problem.
Symptom
Symptom
Indicator LEDs do not illuminate when charger is connected to an AC
power source.
The initial power up display test is not performed upon connection of
battery or batteries.
Possible Cause
Solution
Possible Cause
Solution
No power at AC source
Ensure that power is available at
charger AC input and it is within
acceptable range.
Truecharge2 Battery Charger
Check quality of battery connection and
does not detect battery for one of wires.
the following reasons: Ensure correct polarity (negative
connected to negative, positive
reverse polarity connection connected to positive).
•
•
poor connection
Defective AC wiring or
switches/breakers
Wiring must be inspected and replaced
by a qualified installer.
(blown fuse)
In case there is an accompanying fault,
check the type of fault from
•
•
damaged wiring
Remote panel has been used to Press the On/Standby button on the
put the charger into Standby
mode.
remote panel to turn the charger on.
fuse
•
battery voltage is below 9 V
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Troubleshooting
Symptom
Symptom
Fault indicator LED illuminates. Temp
LEDs flash.
and Battery
indicator
Truecharge2 Battery Charger completes a charging cycle, but the battery
voltage seems too low.
Possible Cause
Solution
Battery has a shorted cell.
Disconnect AC to the charger and
check the battery voltage approximately
one hour later.
NOTE: If the charger is functioning
properly but the charge cycles fail to
bring the resting voltage up above
10 V for 12-volt chargers and 20 V for
24-volt chargers, then this confirms the
battery has a damaged or shorted cell.
EXPLOSION HAZARD
Never charge a frozen battery.
Failure to follow these instructions can result in death or serious
injury.
Possible Cause
Solution
Battery temperature is either too If battery is too hot, allow battery to
hot or too cold for safe charging. cool. Improve ventilation or install in a
cooler location.
Replace battery.
The battery has reached the end of its
useful life and can no longer accept a
charge.
If the optional remote panel is
available, you may reduce the output
current using the Set Max Output
button.
If battery is too cold, allow batteries to
warm up.
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Troubleshooting
Symptom
Symptom
The Truecharge2 Battery Charger appears to be taking too long to charge
battery. Ready indicator LED does not illuminate after 24 hours of
charging.
The Truecharge2 Battery Charger appears to have quickly charged the
battery. Ready indicator LED illuminates sooner than expected.
Possible Cause
Solution
Possible Cause
Solution
Battery capacity is too low for Use a lower capacity charger.
the Truecharge2 Battery Charger Using the optional remote panel (if
Battery capacity is too high for Use a higher capacity charger.
the Truecharge2 Battery Charger
model.
model.
installed), reduce the output current
delivered to the smaller battery.
Load connected to battery is
draining charge current so that
battery does not recharge.
Disconnect all loads or switch loads off.
Replace battery.
Battery has a damaged cell or
has reached the end of its useful
life.
Replace battery.
Battery has a damaged cell or
has reached the end of its useful
life.
The remote panel Max Output
setting is too low for the battery
capacity.
Increase the Max Output setting.
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Troubleshooting
Symptom
The Truecharge2 Battery Charger will not perform equalization.
Possible Cause
Solution
Battery is the wrong type, or set Determine if the battery type is set to
to the wrong type to equalize.
GEL or AGM. These battery types
cannot be equalized.
Not all batteries are fully
charged.
The charger will wait for all batteries to
be in float stage of three-stage charging
or rest stage of two-stage charging
before attempting to equalize (the ready
indicator LED will illuminate).
An active fault is present on the Clear the active fault by disconnecting
bank you are attempting to
equalize.
the AC power source and finding the
cause of the fault from “Interpreting
43.
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Specifications
NOTE: Specifications are subject to change without prior notice.
AC Input Specifications
Physical Specifications
AC input voltage range
Nominal:
Full Performance:
Automatic derating to
80% output:
Base Unit Dimensions: L × W × H
120 Vac, 230 Vac, 240 Vac
104 – 265 Vac ±4 Vac
TC2012, TC4012
TC1024, TC2024
TC6012, TC3024
250×170×70 mm (9.84×6.70×2.76 in.)
250×170×70 mm (9.84×6.70×2.76 in.)
340×170×90 mm (13.38×6.70×3.54 in.)
