TM

TM

Owner’s Guide
Product Numbers

Series Battery Charger Non-IEC Models

804-1220-02,
804-1240-02,
IEC Models
804-1220-03,
804-1240-03,
804-1260-02, 804-1260-03
804-2410, 804-2410-01,
804-2420, 804-2420-01,
804-2430 804-2430-01
Copyright © 2021 Xantrex LLC. All rights reserved. All trademarks are owned by
Xantrex LLC or its affiliated companies.
Exclusion for Documentation Contact Information
UNLESS SPECIFICALLY AGREED TO IN WRITING, SELLER
(A) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY Telephone: 1 800 670 0707 (Toll Free USA/Canada)
TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION;
1 408 987 6030 (Outside USA/Canada)
(B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES,
WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE Email: [email protected],
OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY http://www.xantrex.com/power-products-support/
AT THE USER’S RISK; AND
(C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, Web: www.xantrex.com
ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE
ACCURACY CANNOT BE GUARANTEED. APPROVED CONTENT IS CONTAINED WITH THE ENGLISH
LANGUAGE VERSION WHICH IS POSTED AT WWW.XANTREX.COM.
NOTE: Visit http://www.xantrex.com/ , click Products, select a Product category, select a Product, and search the Information About Your System
Product Documents panel for a translation of the English guide, if available.

Date and Revision Serial Number:

August 2021 Rev E Product Number:
Purchased From:
Document Part Number Purchase Date:
975-0526-01-02

Product Numbers
Non-IEC Models IECa Models
804-1220-02, 804-1220-03,
804-1240-02, 804-1240-03,
804-1260-02, 804-1260-03
804-2410, 804-2410-01,
804-2420, 804-2420-01,
804-2430 804-2430-01
a.IEC refers to the international standard from the International
Electrotechnical Commission for "plugs, socket-outlets and cou-
plers for industrial purposes". IEC models have an AC input recep-
tacle that connects with an IEC cable (not provided).

975-0526-01-02 i
About This Guide

Purpose Abbreviations and Acronyms

The purpose of this Owner’s Guide is to provide explanations and A Amperes
procedures for installing, troubleshooting, operating and maintaining the Ah Amp-hours (a unit of battery capacity)
Truecharge2 Series Battery Charger for Recreational, Commercial and AC Alternating Current [Vac symbol]
Fleet Vehicle, or Marine installations. ACC Accessory in vehicle ignition system
AGM Absorbed Glass Mat (a battery type)
Scope BTS Battery Temperature Sensor
The Guide provides safety and operating guidelines, procedures for DC Direct Current [A DC symbol]
installing the battery charger, as well as information on configuring the GFCI Ground Fault Circuit Interrupter
battery charger. It also provides information about troubleshooting the unit. Hz Hertz (a unit of frequency)
It does not provide details about particular brands of batteries. You need to in-lb inch-pound force (a unit of torque)
consult individual battery manufacturers for this information. kW Kilowatts (1000 watts)
LBCO Low Battery Cutout (or Cutoff)
Audience LCD Liquid Crystal Display
The Guide is intended for users and operators of the Truecharge2 Series LED Light Emitting Diode
Battery Charger. The Installation section is intended for qualified installers LFP LiFePO4 (lithium iron phosphate – a battery type)
who need to install and configure any unit model of the Truecharge2 Series N-m Newton-meters (a unit of torque)
Battery Charger. PN Product Number
PPE Personal Protective Equipment
Qualified personnel have training, knowledge, and experience in: s Seconds (a unit of time)
• Installing electrical equipment, V, VAC, Voltage, Volts AC, Volts DC
• Aapplying all applicable installation codes, VDC
• Analyzing and reducing the hazards involved in performing electrical W Wattage, watt (a unit of power)
work, Related Information
• Selecting and using Personal Protective Equipment (PPE). You can find more information about Xantrex-branded products and
services at www.xantrex.com.

ii Truecharge2 Series Battery Charger Owner’s Guide

Important Safety Instructions

IMPORTANT: READ AND SAVE THIS OWNER’S GUIDE FOR FUTURE

REFERENCE. DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
This chapter contains important safety and installation instructions for the
Truecharge2 Series Battery Chargers. Each time, before using the
Truecharge2 Series Battery Charger, READ ALL instructions and
cautionary markings on or provided with the battery charger, the batteries, WARNING indicates a potentially hazardous situation which, if not
and all appropriate sections of this guide. avoided, can result in death or serious injury.
NOTE: The Truecharge2 Series Battery Charger contains no user-
serviceable parts with the exception of the DC output fuse(s) which are
user-replaceable. See “Replacing the DC Output Fuse” on page 48 for
instructions. For obtaining service other than replacing the fuse, contact CAUTION indicates a potentially hazardous condition which, if not
customer service for guidance. avoided, can result in minor or moderate injury.
NOTE: The Truecharge2 Series Battery Charger must be provided with
equipment-grounding conductors connected to the AC input ground and to
the DC chassis ground. See “Step 2: Connecting the DC Chassis Ground
(Earth)” on page 17 for instructions. NOTICE indicates a potentially hazardous situation, which, if not avoided,
can result in equipment damage.
The addition of either symbol to a “Danger” or “Warning”
 safety label indicates that an electrical hazard exists which will
result in personal injury if the instructions are not followed. IMPORTANT: These notes describe things which are important for you to
This is the safety alert symbol. It is used to alert you to know, however, they are not as serious as a danger, warning, or caution.
 potential personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.

