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Xantrex True Charge2 20a Battery Charger Manual



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Zem Battery ChargerOwners GuideTC2 204060 Series BattChg Owners Guidebook Page i Friday July 8 2011 1144 dEeE bch aeeDdD acEeE bch CEeE bch aeeDCD KEeE bch 9A A 00 60GA 204060 Series BattChg Owners Guidebook Page ii Friday July 8 2011 1144 and Smart choice for power are trademarks of Schneider Electric Services International sprl registered in the US and other countries Other trademarks registered trademarks and product names are the property of their respective owners and are used herein for identification purposes onlyNotice of Series Battery Charger Owners Guide July 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 for USA and RevisionJuly 2011 Rev BDocument Part NumbersContact ModelsIEC ModelsaIEC refers to the international standard from the Commission for plugs socketoutlets and couplers for industrial purposes IEC models have an AC input receptacle that connects with an IEC cable not 804124002 804126002 8042410 8042420 804124003 804242001 800 670 0707Fax1 800 994 204060 Series BattChg Owners Guidebook Page i Friday July 8 2011 1144 Series Battery Charger Owners purpose of this Owners Guide is to provide explanations and procedures for installing operating and maintaining the Truecharge2 Series Battery 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 the unit It does not provide details about particular brands of batteries You need to consult individual battery manufacturers for this 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 alling 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 UsedSTATEMENT OF HAZARDdance or strict to follow these instructions will result in death or serious OF HAZARDdance or strict to follow these instructions can result in death or serious OF HAZARDdance or strict to follow these instructions can result in minor or moderate injuryTC2 204060 Series BattChg Owners Guidebook Page ii Friday July 8 2011 1144 InformationYou can find more information about Xantrex Technology USA Inc as well as its products and services at OF HAZARDContains statements of avoidance or strict to follow these instructions can damage the unit andor damage other notes describe things which are important for you to know however they are not as serious as a danger warning or cautionThe product marking on the left when found imprinted on are to refer to this guide for cautions and warningsTC2 204060 Series BattChg Owners Guidebook Page iii Friday July 8 2011 1144 Series Battery Charger Owners 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 guideNOTE The Truecharge2 Series Battery Charger contains no parts with the exception of the DC output fusesich are See Replacing the DC Output Fuse on page 48 for instructions For obtaining service other than replacing the fuse see Warranty and Return Information on page 58 for guidanceNOTE The Truecharge2 Series Battery Charger must be provided with conductors connected to the AC input ground and to the DC chassis ground See Step 2 Connecting the DC Chassis Ground Earthfor instructions NOTE Turning off the battery charger using the onstandby button on the optional remote panel will not reduce an electrical shock SHOCK HAZARDDo not expose the Truecharge2 Battery Charger to rain snow spray or bilge waterDo 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 wayDo not disassemble the battery charger Internal capacitors remain charged after all power is both AC and DC power from the battery charger before attempting any maintenance or cleaning or working on any circuits charger See note belowDo 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 to follow these instructions will result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page iv Friday July 8 2011 1144 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 engineFIRE AND BURN HAZARDDo not cover or obstruct the air intake vent openings andor install in a zeroclearance compartment See Location on page 10 for proper location to follow these instructions will result in death or serious HAZARDCharge only properly rated such as 12 V and 24 Vleadacid GEL AGM Flooded or batteries because other battery types may explode and burstDo not work in the vicinity of leadacid batteries Batteries generate explosive gases during normal operation See note belowFailure to follow these instructions will result in death or serious injuryPERSONAL INJURY HAZARDThis battery charger is not intended for use by persons including childrenysical 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 chargerFailure to follow these instructions can result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page v Friday July 8 2011 1144 Series Battery Charger Owners When Working With the Truecharge2 Series Battery Charger unit away from batteries in a well ventilated have someone within range of your voice or close enough to come to your aid when you work near a leadacid battery3Always have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes4If 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 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 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 7When 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 dont cause an arcBURN FROM HIGH SHORTCIRCUIT CURRENT FIRE AND EXPLOSION FROM VENTED GASES HAZARDSAlways wear proper nonabsorbent gloves complete eye protection and clothing protection Avoid touching your eyes and wiping your forehead while working near batteries See note 4Remove all personal metal items like rings bracelets and watches when working with batteries See notes 5 and 6Never smoke or allow a spark or flame near the engine or batteriesNever charge a frozen batteryFailure to follow these instructions can result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page vi Friday July 8 2011 1144 When Preparing to and follow all of the battery manufacturers specific precautions such as removing or not removing cell caps while charging whether equalization is acceptable for your battery and recommended rates of charge2For flooded nonsealed batteries add 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 Precautions When Placing the Battery ChargerNOTE For North American marine installations external connections to the charger shall comply with the United States Coast Guard Electrical Regulations 33CFR183 Sub Part IEXPOSURE TO CHEMICALS AND GASES HAZARDMake sure the area around the battery is well ventilatedMake sure the voltage of the batteries matches the output voltage of the battery chargerBe careful to keep corrosion from coming into contact with your eyes and skin when cleaning battery to follow these instructions can result in death or serious injuryRISK OF DAMAGE TO THE BATTERY CHARGERNever allow battery acid to drip on the battery charger when reading gravity or filling batteryNever place the Truecharge2 Series Battery Charger unit directly above batteries gases from a battery will corrode and damage the chargerDo not place a battery on top of the battery chargerFailure to follow these instructions can damage the unit andor damage other equipmentTC2 204060 Series BattChg Owners Guidebook Page vii Friday July 8 2011 1144 Series Battery Charger Owners GuideThis 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 otection 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 there is no guarantee that interference will not occur in a 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 or relocate the receiving the separation between the equipment and the equipment into an outlet on a circuit different from that to which the receiver is the dealer or an experienced radioTV changes or modifications to the equipment could void the users authority to operate the equipmentTC2 204060 Series BattChg Owners Guidebook Page viii Friday July 8 2011 1144 AMRImportant Safety Instructions ivIntroduction 1Truecharge 2 Battery Charger Features 3Preparing For Installation 8Installing the Truecharge 2 Battery Charger 16Installing a Parallel Configuration 25Installing Batteries 27Configuring the Truecharge2 Battery Charger 34Charging Batteries 35Equalizing Flooded Batteries the Charger to ON Standby or Disabled 40Accessing Charger Information 41Using A Generator As Source Power 46Maintaining the Charger 47Replacing the DC Output Fuse 54Warranty and Return Information 58TC2 204060 Series BattChg Owners Guidebook Page i Friday July 8 2011 1144 AMTC2 204060 Series BattChg Owners Guidebook Page ii Friday July 8 2011 1144 chapter describes the standard features of a Truecharge2 Battery Charger as well as its protection featthe different parts of the Truecharge2 Battery Battery ChargerThe Truecharge2 Battery Truecharge2 Battery Charger unitowners guiderubber boots for DC terminalsnuts and washers M6 for DC terminals and ground studstrain relief clamp for AC input cablesthree crimp connectors for AC wiringStandard and Protection FeaturesThe Truecharge2 Battery Charger provides the following standard featuresup to three full current rated outputsbattery monitoring charging voltage for batteries when connected to almost any single phase AC power outlet in the worldlow interference EMIautomatic charge resumption if required after AC power custom charge settingsfully discharged battery to operate two Truecharge2 Battery Chargers in parallel mode with the use of the optional remote panelThe Truecharge2 Battery Charger provides the following protection features battery reverse polarity protection via output fusesAC input outofrange ambient overcharging protection1Not included with IEC models of Truecharge2 Battery the carton and packing material in case you need to return the Truecharge2 Battery Charger for servicing2Each output can charge different batteries that either have the same chemistry or cantolerate the same charge sequence and voltagecurrent ratings3The charger can be programmed with custom charge setpoints using PC interfaceThis programming can only be done using a special configuration tool operated byXantrex or a designated OEM4The charger can initiate charging a nondamaged but zero voltage batteryTC2 204060 Series BattChg Owners Guidebook Page 1 Friday July 8 2011 1144 AM2Truecharge2 Series Battery Charger Owners current limiting provides protection against short circuit conditions on the chargers rating enabling installation in engine spacesisolated designshort 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 versadripproof rubber boots for DC terminals for added moisture protectionIP32 drip protection ratingThe following optional accessories are available for the Truecharge2 Battery Chargeran optional battery temperature sensor BTS andan optional remote panelThe optional Battery Temperature Sensor BTSovides these protection chargicharging at 25 C 13 For belowbattery chargicharging at 70 C 158 Fr higher andcharging voltage compensation based on the temperature of the battery the optional BTS is connected toThe optional Remote Panel provides the following featuresCan be mounted up to 15 meters 50 feet away for remote control maximum output current limiting for charging smaller capacity batteries or to lower the current drawn from the generator or AC ability to enable or disable the charger while AC power is connected ability to display individual