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XC_Charger_Owner.book Page ii Friday, August 12, 2005 3:23 PM About Xantrex Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems.
XC_Charger_Owner.book Page iii Friday, August 12, 2005 3:23 PM About This Guide Purpose The purpose of this Owner’s Guide is to provide explanations and procedures for installing, operating, maintaining, and troubleshooting the Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Charger. Scope The Guide provides safety guidelines, detailed planning and setup information, procedures for installing the charger, as well as information about operating and troubleshooting the unit.
XC_Charger_Owner.book Page iv Friday, August 12, 2005 3:23 PM About This Guide Conventions Used The following conventions are used in this guide. WARNING Warnings identify conditions or practices that could result in personal injury or loss of life CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment. Important: These notes describe things which are important for you to know, but not as serious as a caution or warning.
XC_Charger_Owner.book Page v Friday, August 12, 2005 3:23 PM Important Safety Instructions WARNING This chapter contains important safety and operating instructions as prescribed by safety standards for chargers used in RV and marine applications. Read and keep this Owner’s Guide for future reference. 1.
XC_Charger_Owner.book Page vi Friday, August 12, 2005 3:23 PM Safety 8. The XC Series is provided with an AC ground conductor that must be connected to the AC input ground and a DC ground stud which must be connected to the DC system ground. 9. 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 and Battery Precautions WARNING: Explosion or fire hazard 1.
XC_Charger_Owner.book Page vii Friday, August 12, 2005 3:23 PM Safety 10. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes. 11. Wear complete eye protection and clothing protection. Avoid touching your eyes while working near batteries. 12. 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. 13.
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XC_Charger_Owner.book Page 1 Friday, August 12, 2005 3:23 PM 1 Introduction Chapter 1 describes the XC Series standard features. It also provides information to prepare for installation of the XC Series.
XC_Charger_Owner.book Page 2 Friday, August 12, 2005 3:23 PM Introduction Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Charger Features The XC Series provides the following standard features: • • • • • three full current rated, independently controlled outputs which enable it to charge three different batteries or battery banks. Each bank can be of a different battery type, stage of charging, and temperature compensation one battery temperature sensor (BTS) is included.
XC_Charger_Owner.book Page 3 Friday, August 12, 2005 3:23 PM XC Series Appearance XC Series Appearance This section describes the parts of the XC Series. Figure 1-2 shows the XC Series. 2 1 3 Figure 1-1 XC Series Item Description 1 Remote display for all programming functions and monitoring of the XC Series. 2 Onboard status panel for monitoring charger status and charging current at the XC Series when the remote display is mounted remotely from the charger.
XC_Charger_Owner.book Page 4 Friday, August 12, 2005 3:23 PM Introduction Information Centers of the XC Series Remote Display This section describes the parts of the remote display of the XC Series. The remote display can be rotated 180°, or it can be removed and remotely mounted up to 20 m (65 ft) from the XC Series for convenience. Figure 1-2 shows the remote display.
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XC_Charger_Owner.book Page 6 Friday, August 12, 2005 3:23 PM Introduction Onboard Status Panel This section describes the parts of the onboard status panel of the XC Series. Figure 1-3 shows the panel.
XC_Charger_Owner.book Page 7 Friday, August 12, 2005 3:23 PM Rear Panel Rear Panel This section describes the parts of the rear panel of the XC Series. Figure 1-4 shows the rear panel.
XC_Charger_Owner.book Page 8 Friday, August 12, 2005 3:23 PM Introduction Preparing for Installation The XC Series is designed to be permanently mounted. Figure 1-1 shows a typical installation with three batteries, a BTS and a remote display. It also shows the AC and DC wiring and protection devices required for a successful installation.
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XC_Charger_Owner.book Page 10 Friday, August 12, 2005 3:23 PM Introduction Location Install the XC Series in a location that meets the following requirements: Condition Requirement Dry The XC Series must be installed in a dry location not subject to rain, spray or splashing bilge water. Clean The XC Series should not be exposed to metal filings or any other form of conductive contamination. Cool The ambient air temperature should be between 0 °C - 50 °C (32 °F - 122 °F) for best performance.