975-0526-01-02 iii
Safety Information

ELECTRICAL SHOCK HAZARD FIRE AND BURN HAZARD

• Do not expose the Truecharge2 Battery Charger to rain, snow, spray, Do not cover or obstruct the air intake vent openings and/or install in a
or bilge water. zero-clearance compartment. See “Location” on page 10 for proper
• Do not operate the battery charger if it has received a sharp blow, location requirements.
been dropped, has cracks or openings in the enclosure including if the Failure to follow these instructions will result in death or serious
fuse cover has been lost, damaged, or will not close, or otherwise injury.
damaged in any other way.
• Do not disassemble the battery charger. Internal capacitors remain
charged after all power is disconnected.
• Disconnect both AC and DC power from the battery charger before
attempting any maintenance or cleaning or working on any circuits EXPLOSION HAZARD
connected to the battery charger. See note below. • Charge only properly rated (such as 12 V and 24 V) lead-acid (GEL,
• Do not operate the battery charger with damaged or substandard AGM, Flooded, or lead-calcium) rechargeable batteries because other
wiring. Make sure that all wiring is in good condition and is not battery types may explode and burst.
undersized. See “Wiring Requirements” on page 12 for guidance. • Do not work in the vicinity of lead-acid batteries. Batteries generate
Failure to follow these instructions will result in death or serious explosive gases during normal operation. See note below.
injury. Failure to follow these instructions will result in death or serious
injury.

NOTE: Turning off the battery charger using the on/standby button on the
optional remote panel will not reduce an electrical shock hazard. NOTE: Follow these instructions and those published by the battery
manufacturer and the manufacturer of any equipment you intend to use in
the vicinity of the battery. Review cautionary markings on these products
and on the engine.

iv Truecharge2 Series Battery Charger Owner’s Guide

 Precautions When Working With Batteries

PERSONAL INJURY HAZARD

This battery charger is not intended for use by persons (including BURN FROM HIGH SHORT-CIRCUIT CURRENT, FIRE AND EXPLO-
children) with reduced physical, sensory, or mental capabilities or lack of SION FROM VENTED GASES HAZARDS
experience and knowledge, unless they have been given supervision or • Always wear proper, non-absorbent gloves, complete eye protection,
instruction concerning use of the appliance by a person responsible for and clothing protection. Avoid touching your eyes and wiping your
their safety. Children should be supervised to ensure that they do not play forehead while working near batteries. See note #4.
with the battery charger. • Remove all personal metal items, like rings, bracelets, and watches
Failure to follow these instructions can result in death or serious when working with batteries. See notes #5 and #6.
injury. • Never smoke or allow a spark or flame near the engine or batteries.
• Never charge a frozen battery.
Failure to follow these instructions can result in death or serious
injury.

NOTES:
1. Locate the Truecharge2 Series Battery Charger unit away from
batteries in a well ventilated compartment.
2. Always have someone within range of your voice or close enough to
come to your aid when you work near a lead-acid battery.
3. Always have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing, or eyes.
4. If battery acid contacts skin or clothing, wash immediately with soap
and water. If acid enters your eye, immediately flood it with running
cold water for at least twenty minutes and get medical attention
immediately.

975-0526-01-02 v
5. Use extra caution to reduce the risk or dropping a metal tool on the Precautions When Preparing to Charge
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 EXPOSURE TO CHEMICALS AND GASES HAZARD
burn. • Make sure the area around the battery is well ventilated.
7. When removing a battery, always remove the negative terminal from • Make sure the voltage of the batteries matches the output voltage of
the battery first for systems with grounded negative. If it is grounded the battery charger.
positive, remove the positive terminal first. Make sure all loads • Be careful to keep corrosion from coming into contact with your eyes
connected to the battery and all accessories are off so you don’t cause and skin when cleaning battery terminals.
an arc. Failure to follow these instructions can result in death or serious
injury.

NOTES:
1. Study and follow all of the battery manufacturer's specific precautions,
such as removing or not removing cell caps while charging, whether
equalization is acceptable for your battery, and recommended rates of
charge.
2. For flooded non-sealed batteries, add distilled water in each cell until
battery acid reaches the level specified by the battery manufacturer.
This helps to purge excessive gas from cells. Do not overfill. For a
battery without removable cell caps, carefully follow manufacturer's
instructions.

vi Truecharge2 Series Battery Charger Owner’s Guide

Precautions When Placing the Battery Charger

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 Series Battery Charger unit directly
above batteries; gases from a battery will corrode and damage the
charger.
• Do not place a battery on top of the battery charger.
Failure to follow these instructions can damage the unit and/or
damage other equipment.