battery bank levels andability to operate two Truecharge2 Battery Chargers in parallel for increased output current capacity1In two specific installation Mounting Orientations Deck page 112Part number 8080232013Part number panel comes standard with a 75m 25fte For longer 15m 50ftcable order part number 31626200TC2 204060 Series BattChg Owners Guidebook Page 2 Friday July 8 2011 1144 2 Battery Charger FeaturesThis section describes the different parts of the Truecharge2 Battery ChargerFront PanelFigure 1Truecharge2 Battery Charger Front PanelItem control and status display panel or simply see Onboard Control and Status Display Panel on page 5 for more inTruecharge2 Battery Charger settings and for monitoring charger status and charging current Mounting flanges are used to permanently install the product protects the DC terminals as well as the communication and BTS ports Remove and replace when installing SHOCK the batteries and AC power before opening the fuse access Failure to follow these instructions will result in death or serious injuryFuse 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 fusesTC2 204060 Series BattChg Owners Guidebook Page 3 Friday July 8 2011 1144 Series Battery Charger Owners 2 Battery Charger FeaturesRear PanelThis section describes the parts of the rear panel of the Truecharge2 Battery Charger Item DescriptionAC 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 productDC ground stud for connecting the chargers chassis to Figure 2Truecharge2 Battery Charger Rear Panel40 A model TC4012 shown Other models may varyItem DescriptionBTS port battery temperature sensor port remote panel portBattery positive bank 3 6mm studBattery positive bank 2 6mm studBattery positive bank 1 6mm studBattery negative for all three banks 6mm located inside is the fan assemblyAC wiring compartmentAC pigtail wiring line neutral and ground input wiresTC2 204060 Series BattChg Owners Guidebook Page 4 Friday July 8 2011 1144 2 Battery Charger Control and Status Display PanelThis section describes the parts of the onboard control and status display panel of the Truecharge2 Battery Charger See Reading Onboard Display LEDs on page 41 for more informationTo reduce current draw from the connected battery when AC power is not present the panels LED control and status lights are automatically turned off and the buttons are to temporarily check the status of the connected battery when AC power is not present press the Status button on the optional remote 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 Figure 3Onboard Control and Status Display PanelItem Output LEDsThe 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 chargers current output is 24A The numbers below the LEDs represent the percentage values See Reading Onboard Display LEDs on page 41NOTEWhen 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 currentOne or two LEDs may flash intermittently in combination with a solid Fault LED indicating a faultwith a flashing Fault LED indicating a warningThe icons above the LEDs represent the warning conditions See Reading Onboard Display LEDs on page 41TC2 204060 Series BattChg Owners Guidebook Page 5 Friday July 8 2011 1144 AM6Truecharge2 Series Battery Charger Owners 2 Battery Charger Features2Fault LEDThe LED may illuminate a solid light indicating a faultflash intermittently indicating a warning in combination with flashing Charging Output LEDs See Interpreting Fault and Warning Indicators on page 43 for Status LEDsDisplays the current status of the charger a solid light indicates batteries are fully charged and the charger is in rest stageReady and Charging solid lights indicate batteries are fully charged and the charger is in float stage a solid light indicates charger is performing a normal charge cycleEqualize 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 Item Mode Select buttonPress 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 Bulk Absorption and Float default Bulk and Absorption onlyWhen setting or cancelling an Equalization program Press and hold for five seconds both the Charger Mode and Battery Temp Select Type Select buttonPress and hold the button for three one of five settings An indicator LED NOTE The fifth setting is a custom battery type illuminate See Custom belowEach setting maximizes charger performance for its corresponding battery type Absorbent Glass Mat leadacid battery Leadacid battery default settingGEL Geltype leadacid battery Leadcalcium batteryCustom Only available if a custom algorithm has been programmed by Xantrex or a designated OEMItem DescriptionTC2 204060 Series BattChg Owners Guidebook Page 6 Friday July 8 2011 1144 2 Battery Charger Temp Select buttonPress and hold the button for three seconds to select one of three settings An indicatoIf an optional BTS is connected the indicator LEDs represent realtime battery the optional BTS is not used this selection changes the chargers 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 32RISK OF BATTERY DAMAGEBe sure the appropriate setting is selected before charging For varying conditions use the Warm settingFailure to follow these instructions can damage the unit andor damage other equipmentItem for battery temperature below 5C 41 Fthe charging voltage to compensateWarm for battery temperature between 5 and 30 C 41 and 86 Fdefault setting for battery temperature above 30C 86 Flowers charging voltage to compensateWhen setting or cancelling an Equalization program Press and hold for five seconds both the Charger Mode and Battery Temp Select buttonsTC2 204060 Series BattChg Owners Guidebook Page 7 Friday July 8 2011 1144 Series Battery Charger Owners GuidePreparing For The Truecharge2 Battery Charger is designed to be permanently mounted Figure 4 shows a typical installation with three batemperature sensor BTS and a remote panel both optionalIt also shows the AC and DC wiring and protection devices required for a typical installation Means of overcurrent protection and disconnection must be incorporated into the fixed wiring in accordance with the electrical code that governs each installation IMPROPER INSTALLATION BY AN UNQUALIFIED INSTALLERThe battery charger must be instaccordance with all applicable local or national installation codes Examples of such codes are the US National Electrical Code NFPA 70the American Boat Yacht Council standards E11 and A31 and the US Coast Guard Electrical Regulations to follow these instructions can damage the unit andor damage other 4Configuration for Normal Loads1AC input wiring compartment2AC mains source protected by correct size and type of branch 3DC negative cableTC2 204060 Series BattChg Owners Guidebook Page 8 Friday July 8 2011 1144 For and MaterialsTo mount and connect the Truecharge2 Battery Charger you need the 10mm socket wrench and extension for the DC terminals and ground studPhillips screwdriver for removing and resecuring the AC and DC wiring compartment coverspower bit set for pilot holes for mounting screscrews use 116 drillwire recommended crimp tool for any crimp terminals that You need the following materials3 conductor AC input wiring Use the information in Step 4 Installing AC Wiring on page 21 and your local electrical codes to determine the correct wire and breaker or AC cable strain relief if the one included is not compliant with your local electrical sized DC cables for each battery with suitable connectors at the battery endUse the information in DC Wiring on page 13 and your local electrical codes to determine the correct wire and breaker or sized DC chassis ground earthcable with suitable ring terminals to fit 6mm 14in studs at the charger end Marine grade hardware is recommendedDC fused disconnect or properly rated circuit breaker for each battery mounting screws M3 or 6 marine grade corrosion resistant 4pieces Length dependent on mounting surface4DC positive cables5DC circuit breakers or DC fused disconnects 6Battery or battery bank7Battery Temp Sensoroptional accessory part number ground bus or DC negative bus9Ground bus10DC chassis ground earth11Remote paneloptional accessory part number 808804001TC2 204060 Series BattChg Owners Guidebook Page 9 Friday July 8 2011 1144 Series Battery Charger Owners GuidePreparing For the Truecharge2 Battery Charger in a location that meets the following requirements NOTESWhen 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 IP32 if installed in either of two specific orientations shown in Figure 5 The Truecharge2 Battery Charger must be installed in a dry location not subject to moisture especially rain spray or splashing bilge waterClean The Truecharge2 Battery Charger should not be exposed to metal filings or any other form of ambient air temperature should be between 0 50 C 32 122 FVentilated There must be at least 10cm 4in of clearance on the top and bottom ends of the Truecharge2 Battery Charger for air flow and at least 6cm 25inof clearance on either side see Figure 7entilation openings on the charger must not be obstructed If the charger is mounted in a tight fitting compartment the compartment must be ventilated with cutouts to prevent the charger from overheating SafeThis battery charger except IEC models is equipment so it containing gasoline tanks or fittings which require equipment that it is safest not to install any kind of electrical equipment including the Truecharge2 Battery Charger in these areasClose to batteriesThe Truecharge2 Battery Charger should be installed as 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 to NonIEC models only See Product Numbers on page ibSee Product Numbers on page iEXPLOSION HAZARD FOR IEC MODELS ONLYDo not place the battery charger in machinery space or in areas containing gasoline tanks or fittings in which equipment is to follow these instructions will result in death or serious 204060 Series BattChg Owners Guidebook Page 10 Friday July 8 2011 1144 For 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 The other possible mounting orientations shown in Figure 6 cdwill 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 dryThe 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 ELECTRICAL SHOCK HAZARDIn 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 6Failure to follow these instructions will result in death or serious injuryFigure 5Mounting Orientations Deck and HorizontalDeck Mount this orientation meets IP32 requirements and is Wall Mount with AC wiring higher than DC terminals only this orientation meets IP32 requirements and is dripproofTC2 204060 Series BattChg Owners Guidebook Page 11 Friday July 8 2011 1144 Series Battery Charger Owners GuidePreparing For 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 that wires and fuses or breakered disconnects are correctly sized Maximum continuous DC current available from the charger may be an additional 610 above the nominal current rating of the chargerFigure 6Mounting Orientations VerticalFigure 7Ventilation 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 SHOCK AND FIRE HAZARDDo not operate the battery charger with damaged or sMake sure that all wiring is in good condition and is notes belowFailure to follow these instructions will result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page 12 Friday July 8 2011 1144 For InstallationDC WiringThe following tables show some typical wire sizes for various