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XC_Charger_Owner.book Page 12 Friday, August 12, 2005 3:23 PM Introduction Wiring Requirements WARNING Wire and fuse sizes are dictated by electrical standards. Different standards apply in different countries and different types of installations, for example, boat, home or RV. It is the responsibility of the installer to ensure that the installation complies with all applicable standards. CAUTION Ensure that both wires and fuses are correctly sized.
XC_Charger_Owner.book Page 13 Friday, August 12, 2005 3:23 PM Preparing for Installation Over-current protection disconnect The DC circuit from the battery to the charger must be equipped with a disconnect and over-current protection device. The device usually consists of a DC-rated circuit breaker, a “fused disconnect”, or a separate fuse and disconnect. These devices must be rated for DC voltage and current. Do not substitute devices rated only for AC voltage; they may not operate properly.
XC_Charger_Owner.book Page 14 Friday, August 12, 2005 3:23 PM Introduction Battery Bank Size Requirements The XC Series is designed to work with a minimum battery bank size. Each bank should meet the minimum Ah rating shown in Table 1-2.
XC_Charger_Owner.book Page 1 Friday, August 12, 2005 3:23 PM 2 Installation Chapter 2 provides procedures for installing, testing and configuring the XC Series.
XC_Charger_Owner.book Page 2 Friday, August 12, 2005 3:23 PM Installation Installing the XC Series WARNING: Shock and Energy Hazards Be 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. Disconnect all sources of AC and DC power before proceeding.
XC_Charger_Owner.book Page 3 Friday, August 12, 2005 3:23 PM Installing the XC Series Pre-Installing DC Wiring The procedure for installing the DC wiring applies to a single battery or multiple batteries or battery banks. WARNING: Shock or arc burn hazard To help prevent accidental shorts or sparks, leave the DC disconnects or breakers in the Off position or fuses removed from their fuse holders until installation is complete.
XC_Charger_Owner.book Page 4 Friday, August 12, 2005 3:23 PM Installation 5. Route the wiring to the batteries and to the XC Series, but don’t connect it yet. Avoid routing wiring through an electrical distribution panel, battery isolator, or other device that will add voltage drops. 6. Install crimp lugs on each end of the battery cables using the crimp manufacturer’s instructions and tool. 7. Install rubber boots over the charger end of the DC cables.
XC_Charger_Owner.book Page 5 Friday, August 12, 2005 3:23 PM Installing the XC Series 5. Install the cable strain relief on the XC Series end of the source AC cable. 6. Carefully remove 50 – 75 mm (2 – 3 in.) of the outer jacket, being careful not to cut or nick the insulation on the individual conductors. 7. Pull the XC Series pigtail wires out through the access hole. 8. Thread the source AC cable through the knockout beneath the wiring compartment cover and then pull it out through the access hole. 9.
XC_Charger_Owner.book Page 6 Friday, August 12, 2005 3:23 PM Installation To connect AC wires with the crimp-on butt-splice connector: Important: You must exercise care when crimping butt-splice connectors. Use the crimp tool recommended by the manufacturer for the connector used. a) Using a wire stripper, carefully strip 8 mm (5/16 in.) from the ends of the two wires being connected.
XC_Charger_Owner.book Page 7 Friday, August 12, 2005 3:23 PM Installing the XC Series Mounting the Remote Display WARNING: Shock hazard Even if you intend to leave the remote display in the shipped orientation in the XC Series, you must remove the remote display and secure it in place by removing the non-stick backing on the rear and pressing the remote display flanges in place. If you do not use the non-stick backing, the XC Series will not be drip protected.
XC_Charger_Owner.book Page 8 Friday, August 12, 2005 3:23 PM Installation To remotely mount the display: 1. Remove the display as described on page 2–7. 2. Secure the blank plate in the display socket as described. 3. Ensure that the extension cable used for the remote display is long enough to suit the installation. A standard North American style, 4 conductor (RJ-11) telephone cable extender is adequate. 4. Use the enclosed mounting template to cut a hole for the display in the chosen mounting surface.