NOTE: For North American marine installations, external connections to the

charger shall comply with the United States Coast Guard Electrical
Regulations (33CFR183, Sub Part I) and ABYC standards E-11 and A-31.
For Australia / New Zealand installations, external electrical connections to
the charger shall comply with Local Authority Regulations and with AS/
NZS 3000 requirements.

975-0526-01-02 vii
FCC Information to the User End of Life Disposal
This equipment has been tested and found to comply with the limits for a The Truecharge2 Series Battery Charger is designed with environmental
Class B digital device, pursuant to part 15 of the FCC Rules. These limits awareness and sustainability in mind. At the end of its useful life, the
are designed to provide reasonable protection against harmful interference Truecharge2 Series Battery Charger can be decommissioned and
in a residential installation. This equipment generates, uses, and can radiate disassembled. Components which can be recycled must be recycled and
radio frequency energy and, if not installed and used in accordance with the those that cannot be recycled must be disposed of according to local,
instructions, may cause harmful interference to radio communications. regional, or national environmental regulations.
However, there is no guarantee that interference will not occur in a Many of the electrical components used in the Truecharge2 Series Battery
particular installation. If this equipment does cause harmful interference to Charger are made of recyclable material like steel, copper, aluminum, and
radio or television reception, which can be determined by turning the other alloys. These materials can be auctioned off to traditional scrap metal
equipment off and on, the user is encouraged to try to correct the recycling companies who resell reusable scraps.
interference by one or more of the following measures: Electronic equipment such as the circuit boards, connectors, and fuses can
• Reorient or relocate the receiving antenna. be broken down and recycled by specialized recycling companies whose
• Increase the separation between the equipment and receiver. goal is to avoid having these components end up in the landfill.
• Connect the equipment into an outlet on a circuit different from that to For more information on disposal, contact Xantrex.
which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.

Unauthorized changes or modifications to the equipment could void the

user’s authority to operate the equipment.

viii Truecharge2 Series Battery Charger Owner’s Guide

Contents
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Truecharge 2 Battery Charger Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Preparing For Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing the Truecharge 2 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installing a Parallel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Configuring the Truecharge2 Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Charging Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Equalizing Flooded Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Transitioning the Charger to ON, Standby, or Disabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Accessing Charger Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Using A Generator As Source Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Maintaining the Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Replacing the DC Output Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Introduction
This chapter describes the standard features of a Truecharge2 Battery Standard and Protection Features
Charger, as well as its protection features. It also provides information on
the different parts of the Truecharge2 Battery Charger. The Truecharge2 Battery Charger provides the following standard features:
• up to three2 full current rated outputs,
Truecharge2 Battery Charger • battery monitoring functions,
• correct charging voltage for batteries when connected to almost any
The Truecharge2 Battery Charger ships with the following items: single phase AC power outlet in the world,
• one Truecharge2 Battery Charger unit, • low electromagnetic interference (EMI),
• owner’s guide, • automatic charge resumption, if required, after AC power interruption,
• rubber boots for DC terminals, • programmable custom charge settings3,
• nuts and washers (M6) for DC terminals and ground stud, • fully discharged battery charging4,
• strain relief clamp for AC input cables1, • ability to operate two Truecharge2 Battery Chargers in parallel mode
• three crimp connectors for AC wiring1. with the use of the optional remote panel.

NOTE: Keep the carton and packing material in case you need to return The Truecharge2 Battery Charger provides the following protection
the Truecharge2 Battery Charger for servicing. features:
• battery reverse polarity protection via user-replaceable output fuse(s),
• AC input out-of-range derating and shutdown,
• ambient over-temperature derating and shutdown,
• battery over-charging protection,

2.Each output can charge different batteries that either have the same chemistry or can
tolerate the same charge sequence and voltage/current ratings.
3.The charger can be programmed with custom charge setpoints using PC interface.
This programming can only be done using a special configuration tool operated by
Xantrex or a designated OEM.
1.Not included with IEC models of Truecharge2 Battery Chargers. 4.The charger can initiate charging a non-damaged but zero voltage battery.

975-0526-01-02 1
Introduction
• electronic current limiting provides protection against short circuit The optional Battery Temperature Sensor (BTS) provides these protection
conditions on the charger’s output, features:
• ignition-protected rating, enabling installation in engine spaces, • battery under-temperature charging protection preventing battery
• isolated design, charging at -25 °C (-13 °F) or below,
• short circuit protection for the BTS and communication connector • battery over-temperature charging protection preventing battery
ports including protection from incorrectly inserting the remote panel charging at 70 °C (158 °F) or higher, and
communication cable plug into the BTS port and vice versa, • charging voltage compensation based on the temperature of the battery
• drip-proof rubber boots for DC terminals for added moisture the optional BTS is connected to.
protection,
• IP-32 drip protection rating1, The optional Remote Panel provides the following features:
• Can be mounted up to 15 meters (50 feet)4 away for remote control
The following optional accessories are available for the Truecharge2 and monitoring,
Battery Charger: • maximum output current limiting for charging smaller capacity
• an optional battery temperature sensor2 (BTS) and batteries or to lower the current drawn from the generator or AC
• an optional remote panel3. source,
• ability to enable or disable the charger while AC power is connected,
• ability to display individual battery bank levels, and
• ability to operate two Truecharge2 Battery Chargers in parallel for
increased output current capacity.

