Xantrex Truecharge 20+/40+ Amp Owners Manual User manual

Xantrex

Truecharge 20+/40+ Amp

Multistage Battery Charger

Owner’s Guide

TC20+

TC40+

Owner’s Guide

Truecharge 20+/40+ Amp

Multistage Battery Charger

About Xantrex

Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with

products from 50 watt mobile units to 1 MW utility-scale systems for wind, solar, batteries, fuel cells,

microturbines, and backup power applications in both grid-connected and standalone systems. Xantrex

products include inverters, battery chargers, programmable power supplies, and variable speed drives that

convert, supply, control, clean, and distribute electrical power.

Trademarks

Truecharge is a trademark of Xantrex International. Xantrex is a registered trademark of Xantrex

International.

Other trademarks, registered trademarks, and product names are the property of their respective owners and

are used herein for identification purposes only.

Notice of Copyright

Truecharge 20+/40+ Owner’s Guide © June 2005 Xantrex International.

Disclaimer

UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC.

(“XANTREX”)

(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY

TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.

(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT,

INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH

INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.

Date and Revision

June 2005, Revision A

Part number

445-0050-01-01

Contact information

Phone: 1-800-670-0707 (toll free in North America)

Phone: 1-360-925-5097 (outside of North America)

Fax: 1-360-925-5143

Email: CustomerServ[email protected]

Web: www.xantrex.com

About This Guide

Purpose and scope

This guide introduces the Truecharge+ battery chargers, describes their

features, explains how they charge batteries, and provides procedures for their

installation and operation. The guide does not provide details for particular

brands of batteries. Please consult the battery manufacturer for this

information.

This guide provides information for two products, Truecharge 20+ and

Truecharge 40+. Where information is specific to one product, that product is

referred to by name. Where information applies to both products, they are referred

to collectively as Truecharge+.

Audience

The guide is written for anyone intending to install and operate a Truecharge+

battery charger. Xantrex recommends, however, that the product be installed

by a certified technician or electrician.

Organization

This guide contains four chapters and four appendixes.

Chapter 1, “Introduction” introduces and describes features of the Truecharge+

multistage battery chargers.

Chapter 2, “Installing Truecharge+” lists the materials you receive, provides site

recommendations for installing Truecharge+, and provides the materials and

procedures for its installation.

About This Guide

iv

Chapter 3, “Operation” provides background information for charging

batteries with Truecharge+ and procedures for charging and for

equalizing batteries. Chapter 3 also explains how to calculate charging

times, how generators affect Truecharge+ and explains how the front

panel indicator lights are interpreted.

Chapter 4, “Maintenance and Troubleshooting” provides information for

maintaining and troubleshooting Truecharge+.

Appendix A “Specifications” contains the Truecharge+ physical,

electrical, AC input, and protection feature specifications.

Appendix B “Battery Charging” describes the Truecharge+ multistage

charging algorithm.

Appendix C “Battery Maintenance” contains procedures for maintaining

the battery enclosure, battery terminals and lugs, and battery cables. It

also provides a list of the clothing, tools, equipment, and supplies you

should have before you begin battery maintenance.

Appendix D “Product and System Information” contains the Xantrex

warranty for your product and return instructions. It also contains a place

for you to record the serial number and date of purchase and other details

of your battery charger.

v

Important Safety Instructions

Explosive gas precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–x

Precautions When Working With Batteries - - - - - - - - - - - - - - - - - - - - - - - - - 1–x

1Introduction

Truecharge+ Features- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2

20/40 Amp Continuous Rating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2

Simultaneous Three-Battery Bank Charging - - - - - - - - - - - - - - - - - - - - - - - 1–2

Wide Voltage Range Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2

Selector Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3

Extensive Protection Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3

Isolated Design - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3

Fixed Voltage Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Optional Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Indicator Lights and Settings on the Front Panel - - - - - - - - - - - - - - - - - - - - - - 1–4

How Truecharge+ Works - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6

2 Installing Truecharge+

Materials List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

Preparing for Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2

Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3

Circuits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3

Wiring Requirements- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5

DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–5

AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–6

Tools- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7

Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7

Installing Truecharge+ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8

Mounting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8

Connecting DC Wiring For A Single Battery Or Multiple Batteries- - - - - - - - 2–9

Contents

vi

Connecting to AC Wiring- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11

Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14

Installing Optional Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14

Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14

Remote Display Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–15

3 Operation

About Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

Charging Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

Battery Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3

Using A Generator As Source Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4

Indicator Light Activity On The Front Panel - - - - - - - - - - - - - - - - - - - - - - - 3–4

Charging batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5

Equalizing Flooded Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7

About Equalizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7

Performing An Equalization - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8

4 Maintenance and Troubleshooting

Care and Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2

Troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2

Indicator Light Flashing Sequences - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2