XC_Charger_Owner.book Page 9 Friday, August 12, 2005 3:23 PM Installing the XC Series 3. Secure the enclosed mounting template to the mounting surface with tape. 4. Drill the six pilot holes for the mounting screws, taking care that there is nothing behind the surface that can be damaged by the drill. 5. Mount the XC Series using corrosion resistant, #6 (3 mm) round, pan head (or similar) screws.
XC_Charger_Owner.book Page 10 Friday, August 12, 2005 3:23 PM Installation Final Connections Once the DC cables, AC cables and XC Series are all in place the final connection may be made. Figure 2-1 shows the connection order.
XC_Charger_Owner.book Page 11 Friday, August 12, 2005 3:23 PM Installing the XC Series Final DC Connections WARNING: Shock hazard Make sure that the DC fuse or circuit breaker is still open. To make the last DC connections: 1. Connect the negative cable from the negative terminal on the battery (if you are using only one battery or bank), or the negative ground bar or bus (if you are using more than one battery or bank), to the negative DC terminal on the XC Series (Figure 2-1).
XC_Charger_Owner.book Page 12 Friday, August 12, 2005 3:23 PM Installation 8. Secure cables in place using tie-wraps, P-clamps or cable straps according to electrical codes. Coil and tie any extra BTS or remote display extension cable. 9. The DC breakers may be closed or fuses inserted at this time. Final AC Connections To make the last AC connections: 1. Complete the installation by routing the AC cable to the AC source. 2.
XC_Charger_Owner.book Page 13 Friday, August 12, 2005 3:23 PM Installing Optional Accessories Installing Optional Accessories The XC Series ships with a battery temperature sensor (BTS) and drip protection rubber boots for the DC cables. Battery Temperature Sensor Xantrex strongly recommends that you install a Battery Temperature Sensor (BTS) to protect your battery and improve charging accuracy.
XC_Charger_Owner.book Page 14 Friday, August 12, 2005 3:23 PM Installation Drip Protection Rubber Boots Xantrex recommends that you install the supplied rubber boots over the XC Series DC terminals to provide drip protection. To install rubber boots: 1. Before making the DC connections to the charger, feed the rubber boot over the charger end of the DC cables. 2. Perform all other DC connections as described in “To install DC wiring:” on page 2–3. 3.
XC_Charger_Owner.book Page 15 Friday, August 12, 2005 3:23 PM Configuring the XC Series Configuring the XC Series Once the charger is connected to a battery on bank 1 or to AC, it is live and it may be configured. There will be a short delay of about 15 seconds before the remote display begins reporting. The remote display will use this time to query the charger for the current operating conditions. If AC was already applied, ensure that the charger is in on by pressing ON/STANDBY if necessary.
XC_Charger_Owner.book Page 16 Friday, August 12, 2005 3:23 PM Installation To configure the charging type: 1. Press and hold MODE until set (setup) is displayed. 2. Press MODE to select 2-stage (2st) or 3-stage (3st) charging. When you have selected a charging type that is different from the present configuration, the bank indicator light flashes. See “About Charging” on page 3–2. 3. Press and hold ON/STANDBY until yes is displayed to store the selected mode. 4.
XC_Charger_Owner.book Page 1 Friday, August 12, 2005 3:23 PM 3 Operation Chapter 3 describes the operating states and provides procedures for charging a battery and performing an equalization.
XC_Charger_Owner.book Page 2 Friday, August 12, 2005 3:23 PM Operation About Charging The XC Series has three full current rated, independently controlled outputs which enable it to charge three different batteries or battery banks. Each output can accommodate any one of the four allowable battery types, regardless of what battery types are connected to the other outputs.