cable length runs based on 3 voltage drop on DC cables 75C 167Fwith wiring being inside the engine compartment assumed ambient of 50C 122FNOTE In the event of a conflict between the voltage drop table Table IXand the ampacity table Table VIAuse the larger wire sizeNOTE In the event of a conflict between the voltage drop table Table IXand the ampacity table Table VIAe the larger wire Protection codes require the DC circuit from each battery to the charger to be equipped with a disconnect and an overcurrent protection device usually within 7 inches 178 cm of each battery The devices are usually DCrated circuit breakers fused discdisconnect for each circuit These devices must be rated for DC voltage and Table 1DC Wiring Examples for 12 V based on American Boat Yacht Council E11 2008Table VIA and Table IXWire Lengthmax length one wayWire Size AWG and mm 2DC Wiring Examples for 24 V based on American Boat Yacht Council E11 2008Table VIA and Table IXWire Lengthmax length one wayWire Size AWG and mm 16 13mmNo 10 53mmNo 10 53mm75225No 16 13mmNo 10 53mmNo 10 53mm206No 10 American Boat Yacht Council E11TC2 204060 Series BattChg Owners Guidebook Page 13 Friday July 8 2011 1144 Series Battery Charger Owners GuidePreparing For 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 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 DC Chassis GroundThe DC chassis ground earthshould 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 smaller See Step 2 Connecting the DC Chassis Ground Earthpage 17 for instructionsAC WiringThe 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 belowThe AC input wiring for the Truecharge2 Battery Charger should be threeral 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 providedFor examplein US NEC you may use a 14AWG wire with a 15A breaker for up to 12A continuous current or 12AWG for a 20A breaker for up to 16A continuous currentorfor 230Vac application you may be able to use either a 25mm wire with a 16A breaker or use 15mm wire with a 10A breaker Table 3Fuse Sizes versus Wire Sizes Based on ABYC HAZARDUse only on circuits provided with 20A maximum branch circuit protection in accordance with National Electrical Code NFPA 70Failure to follow these instructions will result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page 14 Friday July 8 2011 1144 For 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 Specifications on page 54 Other examples of AC wiring marine applications the American Boat Yacht Council ABYCrequires stranded wire which is more robust than solid wire when exposed to vibrationFor RV applications the United States National Electrical Code NECallows solid wire in multiconductor cable however stranded wire is also acceptable which will withstand vibration better The AC wiring supplying the Truecharge2 Battery Charger must be protected by the correct size and type of branchcircuit 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 circuitBattery Bank Size 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 chargers rated maximum charging current For example a 20amp charger will charge a minimum 40Ah battery If you are considering new batteries please consult the batterys manufacturer for their recommendation based on the maximum charging current of your the battery manufacturer has specified the maximum charge current please foTable 4Minimum Battery Bank Size12 Vdc ModelsMinimum Battery Bank Size Vdc ModelsMinimum Battery Bank Size 204060 Series BattChg Owners Guidebook Page 15 Friday July 8 2011 1144 Series Battery Charger Owners the Truecharge 2 Battery ChargerBe sure to read the safety guidelines and pay attention to all cautions and 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 To make charger installation quick and easy Xantrex recommends that the performed in the following sequence1Mount the charger in the DC ground3Install DC wiring including installing required disconnects fuses or AC wiring including earth grounds5Power up the chargerStep 1 Mounting the Battery ChargerMount the Truecharge2 Battery Charger using all four mounting slots and holes which are provided Mounting orientations aand b in Figure 5 meet IP32 and dripproof requirements that are needed to ensure safety in the presence of condensation The other possible mounting orientations cdin 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 To mount the a mounting surface that is flat and allows for a minimum of 10 cm 4 intop and bottom ends for air flow and at least 6 cm 25 in of clearance on either sides see Figure 7 Ventilation Clearance on page 122Drill the four pilot holes for thtaking care that there is nothing behind the surface that can be damaged by the drill3Mount the Truecharge2 Battery Charger using corrosion resistant 6 3mmund pan head or similarscrews The top two keyholestyle mounting holes can be used to hold the Truecharge2 Battery Charger in place while fastening the bottom two ting 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 ELECTRICAL SHOCK all sources of AC and DC power before to follow these instructions will result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page 16 Friday July 8 2011 1144 the Truecharge 2 Battery ChargerStep 2 Connecting the DC Chassis Ground EarthNOTE Have an electrician install a properly grounded circuit if one is not availableThe Truecharge2 Battery Charger must be connected to a grounded metal permanent wiring system or an conductor should be run with the circuit conductors and connected to the lead on the charger Connections to the battery charger must comply with all local and codes and recommends that you install a DC chassis ground earthfrom the ground stud on the Truecharge2 Battery Charger to the engine bus or DC ground bus The DC chassis ground earthshould be sized correctly with the power conductors and both must be sized for the battery fuses that are used to protect the DC local electrical your jurisdiction for your applicationTo connect the DC chassis ground earth1Locate the ground stud on the Truecharge2 Battery the DC chassis ground earththe ground stud to the ground bus See Figure 4 Configuration for Normal Loads on page Use a flat washer a lock washer and a nut included in the installation kitthe the nuts to 23 Nm 20 lbin and test that the wire is secure Do not overtighten as this may result in damage to the SHOCK HAZARDImproper connection can result in risk of electric shock See note belowFailure to follow these instructions can result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page 17 Friday July 8 2011 1144 Series Battery Charger Owners the Truecharge 2 Battery ChargerStep 3 Installing DC WiringThe procedure for installing the DC wiring applies to a single battery as well as multiple batteries or battery banks 1Remove the DC compartment cover See Front Panel on page 32Plan 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 3Identify the positive wires by using colorcoded 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 black4Install a DC circuit breaker or fused disconnect in each positive cable that is as close to the battery positive terminal as possible Consult your local electrical codes regarding the distance allowed between the battery and the fuse or breaker For example for most situations ABYC standard E11 requires no more than 7 inches 178cm Be sure the breaker or fused disconnect is open5Route 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 drops6Insert and slide the rubber bootscharger end of the DC ACCIDENTAL SHORT OR SPARK HAZARDLeave the DC disconnects or breakers in the Off position or DC fuses removed from their fuse holders until installation is to follow these instructions can result in death or serious may find it helpful to label each cable associating it with the battery bank it is connected to For example bank 1 bank 1 and so onThe rubber boots must be installed over the Truecharge2 Battery Charger DC terminals to keep water off of live parts and to maintain the chargers Failure to follow these instructions can result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page 18 Friday July 8 2011 1144 the Truecharge 2 Battery crimp lugs on the charger end of the DC battery cables using the crimp manufacturers instructions and toolNOTE 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 termin8Connect the negative cable to the negative DC terminal on the charger See Figure 4 Configuration for Normal Loads on page 8For one battery or bankConnect the negative cable from the negative terminal on the battery to the negative DC terminal on the Truecharge2 Battery ChargerUse a flat washer a lock washer and a nut five of each included in the installation more than one battery or bankConnect the negative cable from the neon 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 the nuts to 23Nm 20lbin torque and test that the wire is secure Do not overtighten as this may result in damage to the 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 the nuts to 23Nm 20lbin torque and test that the wire is secure 12Connect 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 13Connect the free end of the negative cable to the negative terminal on the battery using sufficient torque as recommended by your battery manufacturer REVERSE POLARITY DAMAGEBefore proceeding to the next step carefully check the wiring polarity Do not reverse the connections See note below Failure to follow these instructions can damage the unit andor damage other equipmentTo chargerTC2 204060 Series BattChg Owners Guidebook Page 19 Friday July 8 2011 1144 Series Battery Charger Owners the Truecharge 2 Battery ChargerNOTE 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 cables in place using tiewraps or cable straps according to electrical codes15Slide the rubber boots to cover the DC terminals 16If available route the optional bathe battery one which is located in the warmest ambient temperatureto the charger location 17Proceed to Step 4 Installing AC WiringTC2 204060 Series BattChg Owners Guidebook Page 20 Friday July 8 2011 1144 the Truecharge 2 Battery ChargerStep 4 Installing AC WiringBefore connecting AC wiring make sure the AC source circuit is protected by a breaker switch of the correct size and type to comply with the electrical code for your location and application The current rating of the input breaker should not be larger than 20A for 120Vac applications and 16A for 230Vac applications but may be required to be lower depending on the wire size used1Plan the route that the AC supply wiring will follow from the source usually an AC distribution panelto the Truecharge2 Battery Charger 2Measure and cut the required length of threeconductor L N GNDcable allowing some extra length foslack3Route the AC supply wiring from the charger in its mounted positionto the source4Unscrew the wiring compartment cover from the left rear of the Truecharge2 Battery Charger to expose the AC wiring access hole and chargers AC pigtail remove 50 75mm 2 3inf the outer jacket from the AC supply wiring being careful not to cut or nick the insulation on the individual the chargers AC L N GNDpigtail leads wiresthe AC wiring compartment of the SHOCK the AC source by turning off the breaker feeding the circuit unplugging from shore power and disconnecting any other power sources such as a to follow these instructions will result in death or serious