1.In two specific installation orientations–see “Mounting Orientations (Deck and

Horizontal)” on page 11.
2.Part number: 808-0232-01 4.Remote panel comes standard with a 7.5-m (25-ft) cable. For longer [15-m (50-ft)]
3.Part number: 808-8040-01 cable, order part number 31-6262-00

2 Truecharge2 Series Battery Charger Owner’s Guide

Truecharge 2 Battery Charger Features
This section describes the different parts of the Truecharge2 Battery
Charger. Item Description
1 Onboard control and status display panel or simply
Front Panel onboard display (see “Onboard Control and Status Display
Panel” on page 5 for more information) for controlling the
Truecharge2 Battery Charger settings and for monitoring
charger status and charging current.
1
2 Mounting flanges are used to permanently install the product.
3 DC wiring compartment cover protects the DC terminals, as
well as the communication and BTS ports. Remove and
replace when installing cables.

2
ELECTRICAL SHOCK HAZARD
Disconnect the batteries and AC power before opening the fuse access
3
panel.
Failure to follow these instructions will result in death or serious
4 injury.
5
4 Fuse access panel cover provides access to the DC fuse in the
event of an accidental reverse battery polarity installation.
6
Remove and replace the cover when replacing a fuse or fuses.
Figure 1 Truecharge2 Battery Charger Front Panel

975-0526-01-02 3
Truecharge 2 Battery Charger Features

Item Description Item Description

5 AC wiring compartment cover provides the installer with 1 BTS port- battery temperature sensor port
easy access to the AC wiring compartment, to allow for a
2 Communication port - remote panel port
trouble free installation. Remove and replace when installing
the product. 3 Battery positive (+) for bank 3 (6 mm stud)
6 DC ground stud for connecting the charger’s chassis to 4 Battery positive (+) for bank 2 (6 mm stud)
ground.
5 Battery positive (+) for bank 1 (6 mm stud)

Rear Panel 6 Battery negative (–), common for all three banks (6 mm
stud)
This section describes the parts of the rear panel of the Truecharge2 Battery
7 Air vents - located inside is the fan assembly
Charger.
8 AC wiring compartment
3 40 A model (TC4012) 9 AC pigtail wiring - line, neutral, and ground input wires
shown. Other models
4
8 7 may vary.

5 2
6
1
Figure 2 Truecharge2 Battery Charger Rear Panel

4 Truecharge2 Series Battery Charger Owner’s Guide

 Truecharge 2 Battery Charger Features
Onboard Control and Status Display Panel To reduce current draw from the connected battery when AC power is not
present, the panel’s LED control and status lights are automatically turned
This section describes the parts of the onboard control and status display off and the buttons are disabled.
panel of the Truecharge2 Battery Charger. See “Reading Onboard Display However, to temporarily check the status of the connected battery when AC
LEDs” on page 41 for more information. power is not present, press the Status button on the optional remote panel.

IMPORTANT: To prevent any unintentional changes in the setting, Select Item Description
panel buttons must be pressed and held down for three seconds to advance
to the next selection. 1 Charging Output (%) LEDs
To set and cancel an equalization program, press and hold for five seconds • The LEDs illuminate like a bar graph displaying the present
both the Charger Mode and Battery Temp. Select panel buttons. total output charge current as a percentage of the maximum
rated charge current. For example, unit model TC4012 has a
maximum rated charge current of 40 A so at 60% the
charger’s current output is 24 A. The numbers below the
1 LEDs represent the percentage values. See “Reading
2 Onboard Display LEDs” on page 41.
3 NOTE: When the maximum Charge Output current is
limited via the optional remote panel, the LEDs will still
4 display the total charge output current as a percentage of the
5 maximum rated charge current and NOT as a percentage of
the limited charge current.

6 • One or two LEDs may flash intermittently in combination

with a solid Fault LED (indicating a fault) or with a
flashing Fault LED (indicating a warning). The icons
above the LEDs represent the various types of fault and
warning conditions. See “Reading Onboard Display LEDs”
Figure 3 Onboard Control and Status Display Panel on page 41.