XC_Charger_Owner.book Page 3 Friday, August 12, 2005 3:23 PM About Charging Sequential 2-Stage Charging In sequential charging mode the charger will check all battery banks every 15 minutes to determine which banks are present, healthy, and in most in need of charge. The bank most in need of charge will then be charged for the next 15 minutes. The sequential charging mode employs the 2-stage charging algorithm.
XC_Charger_Owner.book Page 4 Friday, August 12, 2005 3:23 PM Operation Disqualified Batteries The XC Series can identify when a battery will not accept a charge (battery is damaged) or when it is fully charged (healthy) and does not require further charge. Batteries that will not accept a charge will be removed (disqualified) from the charging sequence until all banks are checked again (every 15 minutes).
XC_Charger_Owner.book Page 5 Friday, August 12, 2005 3:23 PM About Charging Things to be aware of When the XC Series is operating, fans and lights (DC loads) may vary in speed or intensity. This is normal. The XC Series will not harm any load connected to it as long as there is a battery present on that bank. When you initially turn the XC Series on and configure it, it is possible that some banks may be disqualified.
XC_Charger_Owner.book Page 6 Friday, August 12, 2005 3:23 PM Operation Charging Batteries Before you start to charge batteries read the “Important Safety Instructions” on page v and follow all safety precautions when working with batteries. To charge your batteries: 1. If possible, disconnect all loads from the battery, by opening a disconnect switch, or by switching the loads off. 2. Ventilate the area around the battery thoroughly.
XC_Charger_Owner.book Page 7 Friday, August 12, 2005 3:23 PM Charging Batteries After charging is complete, the XC Series enters into one of these modes: Float mode When the ready indicator light illuminates, all batteries are fully charged and ready for use. If you selected the 3-stage charging mode, the XC Series is in float mode and will maintain the batteries’ charge.
XC_Charger_Owner.book Page 8 Friday, August 12, 2005 3:23 PM Operation Equalizing Flooded Batteries About Equalizing The XC Series equalizes only flooded lead-acid or lead-calcium batteries. It does not equalize sealed lead-acid batteries since they can be damaged by this process.
XC_Charger_Owner.book Page 9 Friday, August 12, 2005 3:23 PM Equalizing Flooded Batteries Performing An Equalization Turn off or disconnect all DC loads on the battery during equalization. The voltage applied to the battery during equalization may be above the safe levels for some loads. To equalize your batteries: 1. Check the battery electrolyte level. If necessary, refill with distilled water only. All the cells should have similar electrolyte levels.
XC_Charger_Owner.book Page 10 Friday, August 12, 2005 3:23 PM Operation Transitioning the XC Series to On, Disabled or Off There are two ways to turn the XC Series on: • connect AC power at the source • press ON/STANDBY on the remote display if AC is still connected. There are two ways to disable the XC Series: WARNING: Shock hazard The XC Series still has live voltage while disabled.
XC_Charger_Owner.book Page 11 Friday, August 12, 2005 3:23 PM Accessing Charger Information Accessing Charger Information The XC Series can give you a lot of information about the status of the charger and the batteries. Reading Remote Display and Onboard Status Indicator Lights The remote display and onboard status panel show what is happening during the charging process and are also helpful in troubleshooting.
XC_Charger_Owner.book Page 12 Friday, August 12, 2005 3:23 PM Operation Table 3-1 Reading XC Series Status Charger Status Remote Display Onboard Status Indicator Lights Charging in bulk or absorption mode. Remote display shows scrolling display of charging state, battery voltage in volts and charging current in amps. Indicator lights indicate the charging current in % of full charge.
XC_Charger_Owner.book Page 13 Friday, August 12, 2005 3:23 PM Accessing Charger Information Table 3-1 Reading XC Series Status Remote Display Onboard Status Indicator Lights Battery too hot fault ERR HoT Fault indicator light illuminated 100% current indicator light flashes Battery too cold fault ERR CLD Fault indicator light illuminated 10% current indicator light flashes Charger fault condition. The charger is damaged, contact service.