injurywiring compartment AC wiring access holeAC pigtail leadsTC2 204060 Series BattChg Owners Guidebook Page 21 Friday July 8 2011 1144 Series Battery Charger Owners the Truecharge 2 Battery Charger7Feed the AC supply wiring through the wider end of strain relief and out the tapered end8Slide the strain relief on the jacket of the wiring not on the individual 25mm 1in from the end of the jacket9Connect the AC supply wires to the Truecharge2 Battery Charger 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 To connect AC wires with the provided crimpon buttsplice connectoraMake the connections using the provided crimpon connectorsor with other approved connectors required by your code and suitable for your installation For example the ABYC Standards and Recommended Practices for Small Craft prohibit twiston connectors for AC connections on a boat For other types of installation refer to your applicable codebUsing a wire stripper carefully strip 8mm 516in ends of the two wires being Pigtail Color CodeAC Supply Wire Color or or with yellow stripeGreen with yellow stripetapered end of strain reliefAC supply buttsplice connector catalog number BNYF2 is availablefrom connected wires may overheat Exercise care when using any crimp connector use the tool specified by the crimp connector manufacturer and follow all crimping to follow these instructions will result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page 22 Friday July 8 2011 1144 the Truecharge 2 Battery ChargercInsert one wire into one end of the buttsplice until the insulation hits the internal metal crimp section insert the buttsplice into the and crimp firmly The proper location for the crimp is approximately 16mm 116in past where the buttsplice insulation tapers down as showndRepeat Step c for the other end of the all connections are completed push the wiring and connectors inside the AC wiring the strain relief on the AC wiring access hole12Install the wiring compartment cover to fasten the strain relief and tighten the screw on top to secure the cover Do not applicable install the optional remote panel14Connect the AC supply wiring from the charger to the AC panel feeding the charger 15Connect the line conductor to the breaker the neutral to the neutral bus and the ground to the ground bus16Secure cables in place using tiewraps or cable straps according to electrical codes1Use crimper product number CT160from CRIMP TOOLSTRIP 516screw to secure the wiring compartment AC wiring access hole with strain reliefTC2 204060 Series BattChg Owners Guidebook Page 23 Friday July 8 2011 1144 Series Battery Charger Owners the Truecharge 2 Battery ChargerStep 5 Powering UpMake one last check that all connections are correct and secureThe Truecharge2 Battery Charger charger may now be powered up 1Close the DC disconnect switch or breaker2Switch 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 testore reporting charging and battery status Battery qualification may not be correctly performed if AC power is switched on firstNOTE The onboard display LEDs will with DC power alone when DC power is applied and the minimum battery voltage ie the connected ANDOR FIRE HAZARDThe 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 to follow these instructions will result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page 24 Friday July 8 2011 1144 a Parallel ConfigurationA parallel configuration is when two Truecharge2 Battery Chargers are coupled together to increase the output capacity For example a 40amp Truecharge2 Battery Charger can be connected with another 40amp Truecharge2 Battery Charger for a combined 80amp capacity charger This configuration is possible only with the use of the optional remote panelParallel configuration can only be done when the following conditions are metTwo Truecharge2 Battery Chargers must have the same output voltage rating Never parallel a 24volt charger with a 12volt chargerBoth Truecharge2 Battery Chargers must connect to a Truecharge2 Remote Panel Both Truecharge2 Battery Chargers must be correctly installed 1Follow the installation sequence from steps 1 through 4 for a single unit Installing the Truecharge 2 Battery Charger on page 16 2In 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 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 4Connect the primary chargers battery bank 1 to the secondary chargers battery bank 1 Do the same for battery banks 2 and 3NOTEbanks can be connected to a charger system5Leave any unused DC outputs unconnected 6Connect the remote panels communications cable to the primary chargers remote port and to the remote panels primary port Do the same for the secondary the BTS or battery temperature sensorscable plug to the primary chargers BTS port Then connect the BTSs sensor to the batteryNOTE If you have two BTSs you may connect the two seplugs 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 TO THE BATTERY CHARGERDo not parallel Truecharge2 Battery Chargers together without a Truecharge2 Remote Panel part number to follow these instructions can damage the unit andor damage other equipmentTC2 204060 Series BattChg Owners Guidebook Page 25 Friday July 8 2011 1144 Series Battery Charger Owners a Parallel up after installing a parallel the procedures in Step 5 Powering Up on page 242Observe that the Parallel LED on the remote panel lights up to indicate that two chargers are in parallel configuration charging mode During ChargingThe 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 chargers 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 chargersWhen Configuring the Battery ChargersThe secondary chargers configurations are automatically synchronized with the primary charger The configuration can be performed from either the remote panel or the primary chargers onboard display Follow the exact same procedures as a single charger when configuring the paralleled chargersWhen Equalizing can be programmed and cancelled through the remote panel Equalization can be cancelled through both chargers onboard displayFault and Warning ConditionsWhen 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 FaultWarning LED the same way as the faulty charger displays it on its onboard displayRemote panels FaultWarning 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 pointExiting parallel operationOnce 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 TC2 204060 Series BattChg Owners Guidebook Page 26 Friday July 8 2011 1144 installation should 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 deathTo replace an old battery1Turn off the AC source by disconnecting the AC line andor opening the AC source off all devices operating from currently installed the battery cables from the old batteryNOTE s systems disconnect the negative cable first then the positive cable For Positive chassis systems disconnect the positive cable first then Inspect all AC and DC cables for damage and repair if the old battery with the new the battery cables to the new batteryNOTE For Negative chassis systems reconnect the positive cable first then the negative cableFor Positive chassis systems reconnect the negative cable first then Input Voltage Operating and DeratingWhen AC input is within the lon 90108Vac the Truecharge2 Battery Charger derates to 80 of maximum current However when AC input increases above 108Vac up to 265Vac maximum current returns to 100 capacity Furthermore the Truecharge2 Battery Charger will continue to operate at 100 of maximum SHOCK both AC and DC power from the battery charger before g old or defective batterFailure to follow these instructions will result in death or serious the new battery is different from the old one in chemistry temperature or size remember to reconfigure the battery settings accordingly See Setting the Battery Temperature without a BTS on page 32 and Configuring the Battery Bank Type on page 34TC2 204060 Series BattChg Owners Guidebook Page 27 Friday July 8 2011 1144 Series Battery Charger Owners ChargingMost 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 threestage charging Bulk Absorption and Floator twostage charging Bulk and battery banks are not galvanically isolated from each other They share a common negative as shown in the diagram belowThe negative bus to chassis connection as shown below may not be suitable in some 8Typical ThreeBattery banksBTS busRemote 204060 Series BattChg Owners Guidebook Page 28 Friday July 8 2011 1144 ChargingThe threestage 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 oxygenge 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 The charger will restart the charging cycle in the Bulk stage if the lowest battery voltage of the three banks drops below 125V 12Vdc chargers25V 24Vdc chargers 15 minutes After seven days the charger will automatically restart charging in order to refresh the 9ThreeStage Charging CV timeoutmax 5 hrsFLOAT timeoutmax 7 daysTotalABS timeoutStart ofcharging cyclemax 8 voltageVbat Vgasfor 1 minuteVbat 125 Vfor 15 minutesVbat Vabsfor 1 minutefor 1 minutelout 10 204060 Series BattChg Owners Guidebook Page 29 Friday July 8 2011 1144 AM EF HHEFa aHHEF a FHHEFa a aHHEFa fHHEFa aaHH E D ZQX DY QX MDY QX DY EhD EEadPQXEDYCcbB ECDCCe ia D QXDzzYYFFaH EDEDEeE j Bhja RyE TXYaDRy E I c a a CC5vp E PXaYddbQXdd EDYKTX FH FHYYCXddadQX FH Fab pE PXaFYhBQSZX TXCBYQX TXCBYTX Series Battery Charger Owners ChargingThe twostage charging mode employs the following sequence Absorption It runs similar to the threestage 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 9V 12Vdc chargers24Vdc chargers In this manner DC loads draw power supplied by batteries and the charger enters a rest or standby stage Like the threestage sequence the charger will restart the charging cycle in the Bulk stage if the lowest battery voltage of the three banks drops below 125V 12Vdc chargers25V 24Vdc chargersfor 15 minutes After seven days the charger will automatically restart charging in order to refresh the 10TwoStage Charging CV timeoutmax 5 hrsREST Standbytimeout max 7 daysTotalABS timeoutmax 8 hrsBULKVgas voltageVbat Vgasfor 1 minuteGO TO BULK whenVbat 125 V for15 minutesVbat Vabsfor 1 minutefor 1 minutelout 10 ofcharging cycleTC2 204060 Series BattChg Owners Guidebook Page 30 Friday July 8 2011 1144 AMu733LfMono EF HHEFa aHHEF a FHHEFa a aHHEFa fHHEFa aaHH E D ZQX DY QX MDY QX DY EhD EEadPQXEDYCcbB ECDCCe ia D QXDzzYYFFaH EDEDEeE j Bhja RyE TXYaDRy E I c a a CC5vp E PXaYddbQXdd EDYKTX FH FHYYCXddadQX FH Fab pE PXaFYhBQSZX TXCBYQX TXCBYTX Voltage SetpointsThe Truecharge2 Battery Charger charging process is designed to make the battery or battery banks reach the following voltage setpointsThe Truecharge2 Battery Charger will perform a battery qualification on each application of AC or DC 9V for 1224vobattery banks are present and healthyTo force a battery detection sequence 1Turn off AC and DC 2Wait approximately 20 seconds or until all lights on the charger or remote have gone out3Turn on DC4Turn on ACThe charger will then perform a battery detectionThe 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 strongly recommends that you purchase and install the optional Battery Temperature Sensor BTS protect your battery and improve charging accuracy Attach the BTS to the warmest batteryIf no BTS is connected the charger defaults to the Battery Temp selection on the