975-0526-01-02 5
Truecharge 2 Battery Charger Features

Item Description Item Description

2 Fault LED 4 Charger Mode Select button
The LED may illuminate a solid light (indicating a fault) or • Press and hold the button for three seconds to select one of
flash intermittently (indicating a warning) in combination with two settings. An indicator LED corresponds to each setting.
flashing Charging Output (%) LEDs. See “Interpreting Fault Each setting optimizes the charging sequence differently in
and Warning Indicators” on page 43 for details. charging the batteries by stages.
• Three-stage - Bulk, Absorption, and Float;
3 Charger Status LEDs
default setting
Displays the current status of the charger.
• Two-stage - Bulk and Absorption only
• Ready - a solid light indicates batteries are fully charged
• When setting or cancelling an Equalization program: Press
and the charger is in rest stage.
and hold for five seconds both the Charger Mode and
• Ready and Charging - solid lights indicate batteries are
Battery Temp. Select buttons.
fully charged and the charger is in float stage.
• Charging - a solid light indicates charger is performing a 5 Battery Type Select button
normal charge cycle. Press and hold the button for three seconds to select one of five
• Equalize - a solid light indicates that the charger is settings. An indicator LED corresponds to each setting.
performing an equalization cycle. NOTE: The fifth setting is a custom battery type setting and is
- a flashing light indicates that the equalization indicated when all four LEDs illuminate. See “Custom” below.
cycle will begin after the absorption stage is
done. Each setting maximizes charger performance for its
corresponding battery type.
• AGM - Absorbent Glass Mat lead-acid battery
• Flooded - Lead-acid battery; default setting
• GEL - Gel-type lead-acid battery
• Lead Calc. - Lead-calcium battery
• Custom - Only available if a custom algorithm has been
programmed by Xantrex or a designated OEM.

6 Truecharge2 Series Battery Charger Owner’s Guide

 Truecharge 2 Battery Charger Features
Item Description
Item Description
6 Battery Temp. Select button
6 • Cold - for battery temperature below 5 °C (41 °F); raises
• Press and hold the button for three seconds to select one of continued
the charging voltage to compensate
three settings. An indicator LED corresponds to each
• Warm - for battery temperature between
setting.
5 and 30 °C (41 and 86 °F); default setting
If an optional BTS is connected, the indicator LEDs
• Hot - for battery temperature above 30 °C (86 °F);
represent real-time battery temperature.
lowers charging voltage to compensate
• When the optional BTS is not used, this selection changes
the charger's output voltage settings to compensate for the
• When setting or cancelling an Equalization program: Press
battery temperature selected. The Cold setting raises the
and hold for five seconds both the Charger Mode and
voltages, and the Hot setting lowers the voltages. See
Battery Temp. Select buttons.
“Battery Temperature Compensation Levels” on page 32.

RISK OF BATTERY DAMAGE

Be sure the appropriate setting is selected before charging. For varying
conditions, use the Warm setting.
Failure to follow these instructions can damage the unit and/or
damage other equipment.

975-0526-01-02 7
Preparing For Installation
NOTE: Not to scale. For illustration purposes only. 11

IMPROPER INSTALLATION BY AN UNQUALIFIED INSTALLER

1
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), L 2

the American Boat & Yacht Council standards E-11 and A-31, and the US N 10
G
Coast Guard Electrical Regulations (33CFR183). 3
Failure to follow these instructions can damage the unit and/or 9
L
damage other equipment.
N
4 not
G applicable in
NOTE: In some jurisdictions a
NOTE: The Truecharge2 Battery Charger is designed to be permanently double-pole breaker may be
Australia/
8 New
mounted. Figure 4 shows a typical installation with three batteries, a battery required.
Zealand
temperature sensor (BTS) and a remote panel (both optional). It also shows 6
the AC and DC wiring and protection devices required for a typical
5
installation. Means of over-current protection and disconnection must be 6
incorporated into the fixed wiring, in accordance with the electrical code 7
6
that governs each installation.

IMPORTANT: Do not use the Negative bus to Truecharge2 Battery Figure 4 Configuration for Normal Loads
Charger chassis connection in Australia/New Zealand markets.
1 AC input wiring compartment
2 AC mains source protected by correct size and type of branch
rated circuit breaker
3 DC negative cable

8 Truecharge2 Series Battery Charger Owner’s Guide

 Preparing For Installation
4 DC positive cables You need the following materials:
5 DC circuit breakers or DC fused disconnects • 3 conductor AC input wiring
Use the information in “Step 4: Installing AC Wiring” on page 21 and
6 Battery or battery bank
your local electrical codes to determine the correct wire and breaker or
7 Battery Temp. Sensor fuse.
(optional accessory part number: 808-0232-01)
• AC cable strain relief (if the one included is not compliant with your
8 Engine ground bus or DC negative bus local electrical code requirements).
9 Ground bus • appropriately sized DC cables for each battery, with suitable
10 DC chassis ground (earth) connectors at the battery end
11 Remote panel Use the information in “DC Wiring” on page 13 and your local
(optional accessory part number: 808-8040-01) electrical codes to determine the correct wire and breaker or fuse.
• appropriately sized DC chassis ground (earth) cable with suitable
connectors,
Tools and Materials • ring terminals to fit 6 mm (1/4 in.) studs at the charger end (Marine
grade hardware is recommended),
To mount and connect the Truecharge2 Battery Charger you need the
following tools: • DC fused disconnect or properly rated circuit breaker for each battery
bank,
• 10 mm socket wrench and extension for the DC terminals and ground
stud, • mounting screws, M3 or #6 marine grade, corrosion resistant
(4 pieces) (Length dependent on mounting surface).
• Phillips screwdriver for removing and re-securing the AC and DC
wiring compartment covers,
• power drill/screwdriver,
• drill bit set for pilot holes for mounting screws (if using #6 mounting
screws, use 1/16 drill),
• wire stripper,
• manufacturer's recommended crimp tool for any crimp terminals that
are being used.