Typical Problems - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4

A Specifications

Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2

Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2

AC Input Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4

Protection Features- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–4

Approvals- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–5

B Battery Charging

Charging Algorithms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2

Battery Type- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2

Charge Algorithm Stages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–2

Equalization Charge- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–4

Two-Stage Charging- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B–4

C Battery Maintenance

Contents

vii

Maintenance Guidelines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–2

Preparation for Cleaning Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3

Clothing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3

Tools- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3

Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3

Supplies- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–3

Maintaining and Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4

Battery Enclosure and Batteries- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4

Terminals & Lugs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–4

Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C–5

D Product and System Information

Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–2

DISCLAIMER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–4

Product - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–4

Exclusions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–4

WARNING: LIMITATIONS ON USE- - - - - - - - - - - - - - - - - - - - - - - - - - - D–4

Return Material Authorization Policy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–5

Return Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–5

Information about your Truecharge+- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D–7

Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Index–1

viii

ix

Important Safety Instructions

1. Before using the charger, read all instructions and cautionary

markings on the charger, the batteries, and all appropriate sections

of this guide.

2. Do not expose the charger to rain, snow, spray, or bilge water. To

reduce risk of fire hazard, do not cover or obstruct the ventilation

openings. Do not install the charger in a zero-clearance

compartment. Overheating may result.

3. Use only attachments recommended or sold by the manufacturer.

Doing otherwise may result in a risk of fire, electric shock, or injury

to persons.

4. The charger is designed to be permanently connected to your AC

and DC electrical systems. Xantrex recommends that all wiring be

done by a certified technician or electrician to ensure adherence to

the local and national electrical codes applicable in your

application.

5. To avoid a risk of fire and electric shock, make sure that existing

wiring is in good condition and that wire is not undersized. Do not

operate the charger with damaged or substandard wiring.

6. Do not operate the charger if it has received a sharp blow, been

dropped, or otherwise damaged in any way. If the unit is damaged,

see the Warranty section in Appendix D, “Product and System

Information”.

WARNING

This chapter contains important safety and operating

instructions as prescribed by UL and CSA standards for

chargers used in residential, RV, and marine applications.

Read and keep this Owner’s Guide for future reference.

Important Safety Information

x

7. Do not disassemble the charger. See Appendix D, “Product and

System Information” for instructions on obtaining service.

Attempting to service the unit yourself may result in a risk of

electrical shock or fire. Internal capacitors remain charged after all

power is disconnected.

8. To reduce the risk of electrical shock, disconnect both AC and DC

power from the charger before attempting any maintenance or

cleaning or working on any circuits connected to the charger.

Turning off controls will not reduce this risk.

9. The charger must be provided with an equipment-grounding

conductor connected to the AC input ground.

10. For marine applications in the United States, external connections to

the charger shall comply with the United States Coast Guard

Electrical Regulations (33CFR183, Sub part 1).

Explosive gas precautions

1. Working in the vicinity of lead-acid batteries is dangerous. Batteries

generate explosive gases during normal operation. Therefore you

must read this guide and follow the instructions exactly before

installing or using your charger.

2. TrueCharge 20+ and TrueCharge 40+ have been approved as

Ignition Protected. They may be installed in areas containing

gasoline tanks and fittings which require Ignition Protected

equipment. Xantrex recommends, nevertheless, that it is safest not

to install electrical equipment in these areas.

3. To reduce the risk of battery explosion, follow these instructions

and those published by the battery manufacturer and the

manufacturer of the equipment in which the battery is installed.

Precautions When Working With Batteries

1. Have someone within range of your voice or close enough to come

to your aid when you work near a lead-acid battery.

2. Have plenty of fresh water and soap nearby in case battery acid

contacts skin, clothing, or eyes.

Important Safety Information

xi

3. Wear complete eye protection and clothing protection. Avoid

touching your eyes while working near batteries.

4. If battery acid contacts skin or clothing, wash immediately with

soap and water. If acid enters your eye, immediately flood it with

running cold water for at least twenty minutes and get medical

attention immediately.

1

Introduction

Chapter 1, “Introduction” introduces and

describes features of the Truecharge+ multistage

battery chargers.

Introduction

1–2

Truecharge+

Features

Truecharge+ is an advanced battery charger designed specifically for high

performance, deep-cycle lead-acid batteries. It is smaller and lighter than

many other chargers and can be installed or stored in small compartments.

It has AC to DC isolation, a surge protector, and many other safety

features which reduce potential shock and fire hazards.

20/40 Amp Continuous Rating

Truecharge 20+ delivers a 20 amp charging current and the

Truecharge 40+ delivers 40 amps for approximately 75% of the charging

cycle. The chargers only reduce the charging current below these rated

levels when the battery is approaching full charge or when there may be

overheating in high ambient temperatures. Because it delivers rated

current over most of the charge cycle, Truecharge+ charges your batteries

faster than many other chargers with a higher rating.

Many other chargers only deliver their rated charging current for a short

initial part of the charge cycle.

Simultaneous Three-Battery Bank Charging

Truecharge+ has three separate DC positive terminals to allow charging

of three separate batteries (or battery banks). The total current into the

batteries is a maximum of either 20 amperes or 40 amperes, depending on

the model, which is divided amongst the batteries according to their state

of discharge.