onboard display as well as on the optional remote panelTable 5Charging Maximum Voltages for 12volt TypeAbsorption VoltsFloat 6Charging Maximum Voltages for 24volt TypeAbsorption VoltsFloat 204060 Series BattChg Owners Guidebook Page 31 Friday July 8 2011 1144 Series Battery Charger Owners the Battery Temperature without a BTSNOTE Always be aware of the temperature setting observe the batterys actual temperature and adjust the Battery Temperature setting accordingly For varying conditions use the Warm settingTo configure the battery By default the Battery Temp is set to Warm1Press and hold the Battery Temp Select button for three seconds to advance to the next setting2Select the appropriate battery temperature settingThe LEDs will indicate which of the three types is being selected Warm Hot or ColdNOTE Cold is for battery temperature below 5 C 41 Farm default settingbattery temperature between 5 and 30 C 41 and 86 Fbattery temperature above 30 C 86FTable 7 Battery Temperature Compensation Levels on page 32 to see how output voltage is offset by varying the temperature selectionRISK OF BATTERY DAMAGEDo 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 do not set a battery temperature that is higher than the actual temperature in the absence of a BTS as this may result in undercharging the batteryFailure to follow these instructions can damage the unit andor damage other equipmentTable 7Battery Temperature Compensation for battery temperature ofVoltage added for temperature compensation offset from 25 CColdbelow 5 C 41 5 and 30 C41 and 86 30 C86 204060 Series BattChg Owners Guidebook Page 32 Friday July 8 2011 1144 DC LoadsWhen 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 voltages16V for 12volt chargers32V for 24volt chargersTC2 204060 Series BattChg Owners Guidebook Page 33 Friday July 8 2011 1144 Series Battery Charger Owners the Truecharge2 Battery ChargerOnce 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 testbefore reporting charging and battery status the Charger ModeNOTE By default the Charger Mode is set to 3Stage1Press and hold the Charger Mode Select button for three seconds to advance to the next setting2Select the proper charger modeThe LEDs will indicate which of the two modes is being selected threestage defaultr the Battery Bank TypeNOTE By default the battery type is set to Flooded1Press and hold the Battery Type Select button for three seconds to advance to the next setting2Select the proper battery typeThe 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 OEMFigure 11Onboard Display PanelTC2 204060 Series BattChg Owners Guidebook Page 34 Friday July 8 2011 1144 you start to charge batteries read the Important Safety Instructions on page iv and follow all safety precautions when working with batteriesTo charge your batteries1If possible disconnect any heavy loads on the batteries being charged by opening disconnect switches or by switching the loads off2Connect the batteries to the charger by closing the DC disconnect switchesNOTE The onboard display LEDs will light up for a 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 4Apply AC power to the Truecharge2 Battery Charger by closing the AC breaker or turning the generator on All onboard display indicator LEDs will illuminate for one second power on seAfter initialization the indicator LEDs will display present status and settings At this point changes in Battery Type Battery Temperature andor Charger Mode can then be applied These settings are stored in memory even when all power sources are red after every initialization During charging the Charging Output will show the total current being delivered to the battery bank as well as any DC load applied The charger fan may activate as well5After charging is completed reconnect all loads to the batteryThe charger can be in one of eight different situations which will be indicated on the onboard display in the Charger Status Status or Rest twostage threestage chargingReady and in flashingFault solid lightaIn combination with one or more flashing Charging Output flashingTC2 204060 Series BattChg Owners Guidebook Page 35 Friday July 8 2011 1144 Series Battery Charger Owners GuideCharging BatteriesAfter charging is complete the Truecharge2 Battery Charger enters into one When the ready and charging indicator LEDs both illuminate all batteries are fully charged and ready for use If you selected the threestage charging mode the Truecharge2 Battery Charger is in float mode and will maintain the batteries chargeStandby modeOr Rest mode If you selected the twostage charging mode the ready indicator LED shows the charger is now in rest mode and is ng battery voltage With either charging mode the Truecharge2 Battery Charger will begin a charging cycleseven days after the last completed cycle orwhen the minimum battery terminal voltage drops to below 125V 12V chargersr 25V 24V chargersfor 15 minutes orwhen AC is disconnected for more than 15 minutes and then reconnectedTC2 204060 Series BattChg Owners Guidebook Page 36 Friday July 8 2011 1144 Truecharge2 Battery Charger cannot automatically determine when to stop the equalization of a battery The one hour timeout is intended as a safety feature to require the user to continually reactivate it as necessary after checking batteries manually but may not be sufficiently short to prevent battery damageIn the following conditions the Truecharge2 Battery Charger will not enter the battery type is set to GEL or AGMany battery is not fully charged all three battery banks must be charged to float or rest stage before equalization can be activated on there is an active fault on the battery you are trying to chargeXantrex recommends that you run a complete normal charge cycle on the you equalize themRISK OF BATTERY DAMAGEThe Truecharge2 Battery Charger will only equalize flooded leadacid or leadcalcium batteries It does not enter equalization when the battery type is set to sealed leadacid batteries GEL or AGMince they will be damaged by this process Use the correct settings for your battery typesFailure to follow these instructions can damage the unit andor damage other equipmentRISK OF BATTERY DAMAGEYou must monitor the battery specific gravity throughout equalization to determine the end of the equalize cycleFailure to follow these instructions can damage the unit andor damage other equipment1In this case an equalization cycle can be programmed to start once the charge cycleis doneThe battery generates explosive gases during equalization Follow all of the battery safety precautions listed in this guideVentilate 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 Failure to follow these instructions will result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page 37 Friday July 8 2011 1144 Series Battery Charger Owners Flooded An The voltage applied to the battery during equalization may be above safe levels for some loads but the absolute maximum is 16 V for 12volt chargers and 32 V for 24volt chargers within operational temperature 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 immediatelyTo equalize your 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 cycle2Program or initiate an equalize cycle Equalization will begin if all banks are in either float or rest modeRISK OF EQUIPMENT DAMAGETurn off or disconnect all DC loads on the battery during Do not equalize if the level of equalization voltage see note belowdoes not comply with the battery manufacturers to follow these instructions can damage the unit andor damage other FIRE AND BURN HAZARDSAlways wear proper nonabsorbent gloves complete eye protection and clothing protection Avoid touching your eyes and wiping your forehead while working near batteFailure to follow these instructions can result in death or serious 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 to float or rest mode the Equalize LED will flash and equalization will start prior to reaching float or rest modeTC2 204060 Series BattChg Owners Guidebook Page 38 Friday July 8 2011 1144 Flooded 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 modeWhen 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 4Monitor the specific gravity of each cell of the battery during 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 yetCarefully check the specific gravity of each cell and repeat the equalization cycle until they all meet the battery manufacturers specifications for specific gravity or until the specific gravity stabilizes relative to each other for an hourThe charger automatically exits equalization to float mode or rest mode after one cycle To manually exit equalization mode early repeat Step 35Check the battery electrolyte level If necessary refill with distilled water only and repeat a normal charge onboard display and remote panel buttons will not allow selection of equalization for AGM and GEL batteriesTC2 204060 Series BattChg Owners Guidebook Page 39 Friday July 8 2011 1144 Series Battery Charger Owners the Charger to ON Standby or DisabledThere are two ways to turn ON the Truecharge2 Battery ChargerConnect the batteries to the charger ie 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 STANDBY on the optional remote panel while batteries and AC power are both connected to the charger from StandbyThe charger begins to charge the batteries from StandbyThere are two ways to put the Truecharge2 Battery Charger in Standby see Warning AC power at the source ie only the batteries are Press STANDBY on the optional remote panel while batteries and AC power are both connected to the charger from ONThe charger stops charging but continues to monitor the batteriesThere is only ONE way to safely turn the Truecharge2 Battery Charger Disconnect the AC power at the source and disconnect all DC batteriesThis is the only state where the Truecharge2 Battery Charger is completely the Truecharge2 Battery Charger is disabled the optional remote panel is SHOCK HAZARDDo not disassemble the battery charger Internal capacitors remain charged for five minutes after all power is both AC and DC power from the battery charger before attempting any maintenance or cleaning or working on any circuits charger See note belowFailure to follow these instructions will result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page 40 Friday July 8 2011 1144 Charger InformationThe Truecharge2 Battery Charger provides a lot of information about the status of the charger and the Onboard Display LEDsThe Fault LED works in conjunction with the Charging Current The icons at the top row above the Charging Current resent the various types of fault and warning conditions For example a temperature warning is reprThe 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 Table 9 Interpreting Fault and Warning Indicators on page 43 summarizes the various fault conditions that might occur during the operation of the charger Reporting While Charging or configuring the charger and during charging the onboard display panel and the optional remote panel if installedwill show the following information about the charger and the Output CurrentCharger StatusBattery Status available on the optional remote panel onlyIf 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 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 batteryFigure 12Charging Output Fault of fault and Output LEDsCharging