Xantrex Truecharge2 10 Manual

ManualsBrandsXantrex ManualsWind and Solar EnergyXantrex 804-1210 Truecharge2 10 Amp 12 Volt DC Battery Charger

Thank you for purchasing the Truecharge2 12V 10A Battery Charger (PN: 804-1210). The

battery charger provides an efficient three-step charge to smaller 12-volt lead-acid batteries

(flooded, GEL, AGM, or Lead-calcium) used in recreational vehicles and boats. This

product is part of a family of advanced personal renewable energy devices from Xantrex™,

the leader in high-frequency inverter design and battery chargers.

The Truecharge2 12V 10A Battery Charger ships with the following items:

•one 12V 10A Battery Charger unit,

• owner’s guide,

• strain-relief clamp for AC input cables, and

• three crimp connectors for AC wires.

READ THIS GUIDE BEFORE OPERATING THE TRUECHARGE2 12V 10A BATTERY CHARGER,

AND SAVE IT FOR FUTURE REFERENCE.

IMPORTANT SAFETY INFORMATION

Misusing or incorrectly connecting the Truecharge2 12V 10A Battery Charger may damage

the equipment or create hazardous conditions for users. Read the following safety

instructions and pay special attention to all Caution and Warning statements in the guide.

NOTE: Please read sections “Precautions When Working With Batteries”, “Precautions

When Preparing to Charge”, and “Precautions When Placing the Battery Charger” before

proceeding.

PRECAUTIONS WHEN WORKING WITH BATTERIES

NOTES:

1. Locate the Truecharge2 12V 10A Battery Charger unit away from batteries in a well

ventilated compartment.

2. Always have someone within range of your voice or close enough to come to your aid

when you work near a lead-acid battery.

3. Always have plenty of fresh water and soap nearby in case battery acid contacts skin,

clothing, or eyes.

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

enters your eye, immediately flood it with running cold water for at least twenty minutes

and get medical attention immediately.

5. Use extra caution to reduce the risk of dropping a metal tool on the battery. It could spark

or short circuit the battery or other electrical parts and could cause an explosion.

6. Batteries can produce a short circuit current high enough to weld a ring or metal bracelet

or the like to the battery terminal, causing a severe burn.

7. When removing a battery, always remove the negative terminal from the battery first for

systems with grounded negative. If it is grounded positive, remove the positive terminal

first. Make sure all loads connected to the battery and all accessories are off so you don’t

cause an arc.

PRECAUTIONS WHEN PREPARING TO CHARGE

NOTES:

1. Study and follow all of the battery manufacturer's specific precautions, such as removing

or not removing cell caps while charging and recommended rates of charge.

2. For flooded non-sealed batteries, add distilled water in each cell until battery acid

reaches the level specified by the battery manufacturer. This helps to purge excessive gas

from cells. Do not overfill. For a battery without removable cell caps, carefully follow

manufacturer's instructions.

PRECAUTIONS WHEN PLACING THE BATTERY CHARGER

FCC INFORMATION TO THE USER

This equipment has been tested and found to comply with the limits for a Class B digital

device, pursuant to part 15 of the FCC Rules. These limits are designed to provide

reasonable protection against harmful interference in a residential installation. This

equipment generates, uses, and can radiate radio frequency energy and, if not installed and

used in accordance with the instructions, may cause harmful interference to radio

communications.

However, there is no guarantee that interference will not occur in a particular installation. If

this equipment does cause harmful interference to radio or television reception, which can

be determined by turning the equipment off and on, the user is encouraged to try to correct

the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the

receiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

CAUTION: Unauthorized changes or modifications to the equipment could void the user’s

authority to operate the equipment.

STANDARD AND PROTECTION FEATURES

The battery charger provides the following features:

•two

full current-rated DC outputs,

• battery monitoring functions,

• correct charging voltage for batteries when connected to almost any single phase AC

power outlet in the world,

• low electromagnetic interference (EMI),

• fully discharged battery charging

• battery reverse polarity protection via user-replaceable output fuse,

• ambient over-temperature shutdown and automatic recovery,

• battery over-charging protection,

• electronic current limiting provides protection against short circuit conditions on the

charger’s output,

• isolated design, and

• IP-32 drip protection rating

Preparing for Installation

Tools and Materials

Tools needed are:

• flathead screwdriver for the DC terminals and ground connection,

• Phillips screwdriver for removing and re-securing the AC wiring compartment covers,

• power drill/screwdriver,

• drill bit set for pilot holes for mounting screws (if using #6 mounting screws, use 1/16

drill),

• wire stripper,

• manufacturer's recommended crimp tool for any crimp terminals that are being used.

Materials needed are:

• 3 conductor AC input wiring

• Use the information in “Install AC Wiring” and your local electrical codes to determine

the correct wire and breaker or fuse.

• AC cable strain relief (if the one included is not compliant with your local electrical code

requirements).