Wide Voltage Range Operation

Truecharge+ maintains the correct charging voltage for your battery when

the AC line voltage drops as low as 90 VAC, or rises as high as 135 VAC.

A surge protector in Truecharge+ protects it from surges and spikes on the

AC power line.

Note: The three outputs are not independently voltage regulated so it

is important to avoid systems with mixed types of batteries.

Truecharge+ Features

1–3

Selector Switches

Truecharge+ has selector switches for charge mode, battery type, and

battery temperature setting.

Charge mode The charge-mode switch allows you to select three-step charge, two-step

charge or 13.5 volt fixed output modes. Refer to Appendix B, “Battery

Charging” for an explanation of the charging algorithms.

Battery type The battery-type switch allows you to set the Truecharge+ for the

charging characteristics of flooded, AGM, and gel batteries.

Temperature The battery temperature switch allows you to set charging characteristics

based on the battery temperature. By setting the switches correctly before

you begin charging your battery, you will be ensuring that it receives the

best possible charge.

Extensive Protection Features

Truecharge+ provides the following protection features:

• Opening of the internal output fuse if a battery is accidentally

connected with reversed polarity

• Fuse opening or electronic shutdown if there is a short circuit on the

output of the Truecharge+

• Built-in protection against accidental connection to a higher battery

voltage, up to 24 VDC

• Unit shutdown if it becomes overheated because of inadequate

ventilation or a high ambient temperature

• Unit shutdown if the battery gets too hot (with battery temperature

sensor only)

Isolated Design

The DC battery charging circuits of Truecharge+ are galvanically isolated

by a transformer from the AC power circuits. This feature reduces the risk

of electric shock and helps to prevent corrosion problems in marine

applications.

Introduction

1–4

Fixed Voltage Mode

The fixed voltage mode setting is meant to be used as a power supply or

battery eliminator. It is not meant for charging batteries. The battery type,

battery temperature, and equalize switches are all ignored in fixed voltage

mode. The remote battery temperature sensor does not compensate the

voltage, but the battery over-temperature shutdown is still active.

Optional Accessories

Battery

Temperature

Sensor

The remote Battery Temperature Sensor (BTS) automatically adjusts the

charge according to the temperature of one of the batteries. With a BTS

installed, the unit provides a more accurate temperature-compensated

charge for the battery to which the sensor is attached.

Remote panel The remote panel allows you to monitor the charging progress of two

batteries or battery banks, the total charge current, and charger status from

a convenient location.

Indicator Lights and Settings on the Front Panel

This section describes the parts of the front panel of the Truecharge 20+.

Figure 1-1 shows the front panel. Descriptions are provided in Table 1-1

Figure 1-1 Front panel of Truecharge 20+ battery charger

1

3

4

5

2

6

Indicator Lights and Settings on the Front Panel

1–5

The indicator lights are also used to indicate error codes. See Chapter 4,

“Maintenance and Troubleshooting”

Table 1-1 Truecharge+ front panel

Panel

Item Description

1 Status indicator lights which indicate that batteries are charged and

ready for use or that the batteries are being charged or equalized.

2

Indicator lights which show the total charging current, in amps, into

the three battery banks.

The indicator lights show:

1, 3, 5, 10, 20 A (Truecharge20+)

2, 5, 10, 20, 40 A (Truecharge 40+)

3 The recessed Equalize button is triggered manually to enter or leave

the equalization mode.

4 The Charger Mode switch from which you can select a three-stage or

two-stage charge or a 13.5 volt power supply mode to power 12 volt

loads when you don’t have a battery.

5 The battery selection switch for choosing flooded, gel or AGM

batteries.

6 The battery-temperature switch for choosing the battery temperature

for the charge. Temperature settings compensate the output voltage

for the battery temperature.

Note that a battery temperature sensor overrides the temperature

settings on the front panel.

Introduction

1–6

How Truecharge+ Works

Truecharge+ changes the alternating current (AC) supply from the utility

to the controlled low-voltage, direct current (DC) required to charge the

battery by using high-frequency, switched-mode power conversion

circuits. The high-frequency power conversion method is similar to that

used in power supplies for computers and other electronic equipment. It

results in a significantly smaller and lighter charger than other power

conversion methods allow.

The controlled DC output is fed to three isolations diodes, one for each

battery bank. These diodes isolate the batteries from each other and

prevent current flow from one battery to the others.

2

Installing

Truecharge+

Chapter 2, “Installing Truecharge+” lists the

materials you receive, provides site

recommendations for installing Truecharge+, and

provides the materials and procedures for its

installation.

The chapter also makes reference to the

installation codes that may be applicable in your

application, for example, the US National

Electrical Code (NEC, NFPA 70), the Canadian

Electrical Code (CEC, CSA C22.1), and the

American Boat and Yacht Council (ABYC)

Recommended Practices.

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