90 – 108 ±4 Vac
Weight
Max. AC input current
TC2012:
TC2012, TC4012
TC1024, TC2024
TC6012, TC3024
2.2 kg (4.8 lbs)
2.2 kg (4.8 lbs)
4.5 kg (9.9 lbs)
3.9 A
7.7 A
11.6 A
3.9 A
7.7 A
11.6 A
TC4012:
TC6012
TC1024:
TC2024:
TC3024
AC input connections Three color-coded No. 14 AWG wires (L, N,
GND) minimum 152 mm (6 in.) long in a
separate AC wiring enclosure with 21.3 mm
(0.84 in.) hole provision for connection of a
½ inch North American "trade size" strain
relief (included).
Power factor at rated
load
≥0.95
Frequency
47 – 63 Hz
AC input connections IEC 60320 C14 male connector receptacle
(IEC models only)
Efficiency – peak
DC output
connections
Four M6 studs (3 positives and 1 common
negative) for battery cable ring terminals and
one M6 mm DC equipment ground
12/24-volt units: 80% @ 120 Vac
12/24-volt units: 84% @ 230 Vac
Surge protection Line-to-neutral surge protector rated at
275 Vac
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Specifications
DC Output Specifications
DC Output Specifications
Number of isolated battery
bank outputs
3 separated outputs
Normal operating output
range
12-volt units:
24-volt units:
0 – 16 Vdc
0 – 32 Vdc
DC output voltage range
including dead battery
charging voltage
12-volt units:
0 – 16 Vdc
0 – 32 Vdc
Maximum DC output
current (total)
TC2012:
24-volt units:
20 +10% A
40 +10% A
60 +10% A
10 +10% A
20 +10% A
30 +10% A
TC4012:
TC6012
TC1024:
TC2024:
Maximum equalization
voltage
12-volt units:
24-volt units:
16 Vdc
32 Vdc
TC3024:
Absorption voltage:
Voltage accuracy (no load)
12-volt units:
12-volt units
25 °C (77 °F)
14.4 ±0.1
24-volt units
25 °C (77 °F)
28.8 ±0.2
14.4 ±0.1 Vdc @ 25 °C (77 °F)
28.8 ±0.2 Vdc @ 25 °C (77 °F)
24-volt units:
Flooded
GEL
14.2 ±0.1
28.4 ±0.2
AGM
Lead-calcium
14.3 ±0.1
15.5 ±0.1
28.6 ±0.2
31.0 ±0.2
Nominal battery voltage
12-volt units:
12 Vdc
24 Vdc
24-volt units:
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Specifications
DC Output Specifications
DC Output Specifications
Float voltage:
Voltage regulation
Uncompensated load voltage
regulation
12-volt units
25 °C (77 °F)
13.5 ±0.1
13.8 ±0.1
13.4 ±0.1
24-volt units
25 °C (77 °F)
27.0 ±0.2
27.6 ±0.2
26.8 ±0.2
< 0.1Vdc drop from 0 Amps to rated
current output at charger output
terminals (adds in series with
recommended 3% limit for user's
battery cable voltage drop).
Flooded
GEL
AGM
Lead-calcium
13.5 ±0.1
27.0 ±0.2
Equalize mode current
50% rated output ±6%
Environmental Specifications
Equalize mode—maximum
output voltage
Operating range
0 – 60 °C (32 – 140 °F)
with up to 80% current derating
above 40 °C (104 °F) and
up to 50% current derating
above 50 °C (122 °F)
12-volt units:
24-volt units:
16 ±0.1 Vdc
32 ±0.2 Vdc
Off-state current draw
(without remote installed)
<35 mA dc
Storage
–40 to 80 °C (–40 to 176 °F)
Humidity
5 – 95%, RH non-condensing
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Specifications
Protection Features
Protection Features
Battery reverse polarity
Protected by replaceable DC output
fuses
Battery under-temperature
protection
Charger shuts down if battery
temperature below –25 °C (–13 °F) is
sensed by the battery temperature
sensor (BTS).
Over-voltage limits
The Truecharge2 Battery Charger will
stop charging if the output voltage is
above
16.6 ±0.5 Vdc for 12 Vdc units,
33.2 ±0.1 Vdc for 24 Vdc units.
Regulatory Approvals
Safety
North America
Output current limit
NRTL approved to CSA E60335-2-29, UL1236 including
the marine supplement, and UL1564.