• appropriately sized DC cables for each battery, with suitable connectors at the battery

end

• Use the information in “DC Wiring” and your local electrical codes to determine the

correct wire and breaker or fuse.

• appropriately sized DC chassis ground (earth) cable with suitable connectors,

• DC fused disconnect or properly rated circuit breaker for each battery bank, and

• mounting screws, M3 or #6 marine grade, corrosion resistant (4 pieces) (Length

dependent on mounting surface).

Wiring Requirements

NOTES:

• Wiring and fuse sizes are governed by electrical codes and standards. Different

requirements apply in different countries and to different types of installations, for

example, boat, home or RV. It is the responsibility of the installer to ensure that each

installation complies with all applicable codes and standards.

• Ensure that wires and fuses or breakered disconnects are correctly sized. Maximum

continuous DC current available from the charger may be an additional 6–10% above the

nominal current rating of the charger.

Introduction

ELECTRICAL SHOCK HAZARD

• Do not expose the battery charger to rain, snow, spray, or bilge water.

• Do not operate the battery charger if it has received a sharp blow, been

dropped, has cracks or openings in the enclosure, or is otherwise damaged

in any other way.

• Do not disassemble the battery charger. There are no user-serviceable parts

with the exception of a user-replaceable fuse at the DC output wiring

compartment (see illustration in “Features”). Also, internal capacitors remain

charged after all power is disconnected.

• Disconnect both AC and DC power from the battery charger before attempting

any maintenance or cleaning or working on any circuits connected to the

battery charger.

• Do not operate the battery charger with damaged or substandard wiring.

Failure to follow these instructions will result in death or serious

injury.

EXPLOSION HAZARD

• Charge only properly rated 12-volt lead-acid (GEL, AGM, Lead-calcium, or

Flooded) rechargeable batteries because other types may explode and burst.

• Do not work in the vicinity of lead-acid batteries. Batteries generate explosive

gases during normal operation.

• Follow the instructions 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.

PHYSICAL INJURY HAZARD

This battery charger is not intended for use by persons (including children) with

reduced physical, sensory, or mental capabilities or lack of experience and

knowledge, unless they have been given supervision or instruction concerning use

of the appliance by a person responsible for their safety. Children should be

supervised to ensure that they do not play with the battery charger.

Failure to follow these instructions can result in death or serious

injury.

BURN FROM HIGH SHORT-CIRCUIT CURRENT, FIRE AND EXPLO-

SION FROM VENTED GASES HAZARDS

• Always wear proper, non-absorbent gloves, complete eye protection, and

clothing protection. Avoid touching your eyes and wiping your forehead while

working near batteries. See note #4.

• Remove all personal metal items, like rings, bracelets, and watches when

working with batteries. See notes #5 and #6.

• Never smoke or allow a spark or flame near the engine or batteries.

• Never charge a frozen battery.

Failure to follow these instructions can result in death or serious

injury.

EXPOSURE TO CHEMICALS AND GASES HAZARD

• Make sure the area around the battery is well ventilated.

• Make sure the voltage of the batteries matches the output voltage of the battery

charger.

• Be careful to keep corrosion from coming into contact with your eyes and skin

when cleaning battery terminals.

Failure to follow these instructions can result in death or serious

injury.

EXPLOSION HAZARD

Do not place the battery charger in machinery space or in areas containing gasoline tanks

or fittings in which ignition-protected equipment is required.

Failure to follow these instructions will result in death or serious

injury.

RISK OF DAMAGE TO THE BATTERY CHARGER

• Never allow battery acid to drip on the battery charger when reading gravity, or

filling battery.

• Never place the Truecharge2 12V 10A Battery Charger unit directly above

batteries; gases from a battery will corrode and damage the charger.

• Do not place a battery or anything on top of the battery charger.

Failure to follow these instructions can damage the unit and/or

damage other equipment.

Features

1.Each output can charge different batteries that either have the same chemistry or can tolerate the same charge sequence and volt-

age/current ratings.

2.The charger can initiate charging a non-damaged but zero voltage battery.

3.In three specific installation orientations.

10A

TOP VIEW

REAR VIEW

Onboard Display Panel

1a Charging Output (%) LEDs illuminate like a bar graph (from

10 to 100% - numbers below the LEDs) displaying the

present total output charge current as a percentage of the 10-

amp-rated charge current.

The icons above the Charging Output (%) LEDs represent

the various types of fault and warning conditions (for more

info, see 1e).

1b Charger Status displays the current status of the charger.

Ready - a solid light indicates batteries are fully charged

and the charger is in float stage.

Charging - a solid light indicates charger is performing a

normal charge cycle.

1c Battery Type Select button - Press and hold the button for

three seconds to select one of four battery type settings.

Settings are: AGM (Absorbent Glass Mat), Flooded, Gel, and

Lead Calc. (Lead Calcium).

1d Battery Temp. Select button - Press and hold the button for

three seconds to select one of three temperature settings.