Output valuesFault LEDTC2 204060 Series BattChg Owners Guidebook Page 41 Friday July 8 2011 1144 Series Battery Charger Owners GuideReporting Without AC Power or While on 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 dbe 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 batteriesThe remote panel LEDs will turn off after 30 seconds of LEDs on the Onboard Display PanelAll indicator LEDs on the Onboard Display panel and the optional remote panel if for one second when AC or DC power is supplied to the Truecharge2 Battery Charger or when the charger is turned STANDBY button on the remote panel A power on test indicates that the charger is now receiving AC power and all LEDs are functioningThe 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 rangesTo 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 STANDBY button to interrupt the charging processTable 8Charger Status LED Status LED statusReady LED illuminates solidThe charger is in standby or restmode of twostage charging All batteries have been fully chargedReady and Charging LEDs illuminate The charger is in float mode of threestage charging All batteries have been fully LED illuminates solidThe charger is charging in bulk or absorption Equalize LED flashesThe charger will perform an equalization cycle after the absorption solidThe charger is currently implementing an equalization cycle for all batteriesFault LED flashesA warning condition See Interpreting Fault and Warning Indicators on page 43Fault LED illuminates solidA fault condition See IWarning Indicators on page 43TC2 204060 Series BattChg Owners Guidebook Page 42 Friday July 8 2011 1144 9Interpreting Fault and Warning or Warning input out of range fault 85V or 265VCheck AC connections Change to a more stable AC power source and check that the voltage and voltage frequency are within acceptable operating range See Specifications on page 54High Battery Temp fault 70C Check the batteries Do not charge a battery that is rated other than 12 V nominal for all 12volt chargers or 24 V nominal for all 24volt chargers Check that the battery type and temperature settings match the actual battery anDisconnect or turn off other charging sources such as an alternator or the charger on a generator with an electric startAllow the battery or batteriesto normal e See Specifi Flashing LED Solid LEDTC2 204060 Series BattChg Owners Guidebook Page 43 Friday July 8 2011 1144 Series Battery Charger Owners GuideLow Battery Temp fault Check the batteries Do not charge a frozen battery Charging a frozen battery may present a risk of explosion Check that the battery type and temperature settings match the actual batteryAllow the battery or batteriesup to a temperature that is above freezing before charging See Specifications on page 54High Battery voltage 165V for 12volt charging or disconnect AC power source from supplying power to the 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 Charger Temp 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 locationLoss of Remote Reconnect the communication cable to the port It takes about 15 seconds to reestablish communication Flashing LED Solid LEDTable 9Interpreting Fault and Warning or Warning 204060 Series BattChg Owners Guidebook Page 44 Friday July 8 2011 1144 Polarity Fuse Check for reverse battery polarity negative connected to negative positive connected to positive is correctat battery and charger output AC and DC sourfuses the charger See Replacing the DC Output Fuse on page 48Internal faultCall Flashing LED Solid LEDTable 9Interpreting Fault and Warning or Warning 204060 Series BattChg Owners Guidebook Page 45 Friday July 8 2011 1144 Series Battery Charger Owners GuideUsing A Generator As Source PowerThe 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 MSWather than the true sine wave TSWyour utility providesIf 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 shutdown Using the current limiti 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 times1See Configuring the Maximum Output Current Percentage of the Charger on theTruecharge2 Remote Panel Owners GuideTC2 204060 Series BattChg Owners Guidebook Page 46 Friday July 8 2011 1144 the ChargerNOTE The Truecharge2 Series Battery Charger contains no parts with the exception of the DC output fusesich are See Replacing the DC Output Fuse on page 48 for instructions For obtaining service other than replacing the fuse see Warranty and Return Information on page 58 for guidanceThe Truecharge2 Battery Charger contains solidstate 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 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 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 fastenedLoose 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 immediatelyTo clean battery terminals follow the and procedures of the battery SHOCK HAZARDDo not disassemble the battery charger See note belowFailure to follow these instructions will result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page 47 Friday July 8 2011 1144 Series Battery Charger Owners GuideTo replace the DC Output Fuse 1Locate the fuse cover on the chargers top panel see Front Panel on 2Loosen the screw on the fuse cps The screw will not separate from the cover3Pull out the blown fusesly using the provided fuse pullerNOTE The fuse puller is located on the inside of the fuse cover4Install a brand new fusesng as the old one See Fuse Replacement Ratings on page 495Replace the fuse cover making sure that it aligns and fits perfectly leaving no space for moisture or small debris to enter the the screw on the fuse cover but do not the reverse polarity fault which caused the fuse to blow prior to and DC sources to the all AC and DC sources to the INSTALLATION BY AN UNQUALIFIED 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 hazardsFailure to follow these instructions can damage the unit andor damage other SHOCK all AC and DC sources to the charger and wait five minutes for internal voltage and energy levels to reduce to safe levelsFailure to follow these instructions will result in death or serious injuryTC2 204060 Series BattChg Owners Guidebook Page 48 Friday July 8 2011 1144 the DC Output FuseRISK OF EQUIPMENT DAMAGEFor continued protection replace only with Littelfuse type 257 or equivalent ratings as shown belowFailure to follow these instructions can damage the unit andor damage other amber32VdcTC2 204060 Series BattChg Owners Guidebook Page 49 Friday July 8 2011 1144 Series Battery Charger Owners 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 LEDs do not illuminate when charger is connected to an AC The initial power up display test is not performed upon connection of battery or power at AC AC wiring or panel has been used to put the charger into Standby Ensure that power is available at charger AC input and it is within acceptable rangeWiring must be inspby a qualified installer Press the OnStandby button on the remote panel to turn the charger onPossible Battery Charger does not detect battery for one of poor polarity connection damaged wiringopen DC breaker or external battery voltage is below 9VCheck quality of battery connection and Ensure correct polarity negative connected to negative positive In case there is an accompanying fault check the type of fault from Interpreting Fault and Warning Indicators on page 43TC2 204060 Series BattChg Owners Guidebook Page 50 Friday July 8 2011 1144 indicator LED illuminates Temp and Battery indicator LEDs Battery Charger completes a charging cycle but the battery voltage seems too lowEXPLOSION HAZARDNever charge a frozen batteryFailure to follow these instructions can result in death or serious injuryPossible temperature is either too hot or too cold for safe chargingIf battery is too hot allow battery to cool Improve ventilation or install in a If the optional remote panel is reduce the output current using the Set Max Output buttonIf battery is too cold allow batteries to Possible 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 10V for 12volt chargers and 20V for 24volt chargers then this confirms the d or shorted cellReplace battery The battery has reached the end of its useful life and can no longer accept a chargeTC2 204060 Series BattChg Owners Guidebook Page 51 Friday July 8 2011 1144 Series Battery Charger Owners Truecharge2 Battery Charger appears to be taking too long to charge battery Ready indicator LED does not illuminate after 24 hours of chargingThe Truecharge2 Battery Charger appears to have quickly charged the battery Ready indicator LED illuPossible capacity is too high for the Truecharge2 Battery Charger Load connected to battery is draining charge current so that battery does not has a damaged cell or has reached the end of its useful lifeThe remote panel Max Output setting is too low for the battery capacityUse a higher capacity all loads or switch loads offReplace the Max Output capacity is too low for the Truecharge2 Battery Charger has reached the end of its useful lifeUse a lower capacity chargerUsing the optional remote panel if installeduce the output current smaller battery Replace batteryTC2 204060 Series BattChg Owners Guidebook Page 52 Friday July 8 2011 1144 Truecharge2 Battery Charger Possible is the wrong type or set to the wrong type to equalizeNot all batteries are fully chargedAn active fault is present on the bank you are attempting to Determine if the battery type is set to GEL or AGM These battery types cannot be equalizedThe charger will wait for all batteries to be in float stage of threestage charging or rest stage of twostage charging before attempting to equalize the ready indicator LED will the active fault by disconnecting the AC power source and finding the cause of the fault from Interpreting Fault and Warning Indicators on page 43TC2 204060 Series BattChg Owners Guidebook Page 53 Friday July 8 2011 1144 Series Battery Charger Owners GuideNOTE Specifications are subject to change without prior noticePhysical Unit Dimensions L W HTC2012 TC401222kg 48lbsTC1024 TC202422kg 48lbsTC6012 TC302445kg 99lbsAC input colorcoded No 14 AWG wires L N GNDminimum 152mm 6 inseparate AC wiring enclosure with 213mm 084inprovision for connection of a inch North American trade size strain relief includedAC input connections IEC models onlyIEC 60320 C14 male connector M6 studs 3 positives and 1 common negative for battery caone M6 mm DC equipment groundAC Input input voltage derating to 120Vac 230Vac 240Vac104 265Vac 4Vac90 108 4VacMax AC input factor at rated Frequency47 63HzEfficiency peak1224volt units1224volt units80 120Vac84 230VacSurge surge protector rated at 275 VacTC2 204060 Series BattChg Owners Guidebook Page 54 Friday July 8 2011 1144 Trust Inc10UVeriSign Time Stamping Service Root1402UNO LIABILITY ACCEPTED cc EF HHEFa aHHEF a FHHEFa a aHHEFa fHHEFa aaHH E D ZQX DY QX MDY QX DY EhD EEadPQXEDYCcbB ECDCCe ia D QXDzzYYFFaHKS XYXY EDEDEeE j Bhja RyE TXYaDRy E I c a a CC5vAp AE PXaYddbQXdd EDYKTX FH FHYYCXddadQX FH Output of isolated battery bank outputs3 separated outputsDC output voltage range including dead battery 0 16Vdc0 accuracy no load144 01 Vdc 25C 77F288 02 Vdc 25C 77FNominal battery voltage12 Vdc24Vdc12volt units24volt units0 16 Vdc0 32 Vdc Maximum DC output current total20 10A40 10A 60 10A10 10A20 10A30 10AAbsorption voltageGEL AGM units24volt units25C 77F25C 