XC_Charger_Owner.book Page 14 Friday, August 12, 2005 3:23 PM Operation Reporting While Battery Monitoring The XC Series is considered to be battery monitoring if it is experiencing a charger level fault. If there is a charger level fault (affecting all banks), all charging will be suspended until the charger fault is resolved (see “Error Messages on Remote Display” on page 4–4).
XC_Charger_Owner.book Page 15 Friday, August 12, 2005 3:23 PM Accessing Charger Information ◆ Press ON/STANDBY on the optional remote display to initialize another cycle. If AC power is connected, the XC Series will turn on, check which battery banks are present and healthy, and begin charging. While the XC Series is off, and a fault is present, the remote display will turn itself on approximately once per minute to show the fault and then turn itself off.
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XC_Charger_Owner.book Page 1 Friday, August 12, 2005 3:23 PM 4 Troubleshooting Chapter 4 contains information on error codes and procedures for troubleshooting your XC Series charger.
XC_Charger_Owner.book Page 2 Friday, August 12, 2005 3:23 PM Troubleshooting Care and Maintenance WARNING: Risk of electric shock The XC Series contains no user serviceable components. Attempting any kind of service will void your warranty. Contact your dealer or the manufacturer for service information. The XC Series contains solid-state electronic components that require no maintenance.
XC_Charger_Owner.book Page 3 Friday, August 12, 2005 3:23 PM Indicator Light Flashing Sequences Indicator Light Flashing Sequences Table 4-1 Indicator Light Sequences on the XC Series Activity Charger status Charging indicator light illuminates The unit is charging in bulk or absorption mode Charging indicator light flashes The unit is performing the equalization charge.
XC_Charger_Owner.book Page 4 Friday, August 12, 2005 3:23 PM Troubleshooting Error Messages on Remote Display Table 4-2 Error Messages Display ERR Onboard Status Panel Indicator lights Red fault indicator light flashing or illuminated ACL Fault Solution Fault A fault has been detected. The fault code will be shown immediately after Err. AC Low Warning Check AC connections, check AC availability at source.
XC_Charger_Owner.book Page 5 Friday, August 12, 2005 3:23 PM Error Messages on Remote Display Table 4-2 Error Messages Display Onboard Status Panel Indicator lights Fault Solution Err CLd Red fault indicator light illuminated Green 10% indicator light flashes Display green bank indicator light for affected battery bank illuminated Battery Too Cold Shutdown Allow batteries to warm up before attempting to charge again. Charging a battery that has frozen is a potential explosion hazard.
XC_Charger_Owner.book Page 6 Friday, August 12, 2005 3:23 PM Troubleshooting Table 4-2 Error Messages Display Onboard Status Panel Indicator lights Fault Solution Allow battery to cool. Improve ventilation or install in cooler location. It may indicate a shorted cell in the battery or excessive water loss. If the temperature increases, the XC Series will enter the fault level and stop charging the affected bank.
XC_Charger_Owner.book Page 7 Friday, August 12, 2005 3:23 PM Problem Solving Problem Solving If the remote display is not functioning, troubleshoot your XC Series using the tables below. In the event that you have a problem with your XC Series, the following tables will help you to identify the problem and offer possible solutions to the problem. Symptom Indicator lights do not illuminate when charger is connected to AC power.
XC_Charger_Owner.book Page 8 Friday, August 12, 2005 3:23 PM Troubleshooting Symptom Fault indicator light flashes. XC Series stops functioning. Possible Cause Solution XC Series hardware failure Call for service Symptom Fault indicator light illuminates. 100% indicator light flashes. Possible Cause Solution Battery temperature is too hot for safe charging. Allow battery to cool. Improve ventilation or install in cooler location.
XC_Charger_Owner.book Page 9 Friday, August 12, 2005 3:23 PM Problem Solving Symptom The XC Series appears to be taking too long to charge battery. Ready indicator light does not illuminate after 24 hours of charging. Possible Cause Solution Battery capacity is too high for the XC Series model. Use a higher capacity charger. Load connected to battery is draining charge current so that battery does not recharge. Disconnect load or switch load off. Battery has a damaged cell. Replace battery.