ABYC E11 - Alternating Current and Direct Current
Electrical Systems on Boats, and
TC2012:
20 +10% A
40 +10% A
60 +10% A
10 +10% A
20 +10% A
30 +10% A
TC4012:
TC6012:
TC1024:
TC2024:
TC3024:
ABYC A31 - Battery Chargers and Inverters.
CE marked for the Low Voltage Directive 2006-95-EC,
(complying with EN60335-2-29 Battery Chargers).
EN 28846 - Small Craft Electrical Devices, Protection
against ignition of surrounding flammable gases.
Designed to IEC60335-2-29 including Australian
deviations.
European Union
Australia
Over-temperature
(measured internally)
Shutdown at 65 ±5 °C (149 ±9 °F)
Restart at 60 ±5 °C (140 ±9 °F)
EMC
Battery over-temperature
protection
Charger shuts down if battery
temperature above 70 °C (158 °F) is
sensed by the battery temperature
sensor (BTS).
Class B according to FCC Part 15B and Industry Canada
ICES-003.
CE marked for the EMC Directive 2004-108-EC
(complying with EN55014-1, EN55014-2, EN61000-3-2,
and EN61000-3-3).
North America
European
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Warranty and Return Information
Warranty
Hawaii and outside of the United States and Canada are excluded. Contact
Xantrex Customer Service for details on freight policy for return shipments
from excluded areas.
What does this warranty cover and how long does it last? This
Limited Warranty is provided by Xantrex Technology USA Inc.
(“Xantrex”) and covers defects in workmanship and materials in your
Truecharge2 Series Battery Charger. This warranty period lasts for 24
months from the date of purchase at the point of sale to you, the original end
user customer, unless otherwise agreed in writing (the “Warranty Period”).
You will be required to demonstrate proof of purchase to make warranty
claims.
How do you get service? If your product requires troubleshooting or
warranty service, contact your merchant. If you are unable to contact your
merchant, or the merchant is unable to provide service, contact Xantrex
directly at:
This Limited Warranty is transferable to subsequent owners but only for the
unexpired portion of the Warranty Period. Subsequent owners also require
original proof of purchase as described in “What proof of purchase is
required?”
Telephone: 1 800 670 0707
Fax:
1 800 994 7828
Website:
What will Xantrex do? During the Warranty Period Xantrex will, at
its option, repair the product (if economically feasible) or replace the
defective product free of charge, provided that you notify Xantrex of the
product defect within the Warranty Period, and provided that Xantrex
through inspection establishes the existence of such a defect and that it is
covered by this Limited Warranty.
Direct returns may be performed according to the Xantrex Return Material
Authorization Policy described in your product manual. For some products,
Xantrex maintains a network of regional Authorized Service Centers. Call
Xantrex or check our website to see if your product can be repaired at one
of these facilities.
Xantrex will, at its option, use new and/or reconditioned parts in
performing warranty repair and building replacement products. Xantrex
reserves the right to use parts or products of original or improved design in
the repair or replacement. If Xantrex repairs or replaces a product, its
warranty continues for the remaining portion of the original Warranty
Period or 90 days from the date of the return shipment to the customer,
whichever is greater. All replaced products and all parts removed from
repaired products become the property of Xantrex.
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,
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Warranty and Return Information
by Xantrex at your direction for incorporation into the product;
f) the product if its original identification (trade-mark, serial number)
markings have been defaced, altered, or removed;
What proof of purchase is required? In any warranty claim, dated
proof of purchase must accompany the product and the product must not
have been disassembled or modified without prior written authorization by
Xantrex.
g) the product if it is located outside of the country where it was
purchased; and
Proof of purchase may be in any one of the following forms:
h) any consequential losses that are attributable to the product losing
power whether by product malfunction, installation error or misuse.
•
•
•
The dated purchase receipt from the original purchase of the
product at point of sale to the end user; or
The dated dealer invoice or purchase receipt showing original
equipment manufacturer (OEM) status; or
The dated invoice or purchase receipt showing the product
exchanged under warranty.
What does this warranty not cover? Claims are limited to repair and
replacement, or if in Xantrex's discretion that is not possible,
reimbursement up to the purchase price paid for the product. Xantrex will
be liable to you only for direct damages suffered by you and only up to a
maximum amount equal to the purchase price of the product.