Settings are: Cold for a battery temperature < 5 °C (41 °F),

Warm for 5 to 30 °C (41 to 86 °F), and Hot for > 30 °C (86

°F)

1e Fault LED illuminates a solid light (indicating a fault) or flash

intermittently (indicating a warning) in combination with a

flashing Charging Output (%) LEDs (for more info, see 1a).

Truecharge2 12V 10A Battery Charger Features

Item Description

1 Onboard Display Panel shows charging current (1a), charger status (1b), and fault and warning

conditions (1e). It also controls battery charger settings such as battery type (1c) and temperature (1d).

2 Mounting Flanges are used to permanently install the product.

3 AC Wiring Compartment houses the AC cable with leads. Its cover is secured in place by a screw and

provides the installer with easy access to the AC wiring compartment to allow for a trouble free

installation. Remove and replace the cover (the screw does not separate from the cover) when installing

the product.

4 Air Intake (at the front) and Exhaust Fan (at the rear)

5 User-replaceable Fuse can be replaced with a 15-amp fast-acting blade fuse such as Littelfuse® ATO/

ATC 15A 32 V (blue).

6 DC Output terminal block has four contacts each in a plastic housing with a screw-on type contact . The

terminal contacts are arranged from left to right as: Battery positive (+) for bank 1, Battery positive (+)

for bank 2, Common battery negative (–), and a ground terminal.

Charger Installation

IMPROPER INSTALLATION BY AN UNQUALIFIED INSTALLER

The battery charger must be installed by a qualified installer in accordance with all

applicable local or national installation codes. Examples of such codes are the US

National Electrical Code (NFPA 70), the American Boat and Yacht Council

standards E-11 and A-31, and the US Coast Guard Electrical Regulations

(33CFR183).

Failure to follow these instructions can damage the unit and/or

damage other equipment.

ELECTRICAL SHOCK AND FIRE HAZARD

Do not operate the battery charger with damaged or substandard wiring. Make sure

that all wiring is in good condition and is not undersized. See notes below.

Failure to follow these instructions will result in death or serious

injury.

NOTE: Not to scale.

For illustration purposes only.

NOTE: In some jurisdictions a

double-pole breaker may be

required.

Figure 1

Configuration for Normal Loads

NOTE: The battery charger is designed to be permanently

mounted. Figure 1 shows a typical installation with two

batteries. It also shows the AC and DC wiring and

protection devices required for a typical installation.

Means of over-current protection and disconnection must

be incorporated into the fixed wiring, in accordance with

the electrical code that governs each installation.

1 AC input wiring compartment

2 AC mains source protected by correct size and

type of branch rated circuit breaker

3 DC negative cable

4 DC positive cables

5 DC circuit breakers or DC fused disconnects

6 Battery or battery bank

7 Engine ground bus or DC negative bus

8 Ground bus

9 DC chassis ground (earth)

12V 10A BATTERY CHARGER

975-0565-TC2_10A_Charger_domestic_XTUI.fm Page 1 Tuesday, May 10, 2011 2:57 PM

Summary of content (4 pages)

PAGE 1
975-0565-TC2_10A_Charger_domestic_XTUI.fm Page 1 Tuesday, May 10, 2011 2:57 PM 12V 10A BATTERY CHARGER Introduction Thank you for purchasing the Truecharge2 12V 10A Battery Charger (PN: 804-1210). The battery charger provides an efficient three-step charge to smaller 12-volt lead-acid batteries (flooded, GEL, AGM, or Lead-calcium) used in recreational vehicles and boats.
PAGE 2
975-0565-TC2_10A_Charger_domestic_XTUI.fm Page 2 Tuesday, May 10, 2011 2:57 PM DC Wiring The following table shows some typical wire sizes for various cable length runs, based on 3% voltage drop on DC cables, 75 °C (167 °F) rated wire with wiring being inside the engine compartment – assumed ambient of 50 °C (122 °F). DC Wiring Examples Based on ABYC1 E-11 20087 Table VI-A and Table IX Wire Length (one way) Wire Size (AWG, mm2) 5 ft 1.5 m No. 14, 2.1 mm2 7.5 ft 2.25 m No. 12, 3.3 mm2 15 ft 4.5 m No.
PAGE 3
975-0565-TC2_10A_Charger_domestic_XTUI.fm Page 3 Tuesday, May 10, 2011 2:57 PM Charging Voltage Setpoints The Truecharge2 Battery Charger charging process is designed to make the battery or battery banks reach the following voltage setpoints. Battery Installation Battery installation should always be treated like a brand new installation.
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975-0565-TC2_10A_Charger_domestic_XTUI.fm Page 4 Tuesday, May 10, 2011 2:57 PM Charger Maintenance Maintaining the Battery Charger ELECTRICAL SHOCK HAZARD Do not disassemble the battery charger. See note below. Failure to follow these instructions will result in death or serious injury. NOTE: The battery charger contains no user-serviceable parts with the exception of the DC output fuse which is user-replaceable. See “Replacing a Blown Fuse” for instructions.