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XC_Charger_Owner.book Page 1 Friday, August 12, 2005 3:23 PM A Specifications Appendix A details the specifications for the XC Series.
XC_Charger_Owner.book Page 2 Friday, August 12, 2005 3:23 PM Specifications Physical Specifications Dimensions Base unit: 367 mm x 240 mm x 106 mm 14.45 in. x 9.45 in. x 4.17 in. Remote Display: 118 mm x 41 mm x 32 mm 4.65 in. x 1.6 in. x 1.26 in. Weight 5.7 kg (12.6 lbs) AC input connections Two color-coded No. 16 AWG wires (L, N) and one No. 18 AWG (G) minimum 152 mm (6 in.) long in a separate AC wiring enclosure with 21.3 mm (0.84 in.
XC_Charger_Owner.book Page 3 Friday, August 12, 2005 3:23 PM AC Input Specifications Float voltage (in VDC for XC3012 and XC5012) (Multiply VDC by 2 to get the float voltage for XC1524 and XC2524) Flooded 12.8 Gel 13.1 AGM 12.9 Lead-calcium 12.8 Equalize mode current 50% rated output Equalize mode—maximum output voltage XC3012: XC5012: XC1524: XC2524: 16.0 VDC 16.0 VDC 32.0 VDC 32.
XC_Charger_Owner.book Page 4 Friday, August 12, 2005 3:23 PM Specifications Temperature Specifications Nominal ambient 25 °C (77 °F) Operating range 0 – 50 °C (32 – 122 °F) Current de-rating approx. 2% (Imax) / °C (50 – 65 °C) (122 – 149 °F) Storage -40 – 80 °C (-40 – 176 °F) Humidity 5 – 95%, RH non-condensing Protection Features Battery reverse polarity No damage incurred by reverse polarity.
XC_Charger_Owner.book Page 5 Friday, August 12, 2005 3:23 PM Approvals Approvals Safety CSA/NRTL approved to CSA107.
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XC_Charger_Owner.book Page 1 Friday, August 12, 2005 3:23 PM Warranty and Product Information Limited Warranty for: Xantrex XC3012 Battery Charger Xantrex XC5012 Battery Charger Xantrex XC1524 Battery Charger Xantrex XC2524 Battery Charger "XC Series" What does this warranty cover and how long does it last? This Limited Warranty is provided by Xantrex Technology Inc. ("Xantrex") and covers defects in workmanship and materials in your Xantrex XC Series product.
XC_Charger_Owner.book Page 2 Friday, August 12, 2005 3:23 PM Warranty and Product Information What does this warranty not cover? This Limited Warranty does not cover normal wear and tear of the product or costs related to the removal, installation, or troubleshooting of the customer's electrical systems.
XC_Charger_Owner.book Page 3 Friday, August 12, 2005 3:23 PM WARNING: LIMITATIONS ON USE Please refer to your product user manual for limitations on uses of the product. Specifically, please note that the Xantrex Battery Charger is not intended for use in connection with life support systems and Xantrex makes no warranty or representation in connection with any use of the product for such purposes. Xantrex Technology, Inc.
XC_Charger_Owner.book Page 4 Friday, August 12, 2005 3:23 PM Warranty and Product Information Information About Your System As soon as you open your Xantrex XC3012, XC5012, XC1524 or XC2524 Battery Charger package, record the following information and be sure to keep your proof of purchase.
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XC_Charger_Owner.book Page 6 Friday, August 12, 2005 3:23 PM Xantrex Technology Inc. Phone: 1 800 670 0707 (toll free North America) +34 93 470 5330 (Europe) 1 360 925 5097 (direct and rest of world) Fax: 1-800 994 7828 (toll free North America) +34 93 473 6093 (Europe) 1 360 925 5143 (direct and rest of world) Email: customerservice@xantrex.com (North America) support.europe@xantrex.com (Europe) customerservice@xantrex.