This Limited Warranty does not warrant uninterrupted or error-free
operation of the product or cover normal wear and tear of the product or
costs related to the removal, installation, or troubleshooting of the
customer's electrical systems. This warranty does not apply to and Xantrex
will not be responsible for any defect in or damage to:
a) the product if it has been misused, neglected, improperly installed,
physically damaged or altered, either internally or externally, or
damaged from improper use or use in an unsuitable environment;
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 limited to high
input voltage from generators and lightning strikes;
c) the product if repairs have been done to it other than by Xantrex or its
authorized service centers (hereafter “ASCs”);
d) the product if it is used as a component part of a product expressly
warranted by another manufacturer;
e) component parts or monitoring systems supplied by you or purchased
975-0526-01-02
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Warranty and Return Information
CONSUMERS IN THE EUROPEAN UNION:
Disclaimer
IF YOU ARE A CONSUMER (RATHER THAN A PURCHASER OF THE PRODUCT IN THE
COURSE OF A BUSINESS) AND PURCHASED THE PRODUCT IN A MEMBER STATE OF THE
EUROPEAN UNION, THIS LIMITED WARRANTY SHALL BE SUBJECT TO YOUR
STATUTORY RIGHTS AS A CONSUMER UNDER THE EUROPEAN UNION PRODUCT
WARRANTY DIRECTIVE 1999/44/EC AND AS SUCH DIRECTIVE HAS BEEN IMPLEMENTED
IN THE EUROPEAN UNION MEMBER STATE WHERE YOU PURCHASED THE PRODUCT.
FURTHER, WHILE THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, YOU
MAY HAVE OTHER RIGHTS WHICH MAY VARY FROM EU MEMBER STATE TO EU
MEMBER STATE OR, IF YOU DID NOT PURCHASE THE PRODUCT IN AN EU MEMBER
STATE, IN THE COUNTRY YOU PURCHASED THE PRODUCT WHICH MAY VARY FROM
COUNTRY TO COUNTRY AND JURISDICTION TO JURISDICTION.
Product
THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY
XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS, WHERE
PERMITTED BY LAW, IN LIEU OF ALL OTHER WARRANTIES, CONDITIONS, GUARANTEES,
REPRESENTATIONS, OBLIGATIONS AND LIABILITIES, EXPRESS OR IMPLIED, STATUTORY
OR OTHERWISE IN CONNECTION WITH THE PRODUCT, HOWEVER ARISING (WHETHER
BY CONTRACT, TORT, NEGLIGENCE, PRINCIPLES OF MANUFACTURER'S LIABILITY,
OPERATION OF LAW, CONDUCT, STATEMENT OR OTHERWISE), INCLUDING WITHOUT
RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY,
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE
EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE
LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED WARRANTY.
CONSUMERS IN THE REST OF THE WORLD:
Exclusions
IN NO EVENT WILL XANTREX BE LIABLE FOR: (A) ANY SPECIAL, INDIRECT,
INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING LOST PROFITS, LOST
REVENUES, FAILURE TO REALIZE EXPECTED SAVINGS, OR OTHER COMMERCIAL OR
ECONOMIC LOSSES OF ANY KIND, EVEN IF XANTREX HAS BEEN ADVISED, OR HAD
REASON TO KNOW, OF THE POSSIBILITY OF SUCH DAMAGE; (B) ANY LIABILITY
ARISING IN TORT, WHETHER OR NOT ARISING OUT OF XANTREX'S NEGLIGENCE, AND
ALL LOSSES OR DAMAGES TO ANY PROPERTY OR FOR ANY PERSONAL INJURY OR
ECONOMIC LOSS OR DAMAGE CAUSED BY THE CONNECTION OF A PRODUCT TO ANY
OTHER DEVICE OR SYSTEM; AND (C) ANY DAMAGE OR INJURY ARISING FROM OR AS A
RESULT OF MISUSE OR ABUSE, OR THE INCORRECT INSTALLATION, INTEGRATION OR
OPERATION OF THE PRODUCT BY PERSONS NOT AUTHORIZED BY XANTREX.