975-0526-01-02 9
Preparing For Installation
Location Condition Requirement
Install the Truecharge2 Battery Charger in a location that meets the Close to The Truecharge2 Battery Charger should be installed as
following requirements: batteries close as possible to the batteries, but not in the same
compartment to prevent corrosion. Avoid excessive cable
Condition Requirement lengths and use the recommended wire sizes. Xantrex
Dry The Truecharge2 Battery Charger must be installed in a recommends installing with cables sized to achieve less
dry location not subject to moisture especially rain, spray, than 3% voltage drop on battery cables under full load.
or splashing bilge water. This will maximize the performance of the charger.
Clean The Truecharge2 Battery Charger should not be exposed a.Applicable to Non-IEC models only. See “Product Numbers” on page i.
b.See “Product Numbers” on page i.
to metal filings or any other form of contamination.
Cool The ambient air temperature should be between
0 – 50 °C (32 – 122 °F) for best performance.
Ventilated There must be at least 10 cm (4 in.) of clearance on the top EXPLOSION HAZARD FOR IEC MODELS ONLY
and bottom ends of the Truecharge2 Battery Charger for Do not place the battery charger in machinery space or in areas
air flow and at least 6 cm (2.5 in.) of clearance on either containing gasoline tanks or fittings in which ignition-protected
side (see Figure 7). Ventilation openings on the charger equipment is required.
must not be obstructed. If the charger is mounted in a tight
Failure to follow these instructions will result in death or serious
fitting compartment, the compartment must be ventilated
injury.
with cut-outs to prevent the charger from overheating.
Safea This battery charger (except IEC modelsb) is ignition-
protected equipment, so it can be installed in areas NOTES:
containing gasoline tanks or fittings which require When planning to install the Truecharge2 Battery Charger, be sure that you
ignition-protected equipment. Nevertheless, Xantrex consider the location and orientation carefully. The Truecharge2 Battery
recommends that it is safest not to install any kind of Charger is considered to have an IP rating of IP-32, if installed in either of
electrical equipment including the Truecharge2 Battery two specific orientations [shown in Figure 5 (a) and (b)] and only if all
Charger in these areas.

10 Truecharge2 Series Battery Charger Owner’s Guide

 Preparing For Installation
panel covers are attached and secured. This rating means that it meets
standards to prevent dripping water from entering the enclosure, and
causing shock hazard and damage to equipment. (a)
The other possible mounting orientations [shown in Figure 6 (c) and (d)] Deck Mount - this orientation
will not prevent the entry of dripping water, and are not suitable for marine meets IP-32 requirements and is
or other moist environments without the installation of additional drip drip-proof.
protection. They are only acceptable for use in locations that are always dry.
The environment, therefore, will determine the mounting orientations that
are suitable for each installation. Is the installation environment one that (b)
will always be dry or will moisture or condensation sometimes enter the Horizontal Wall Mount (with AC
area? wiring higher than DC terminals
only) - this orientation meets IP- AC
32 requirements and is drip-
proof.
ELECTRICAL SHOCK HAZARD
DC
In marine environments, there is a likelihood that condensation will be
present, and may drip on to the charger. Use the appropriate mounting
orientations as shown in Figure 5 and Figure 6.
Figure 5 Mounting Orientations (Deck and Horizontal)
Failure to follow these instructions will result in death or serious
injury.

975-0526-01-02 11
Preparing For Installation
Wiring Requirements
Vertical Wall Mount
(Rear panel facing
down or up) - this
orientation is allowed
in locations that are
ELECTRICAL SHOCK AND FIRE HAZARD
always dry but is
approved for marine
Do not operate the battery charger with damaged or substandard wiring.
installations only with Make sure that all wiring is in good condition and is not undersized. See
additional drip notes below.
protection. Failure to follow these instructions will result in death or serious
injury.
(c) (d)
NOTES:
Figure 6 Mounting Orientations (Vertical) • Wiring and fuse sizes are governed by electrical codes and standards.
Different requirements apply in different countries and to different
types of installations, for example, boat, home or RV. It is the
responsibility of the installer to ensure that each installation complies
with all applicable codes and standards.
10 cm. • Ensure that wires and fuses or breakered disconnects are correctly
(4 in.) sized. Maximum continuous DC current available from the charger
may be an additional 6–10% above the nominal current rating of the
charger.