77F144 01288 02142 01284 02143 01286 02155 01310 02DC Output 204060 Series BattChg Owners Guidebook Page 55 Friday July 8 2011 1144 Series Battery Charger Owners GuideFloat voltageAGM units24volt units25C 77F25C 77F135 01270 02138 01276 02134 01268 02135 01270 02Equalize mode current 50 rated output 6Equalize modemaximum 16 01 Vdc3202 VdcOffstate current draw without remote installed35mA dcDC Output load voltage 01Vdc drop from 0 Amps to rated current output at charger output terminals adds in series with recommended 3 limit for users battery cable voltage 60C 32 140Fwith up to 80 current deratingabove 40C 104Fup to 50 current deratingabove 50C 122FStorage40 to 80C 40 to 176F5 95 RH Output 204060 Series BattChg Owners Guidebook Page 56 Friday July 8 2011 1144 reverse by replaceable DC output limitsThe Truecharge2 Battery Charger will stop charging if the output voltage is 16605 Vdc for 12Vdc units33201 Vdc for 24Vdc unitsOutput current 10A 40 10A 60 10A10 10A 20 10A 30 at 65 5C 149 9FRestart at 60 5C 140 9FBattery Charger shuts down if battery temperature above 70C 158Fis sensed by the battery temperature sensor BTSBattery shuts down if battery temperature below 25C 13Fis sensed by the battery temperature sensor BTSRegulatory AmericaNRTL approved to CSA E60335229 UL1236 including the marine supplement and UL1564ABYC E11 Alternating Current and Direct Current Electrical Systems on Boats andABYC A31 Battery Chargers and UnionCE marked for the Low Voltage Directive 200695EC complying with EN60335229 Battery ChargersEN 28846 Small Craft Electrical Devices Protection against ignition of surrounding flammable to IEC60335229 including Australian AmericaClass B according to FCC Part 15B and Industry Canada marked for the EMC Directive 2004108EC complying with EN550141 EN550142 EN6100032 and FeaturesTC2 204060 Series BattChg Owners Guidebook Page 57 Friday July 8 2011 1144 Series Battery Charger Owners GuideWarranty and Return your Xantrex product was installed as original equipment by a vehicle boat or equipment manufacturer an OEM please be aware that the Xantrex Limited Warranty is NOT aSuch OEM and not Xantrexwill be responsible for all warranty obligations for OEM installed Xantrex products The warranty terms including the warranty period applicable to such OEM installed products will be defined by the OEM and you must seek service or support from such OEM through its service and support networkIf your Xantrex product was purchased by you from a Xantrex authorized dealer or distributor refer to the Xantrex Limited Warranty and Return Material Authorization Policy belowWhat does this warranty cover and how long does it lastThis Limited Warranty is provided by Xantrex Technology USA Inc Xantrexcovers defects in workmanship and materials in your Truecharge2 Series Battery ChargerThe warranty period lasts for 12 months from the date of purchase at the point of sale to you the original end user customer unless otherwise agreed in writing or extended in accordance with the extension option described in the next sentence the Warranty Periodou can extend the warranty period from 12 months to 24 months by registering your Truecharge2 Series Battery Charger within 6 months from the date of purchase at Your warranty claims are conditional upon and subject to your demonstration and proof of purchase of the product as described in What proof of purchase is required This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the Warranty Period Warranty claimsowners are also subject to the same proof of purchase requirements referenced above and described belowWhat will Xantrex do During the Warranty Period Xantrex will at its option repair the product if economically feasible 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 If the initial assessment suggests that the defect is such that it may not be covered by this Limited Warranty billing information will be required If it is ultimately determined that the product is performing to the manufacturers specifications and that no repair is required or if a required repair is not covered under this Limited Warranty you will be responsible for all costs associated with such noncovered repair including costs for replacement parts and labor at Xantrexs standard Xantrex will at its option use new andor 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 t If Xantrex repairs or replaces a product its warranty continues for the remaining portion of the original Warranty WHERE XANTREX PRODUCT WAS SOLD AS ORIGINAL EQUIPMENTWHERE XANTREX PRODUCT WAS PURCHASEDBY END USERTC2 204060 Series BattChg Owners Guidebook Page 58 Friday July 8 2011 1144 and Return 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 XantrexXantrex covers both parts and labor necessary to repair the product and return shipment to the customer via a nonexpedited surface freight within the contiguous United States and Canada Alaska 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 areasHow do you get serviceIf your product requires or t Xantrex TollFree at 18006700707 within the United States and Canada or at 14089876030 outside of the United States and Canada 530am500pm PST MonFriDirect 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 facilitiesWhat proof of purchase is requiredIn 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 Proof of purchase may be in any one of the following formsThe dated purchase receipt from the original purchase of the product at point of sale to the end user orThe dated invoice or purchase receipt showing the product exchanged under warrantyIn the event a proof of purchase is not available then the original Xantrex dated invoice will be used If no original Xantrex dated invoice can be found the manufacturing date of the product will be usedClaims are limited to repair and replacement or if in Xantrexs 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 productThis Limited Warranty does not warrant uninterrupted or errorfree operation of the product or cover normal wear and tear of the product or costs related to the removal instcustomers electrical systems This warranty does not apply to and Xantrex will not be responsible for any defect in or damage toathe 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 including any environment or location that causes excessive wear and tear or debris buildup within the systembthe 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 ifications including butinput voltage from generators and lightning strikescthe product if repairs have been done to it other than by Xantrex or its authorized service centers unless such repairs and service providers were authorized by the Xantrex Field Service Manager or Technical Support Representative prior to the performance of such repairs dthe product if it is used as a component part of a product expressly warranted by another parts or monitoring systems supplied by you or purchased by Xantrex at your direction for incorporation into the productfthe product if its original identid altered or removedgthe product if it is located outside of the country where it was purchased andhany consequential losses that are attributable to the product losing power whether by product malfunction installation error or misuseTC2 204060 Series BattChg Owners Guidebook Page 59 Friday July 8 2011 1144 Series Battery Charger Owners GuideWarranty and Return IN THE EUROPEAN EU MEMBERSTATE EU IN THE REST OF THE 204060 Series BattChg Owners Guidebook Page 60 Friday July 8 2011 1144 and Return Material Authorization PolicyFor those products that are not being repaired in the field and are being returned to Xantrex before returnmust obtain a Return Material Authorization RMAmber 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 locationWhen you contact Xantrex to obtain service please have your instruction d be prepared to supplyThe serial number of your about the installation and use of the about the failure andor reason for the returnA copy of your dated proof of purchaseRecord these details on page62Return 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 the followingThe RMA number supplied by Xantrex Technology USA Inc clearly marked on the outside of the boxA return address where the unit can be shipped Post office boxes are not acceptableA contact telephone number where you can be reached during A brief description of the problemShip the unit prepaid to the address provided by your Xantrex customer service you are returning a product from outside of the USA or CanadaIn addition to the above you MUST include return freight funds and are fully responsible for all documents duties tariffs and deposits If you are returning a product to a Xantrex Authorized Service A Xantrex return material authorization RMAnot 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 productTC2 204060 Series BattChg Owners Guidebook Page 61 Friday July 8 2011 1144 Series Battery Charger Owners GuideWarranty and Return About Your SystemAs soon as you open your Truecharge2 Series Battery Charger package record the following information and be sure to keep your proof of purchaseIf you need to contact Customer Service please record the following details before calling This information will help our give you better serviceSerial Number 804122002 804124002 804126002 8042410 8042420 804124003 804126003 804241001 804242001 FromPurchase DateType of installation eg RV truckLength of time unit has been bank sizeBattery type eg flooded sealed gel cell AGMAlarm of indicators on front panelwhen problem of problemTC2 204060 Series BattChg Owners Guidebook Page 62 Friday July 8 2011 1144 AMTC2 204060 Series BattChg Owners Guidebook Page i Friday July 8 2011 1144 AM1 800 670 0707 Tel1 800 994 7828 in ChinaTC2 204060 Series BattChg Owners Guidebook Page ii Friday July 8 2011 1144 namecdpost 9A A 00 60GA F1rr 101U1 3A Series Battery Charger Owners GuideWarranty and Return does this warranty cover and how long does it lastThis Limited Warranty is provided by Xantrex Technology USA Inc 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 PeriodYou will be required to demonstrate proof of purchase to make warranty claimsThis 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 requiredWhat will Xantrex do During the Warranty Period Xantrex will at its option repair the product if economically feasibler 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 Xantrex will at its option use new andor 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 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 XantrexXantrex covers both parts and labor necessary to repair the product and return shipment to the customer via a nonexpedited surface freight within the contiguous United States and Canada Alaska Hawaii and outside of the United States and Canada are Xantrex Customer Service for details on freight policy for return shipments How do you get serviceIf your product requires or warranty service contact your merchant If you are unable to contact your rchant is unable to provide service contact Xantrex directly atDirect 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 800 670 0707Fax1 800 994 Page 58 Thursday August 4 2011 112 Series Battery Charger Owner222s GuideWarranty and Return does this warranty cover and how long does it lastThis Limited Warranty is provided by Xantrex Technology USA Inc 