IF THIS PRODUCT IS A CONSUMER PRODUCT, FEDERAL LAW DOES NOT ALLOW AN
EXCLUSION OF IMPLIED WARRANTIES. TO THE EXTENT YOU ARE ENTITLED TO
IMPLIED WARRANTIES UNDER FEDERAL LAW, TO THE EXTENT PERMITTED BY
APPLICABLE LAW THEY ARE LIMITED TO THE DURATION OF THIS LIMITED
WARRANTY. SOME STATES, PROVINCES AND JURISDICTIONS DO NOT ALLOW
LIMITATIONS OR EXCLUSIONS ON IMPLIED WARRANTIES OR ON THE DURATION OF AN
IMPLIED WARRANTY OR ON THE LIMITATION OR EXCLUSION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION(S) OR EXCLUSION(S) MAY
NOT APPLY TO YOU. THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS.
YOU MAY HAVE OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE, PROVINCE
TO PROVINCE OR JURISDICTION TO JURISDICTION.
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Warranty and Return Information
Ship the unit prepaid to the address provided by your Xantrex customer
service representative.
Return Material Authorization Policy
If you are returning a product from outside of the USA or
Canada In addition to the above, you MUST include return freight funds
and are fully responsible for all documents, duties, tariffs, and deposits.
For those products that are not being repaired in the field and are being
returned to Xantrex, before returning a product directly to Xantrex you
must obtain a Return Material Authorization (RMA) number and the
correct factory “Ship To” address. Products must also be shipped prepaid.
Product shipments will be refused and returned at your expense if they are
unauthorized, returned without an RMA number clearly marked on the
outside of the shipping box, if they are shipped collect, or if they are
shipped to the wrong location.
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 procedures that may
apply to that particular facility and that the ASC repairs this particular
Xantrex product.
When you contact Xantrex to obtain service, please have your instruction
manual ready for reference and be prepared to supply:
•
•
•
•
The serial number of your product
Out of Warranty Service
If the warranty period for your product has expired, if the unit was damaged
by misuse or incorrect installation, if other conditions of the warranty have
not been met, or if no dated proof of purchase is available, your unit may be
serviced or replaced for a flat fee.
Information about the installation and use of the unit
Information about the failure and/or reason for the return
A copy of your dated proof of purchase
Record these details on page 62.
To return your product for out of warranty service, contact Xantrex
Customer Service for a Return Material Authorization (RMA) number and
follow the other steps outlined in “Return Procedure” on page 61.
Payment options such as credit card or money order will be explained by
the Customer Service Representative. In cases where the minimum flat fee
does not apply, as with incomplete units or units with excessive damage, an
additional fee will be charged. If applicable, you will be contacted by
Customer Service once your unit has been received.
Return Procedure
Package the unit safely, preferably using the original box and packing
materials. Please ensure that your product is shipped fully insured in the
original packaging or equivalent. This warranty will not apply where the
product is damaged due to improper packaging.
Include the following:
•
•
•
•
The RMA number supplied by Xantrex Technology USA Inc.
clearly marked on the outside of the box.
A return address where the unit can be shipped. Post office boxes
are not acceptable.
A contact telephone number where you can be reached during
work hours.
A brief description of the problem.
975-0526-01-02
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Warranty and Return Information
If you need to contact Customer Service, please record the following details
before calling. This information will help our representatives give you
better service.
Information About Your System
As soon as you open your Truecharge2 Series Battery Charger package,
record the following information and be sure to keep your proof of
purchase.
______________________
❐
❐
Type of installation (e.g.
RV, truck)
Length of time unit
______________________
______________________
❐
❐
Serial Number
Product Number/s
804-1220-02, 804-1240-02,
804-1260-02, 804-2410,
804-2420, 804-2430
has been installed
Battery/battery bank size
Battery type (e.g. flooded,
______________________
______________________
❐
❐
sealed gel cell, AGM)
DC wiring size and length
Alarm sounding?
Description of indicators
on front panel
804-1220-03, 804-1240-03,
804-1260-03, 804-2410-01,
804-2420-01, 804-2430-01
______________________
______________________
______________________
______________________
❐
❐
❐
❐
❐
Purchased From
Purchase Date
______________________
______________________
______________________
❐
❐
Appliances operating
when problem occurred
Description of problem
________________________________________________
________________________________________________
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Xantrex Technology USA Inc.
1 800 670 0707 Tel
1 800 994 7828 Fax
975-0526-01-02
Printed in China.
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