6 cm.
(2.5 in.)
(c) (d)
Figure 7 Ventilation Clearance

12 Truecharge2 Series Battery Charger Owner’s Guide

 Preparing For Installation
DC Wiring
Table 2 DC Wiring Examples for 24 V chargersa
The following tables show some typical wire sizes for various cable length
runs, based on 3% voltage drop on DC cables, 75 °C (167 °F) rated wire Wire Length Wire Size (AWG and mm2)
with wiring being inside the engine compartment – assumed ambient of (max length one way)
50 °C (122 °F). feet meters TC1024 TC2024 TC3024
5 1.5 No. 16 No. 10 No. 10
Table 1 DC Wiring Examples for 12 V chargersa
(1.3 mm2 ) (5.3 mm2 ) (5.3 mm2 )
Wire Length Wire Size (AWG and mm2) 7.5 2.25 No. 16 No. 10 No. 10
(max length one way) (1.3 mm2 ) (5.3 mm2 ) (5.3 mm2 )
20 6 No. 10 No. 8 No. 6
feet meters TC2012 TC4012 TC6012
(5.3 mm2 ) (8.4 mm2 ) (13.3 mm2 )
5 1.5 No. 10 No. 8 No. 6
a.Values based on American Boat & Yacht Council E-11 2018
(5.3 mm2 ) (8.4 mm2 ) (13.3 mm2 ) Table 6A and Table 9.
7.5 2.25 No. 10 No. 6 No. 4 NOTE: In the event of a conflict between the voltage drop table (Table 9)
(5.3 mm2 ) (13.3 mm2 ) (21.2 mm2 ) and the ampacity table (Table 6A) use the larger wire size.
20 6 No. 6 No. 2 No. 1
(13.3 mm2 ) (33.6 mm2 ) (42.4 mm2 )
Over-current Protection Disconnect
Electrical codes require the DC circuit from each battery to the charger to
a.Values based on American Boat & Yacht Council E-11 2018
Table 6A and Table 9.
be equipped with a disconnect and an over-current protection device,
usually within 7 inches (17.8 cm) of each battery1. The devices are usually
NOTE: In the event of a conflict between the voltage drop table (Table 9) DC-rated circuit breakers, fused disconnects, or a separate fuse and
and the ampacity table (Table 6A) use the larger wire size. disconnect for each circuit. These devices must be rated for DC voltage and

1.Per American Boat & Yacht Council E-11.

975-0526-01-02 13
Preparing For Installation
current and be rated to withstand the short circuit current available from the AC Wiring
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 FIRE HAZARD
fault. Use only on circuits provided with 20A maximum branch circuit
protection in accordance with National Electrical Code, NFPA 70.
Table 3 Fuse Sizes versus Wire Sizes Based on ABYC Regulations Failure to follow these instructions will result in death or serious
AWG Max. Fuse/Breaker injury.
14 15 A
12 20 A The AC wiring must be of sufficient size, and it must be protected by the
10 30 A appropriate size and type of input breaker, based on the jurisdiction and
8 50 A application. Some basic examples are given below.
6 80 A The AC input wiring for the Truecharge2 Battery Charger should be three-
4 100 A conductor cable, providing a line, neutral, and ground conductor (or L, N,
2 125 A GND) in an outer jacket, rated a minimum of 75C, and sized based on the
1 150 A AC input current to the charger (see “AC Input Specifications” on page 54)
and on the value of overcurrent protection provided.
DC Chassis Ground For example:
The DC chassis ground (earth) wire should also be sized correctly to • in US NEC, you may use a 14 AWG wire with a 15 A breaker for up to
provide proper protection. Refer to the local electrical codes for your 12 A continuous current (or 12 AWG for a 20 A breaker for up to 16 A
specific installation to determine the correct gauge. The ABYC standards continuous current) or
require this DC chassis ground wire to be the same size as the largest DC + • for 230 Vac application, you may be able to use either a 2.5mm2 wire
and – conductors connected to the charger, or no more than one wire size with a 16 A breaker or use 1.5 mm2 wire with a 10 A breaker.
smaller. See “Step 2: Connecting the DC Chassis Ground (Earth)” on page
17 for instructions.

14 Truecharge2 Series Battery Charger Owner’s Guide

 Preparing For Installation
Note that every jurisdiction will have different requirements as will each Battery Bank Size Requirements
application, so research the regulations for your local jurisdiction to
determine which wire size and type is correct based on the maximum AC The Truecharge2 Battery Charger is designed to work with a minimum
input current marked on the chargers and given in “AC Input battery bank size. Each bank should meet the minimum Ah rating shown in
Specifications” on page 54. Table 4. These minimum values are based on twice the charger’s rated
maximum charging current. For example, a 20-amp charger will charge a
Other examples of AC wiring requirements: minimum 40 Ah battery. If you are considering new batteries, please
consult the battery’s manufacturer for their recommendation based on the
• For marine applications, the American Boat & Yacht Council (ABYC) maximum charging current of your charger.
requires stranded wire, which is more robust than solid wire when
exposed to vibration. IMPORTANT: If the battery manufacturer has specified the maximum
• For RV applications, the United States National Electrical Code (NEC) charge current, please follow their recommendation.
allows solid wire in multi-conductor cable, however, stranded wire is
also acceptable which will withstand vibration better. Table 4 Minimum Battery Bank Size
The AC wiring supplying the Truecharge2 Battery Charger must be
12 Vdc Models Minimum Battery Bank Size (Ah)
protected by the correct size and type of branch-circuit rated fuse or breaker
to meet the applicable installation codes. If a fuse is used instead of a TC2012 40
breaker, a correctly rated disconnect switch is required ahead of the fuse so TC4012 80
that power can be turned off, allowing fuse replacement and safe
TC6012 120
maintenance of other equipment on the mains circuit.
24 Vdc Models Minimum Battery Bank Size (Ah)
TC1024 20
TC2024 40
TC3024 60

