Xantrex Technology Battery Charger TC2 204060 User Manual

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 USERS 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  
975-0526-01-02  
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TC2 204060 Series BattChg Owners Guide.book Page ii Friday, July 8, 2011 11:44 AM  
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  
as its products and services at www.xantrex.com.  
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 OWNERS 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  
undersized. See “Wiring Requirements” on page 12 for guidance.  
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  
(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  
Installing the Truecharge 2 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
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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  
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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  
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  
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  
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.  
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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.  
975-0526-01-02  
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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  
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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)  
Use the information in “DC Wiring” on page 13 and your local  
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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TC2 204060 Series BattChg Owners Guide.book Page 13 Friday, July 8, 2011 11:44 AM  
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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TC2 204060 Series BattChg Owners Guide.book Page 25 Friday, July 8, 2011 11:44 AM  
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  
2. In “Step 4: Installing AC Wiring” on page 21, make sure that the two  
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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TC2 204060 Series BattChg Owners Guide.book Page 26 Friday, July 8, 2011 11:44 AM  
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.  
1. Follow the procedures in “Step 5: Powering Up” on page 24.  
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  
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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TC2 204060 Series BattChg Owners Guide.book Page 41 Friday, July 8, 2011 11:44 AM  
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  
operating ranges. See “Specifications” on page 54 for more information on  
normal operating ranges.  
Fault LED flashes  
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  
open DC breaker or external “Interpreting Fault and Warning  
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  
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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TC2 204060 Series BattChg Owners Guide.book Page 56 Friday, July 8, 2011 11:44 AM  
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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TC2_204060_Chapters.fm Page 58 Thursday, August 4, 2011 1:12 PM  
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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TC2_204060_Chapters.fm Page 59 Thursday, August 4, 2011 1:12 PM  
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  
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TC2_204060_Chapters.fm Page 60 Thursday, August 4, 2011 1:12 PM  
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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TC2_204060_Chapters.fm Page 61 Thursday, August 4, 2011 1:14 PM  
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.  
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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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TC2 204060 Series BattChg Owners Guide.book Page i Friday, July 8, 2011 11:44 AM  
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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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