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 223Warranty Period224You will be required to demonstrate proof of purchase to make warranty claimsThis 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 223What proof of purchase is will Xantrex do During the Warranty Period Xantrex will at its option repair the product if economically feasibler 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 Xantrex will at its option use new andor 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 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 XantrexXantrex covers both parts and labor necessary to repair the product and return shipment to the customer via a nonexpedited surface freight within the contiguous United States and Canada Alaska Hawaii and outside of the United States and Canada are Xantrex Customer Service for details on freight policy for return shipments How do you get serviceIf your product requires or warranty service contact your merchant If you are unable to contact your rchant is unable to provide service contact Xantrex directly atDirect 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 800 670 0707Fax1 800 994 Page 58 Thursday August 4 2011 112 and Return proof of purchase is requiredIn 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 Proof of purchase may be in any one of the following formsThe dated purchase receipt from the original purchase of the product at point of sale to the end user orThe dated dealer invoice or purhowing original equipment manufacturer OEMorThe dated invoice or purchase receipt showing the product exchanged under warrantyWhat does this warranty not coverClaims are limited to repair and replacement or if in Xantrexs 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 productThis Limited Warranty does not warrant uninterrupted or errorfree operation of the product or cover normal wear and tear of the product or costs related to the removal installation or of the customers electrical systems This warranty does not apply to and Xantrex will not be responsible for any defect in or damage toathe 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 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 butinput voltage from generators and lightning strikescthe product if repairs have been done to it other than by Xantrex or its authorized service centers hereafter ASCs dthe product if it is used as a component part of a product expressly ecomponent parts or monitoring syyou or purchased by Xantrex at your direction for incorporation into the productfthe product if its original identid altered or removedgthe product if it is located outside of the country where it was purchased andhany consequential losses that are attributable to the product losing power whether by product malfunction installation error or Page 59 Thursday August 4 2011 112 and Return proof of purchase is requiredIn 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 Proof of purchase may be in any one of the following forms225The dated purchase receipt from the original purchase of the product at point of sale to the end user or225The dated dealer invoice or purhowing original equipment manufacturer OEMor225The dated invoice or purchase receipt showing the product exchanged under warrantyWhat does this warranty not coverClaims are limited to repair and replacement or if in Xantrexs 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 productThis Limited Warranty does not warrant uninterrupted or errorfree operation of the product or cover normal wear and tear of the product or costs related to the removal installation or of the customers electrical systems This warranty does not apply to and Xantrex will not be responsible for any defect in or damage toathe 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 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 limithe Xantrex product specifications including butinput voltage from generators and lightning strikescthe product if repairs have been done to it other than by Xantrex or its authorized service centers hereafter 223ASCs224 dthe product if it is used as a component part of a product expressly ecomponent parts or monitoring syyou or purchased by Xantrex at your direction for incorporation into the productfthe product if its original identid altered or removedgthe product if it is located outside of the country where it was purchased andhany consequential losses that are attributable to the product losing power whether by product malfunction installation error or Page 59 Thursday August 4 2011 112 Series Battery Charger Owners GuideWarranty and Return IN THE EUROPEAN EU MEMBERSTATE EU IN THE REST OF THE Page 60 Thursday August 4 2011 112 Series Battery Charger Owner222s GuideWarranty and Return IN THE EUROPEAN EU IN THE REST OF THE Page 60 Thursday August 4 2011 112 and Return Material Authorization PolicyFor those products that are not being repaired in the field and are being returned to Xantrex before returnmust obtain a Return Material Authorization RMAmber and the correct factory 223Ship To224 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 locationWhen you contact Xantrex to obtain service please have your instruction d be prepared to supply225The serial number of your about the installation and use of the about the failure andor reason for the return225A copy of your dated proof of purchaseRecord these details on page62Return 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 the RMA number supplied by Xantrex Technology USA Inc clearly marked on the outside of the box225A return address where the unit can be shipped Post office boxes are not acceptable225A contact telephone number where you can be reached during 225A brief description of the problemShip the unit prepaid to the address provided by your Xantrex customer service you are returning a product from outside of the USA or CanadaIn addition to the above you MUST include return freight funds and are fully responsible for all documents duties tariffs and deposits If you are returning a product to a Xantrex Authorized Service A Xantrex return material authorization RMAnot 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 productOut of Warranty ServiceIf 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 feeTo 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 223Return Procedure224 on page61 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 Page 61 Thursday August 4 2011 114 and Return Material Authorization PolicyFor those products that are not being repaired in the field and are being returned to Xantrex before returnmust obtain a Return Material Authorization RMAmber and the correct factory 223Ship To224 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 locationWhen you contact Xantrex to obtain service please have your instruction d be prepared to supply225The serial number of your about the installation and use of the about the failure andor reason for the return225A copy of your dated proof of purchaseRecord these details on page62Return 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 the RMA number supplied by Xantrex Technology USA Inc clearly marked on the outside of the box225A return address where the unit can be shipped Post office boxes are not acceptable225A contact telephone number where you can be reached during 225A brief description of the problemShip the unit prepaid to the address provided by your Xantrex customer service you are returning a product from outside of the USA or CanadaIn addition to the above you MUST include return freight funds and are fully responsible for all documents duties tariffs and deposits If you are returning a product to a Xantrex Authorized Service A Xantrex return material authorization RMAnot 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 productOut of Warranty ServiceIf 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 feeTo 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 223Return Procedure224 on page61 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 Page 61 Thursday August 4 2011 114 Series Battery Charger Owner222s GuideWarranty and Return About Your SystemAs soon as you open your Truecharge2 Series Battery Charger package record the following information and be sure to keep your proof of purchaseIf you need to contact Customer Service please record the following details before calling This information will help our give you better serviceSerial Number 804122002 804124002 804126002 8042410 8042420 804124003 804126003 804241001 804242001 FromPurchase DateType of installation eg RV truckLength of time unit has been bank sizeBattery type eg flooded sealed gel cell AGMAlarm of indicators on front panelwhen problem of Page 62 Thursday August 4 2011 114 Series Battery Charger Owner222s GuideWarranty and Return About Your SystemAs soon as you open your Truecharge2 Series Battery Charger package record the following information and be sure to keep your proof of purchaseIf you need to contact Customer Service please record the following details before calling This information will help our give you better serviceSerial Number 804122002 804124002 804126002 8042410 8042420 804124003 804126003 804241001 804242001 FromPurchase DateType of installation eg RV truckLength of time unit has been bank sizeBattery type eg flooded sealed gel cell AGMAlarm of indicators on front panelwhen problem of Page 62 Thursday August 4 2011 114 namexpost 9A A 00 60GA vZuQ5l V3VvxkeI WPlq 9K5Uyh IlNOER7Qfh x4 namexpost 9A A 00 60GA vZuQ5l V3VvxkeI WPlq 9K5Uyh IlNOER7Qfh x4 namexpost 9A A 00 60GA vZuQ5l V3VvxkeI WPlq 9K5Uyh IlNOER7Qfh x4 dEeE bch aeeDdD acEeE bch CEeE bch aeeDCD KEeE bch 9A A 00 60GA and RevisionAugust 2011 Rev CDocument Part NumbersContact ModelsIEC ModelsaIEC refers to the international standard from the Commission for plugs socketoutlets and couplers for industrial purposes IEC models have an AC input receptacle that connects with an IEC cable not 804124002 804126002 8042410 8042420 804124003 804242001 800 670 0707Fax1 800 994 Page i Thursday August 4 2011 111 and Smart choice for power are trademarks of Schneider Electric Services International sprl registered in the US and other countries Other trademarks registered trademarks and product names are the property of their respective owners and are used herein for identification purposes onlyNotice of Series Battery Charger Owners 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 for USA and Smart choice for power are trademarks of Schneider Electric Services International sprl registered in the US and other countries Other trademarks registered trademarks and product names are the property of their respective owners and are used herein for identification purposes onlyNotice of Series Battery Charger Owner222s Guide251 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 for USA and RevisionAugust 2011 Rev CDocument Part NumbersContact ModelsIECaIEC refers to the international standard from the Commission for plugs socketoutlets and couplers for industrial purposes IEC models have an AC input receptacle that connects with an IEC cable not 804124002 804126002 8042410 8042420 804124003 804242001 800 670 0707Fax1 800 994 Page i Thursday August 4 2011 111 namexpost 9A A 00 60GA vZuQ5l V3VvxkeI WPlq 9K5Uyh IlNOER7Qfh x4

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