975-0526-01-02 15
Installing the Truecharge 2 Battery Charger
Be sure to read the safety guidelines and pay attention to all cautions and Step 1: Mounting the Battery Charger
warnings throughout the installation procedure. The installer is responsible
for ensuring compliance with the installation codes for your particular Mount the Truecharge2 Battery Charger using all four mounting slots and
application. See CAUTION statement under “Preparing For Installation” on holes which are provided. Mounting orientations a) and b) in Figure 5 meet
page 8. IP-32 and drip-proof requirements that are needed to ensure safety in the
presence of condensation. The other possible mounting orientations c) and
d) shown in Figure 6 will not prevent the entry of dripping water, and are
not suitable for use in marine installations or other moist environments
ELECTRICAL SHOCK HAZARD without the installation of additional drip protection. They are only
Disconnect all sources of AC and DC power before proceeding. acceptable for use in locations that are always dry.
Failure to follow these instructions will result in death or serious
injury. To mount the Truecharge2 Battery Charger:
1. Select a mounting surface that is flat and allows for a minimum of 10
cm (4 in.) of clearance on the top and bottom ends for air flow and at
Installation Sequence least 6 cm (2.5 in.) of clearance on either sides (see Figure 7,
“Ventilation Clearance” on page 12).
To make charger installation quick and easy, Xantrex recommends that the 2. Drill the four pilot holes for the mounting screws, taking care that
installation tasks be performed in the following sequence: there is nothing behind the surface that can be damaged by the drill.
1. Mount the charger in position. 3. Mount the Truecharge2 Battery Charger using corrosion resistant, #6
2. Connect the DC ground. (3 mm) round, pan head (or similar) screws.
3. Install DC wiring including installing required disconnects, fuses, or The top two keyhole-style mounting holes can be used to hold the
breakers. Truecharge2 Battery Charger in place while fastening the bottom two
screws. For secure, permanent mounting, use the holes in all four
4. Install AC wiring including earth grounds.
mounting flanges and fasten all four screws. Do not rely on screws
5. Power up the charger. only in the keyhole slots for the installation of the charger.

16 Truecharge2 Series Battery Charger Owner’s Guide

 Installing the Truecharge 2 Battery Charger
Step 2: Connecting the DC Chassis Ground (Earth)
To connect the DC chassis ground (earth):
1. Locate the ground stud on the Truecharge2 Battery Charger.

ELECTRICAL SHOCK HAZARD 2. Connect the DC chassis ground (earth) from the ground stud to the
Improper connection can result in risk of electric shock. See note below. ground bus. See Figure 4, “Configuration for Normal Loads” on page
8.
Failure to follow these instructions can result in death or serious Use a flat washer, a lock washer and a nut (included in the installation
injury. kit) to secure the connection.
3. Tighten the nuts to 2.3 N-m (20 lb-in.) torque and test that the wire is
NOTE: Have an electrician install a properly grounded circuit if one is not secure. Do not over-tighten as this may result in damage to the charger.
available.
The Truecharge2 Battery Charger must be connected to a grounded, metal,
permanent wiring system, or an equipment-grounding conductor should be
run with the circuit conductors and connected to the equipment-grounding
lead on the charger. Connections to the battery charger must comply with
all local and application-specific codes and ordinances.
Xantrex recommends that you install a DC chassis ground (earth) wire from
the ground stud on the Truecharge2 Battery Charger to the engine bus or
DC ground bus. The DC chassis ground (earth) wire should be sized
correctly with the power conductors, and both must be sized for the battery
fuses that are used to protect the DC wiring. Refer to your local electrical
codes to verify the requirements in your jurisdiction for your application.

975-0526-01-02 17
Installing the Truecharge 2 Battery Charger
4. Install a DC circuit breaker or fused disconnect in each positive cable
Step 3: Installing DC Wiring that is as close to the battery positive terminal as possible.
Consult your local electrical codes regarding the distance allowed
The procedure for installing the DC wiring applies to a single battery, as
between the battery and the fuse or breaker. For example, for most
well as multiple batteries or battery banks.
situations ABYC standard E-11 requires no more than 7 inches
(17.8 cm). Be sure the breaker or fused disconnect is open.
5. Route the wiring to the batteries and to the Truecharge2 Battery
ACCIDENTAL SHORT OR SPARK HAZARD Charger. Avoid routing wiring through an electrical distribution panel,
Leave the DC disconnects or breakers in the Off position or DC fuses battery isolator, or other device that will add voltage drops.
removed from their fuse holders until installation is complete.
Failure to follow these instructions can result in death or serious
injury.
SHOCK HAZARD
The rubber boots must be installed over the Truecharge2 Battery Charger
1. Remove the DC compartment cover. See “Front Panel” on page 3. DC terminals to keep water off of live parts and to maintain the chargers'
2. Plan the route that the DC wires will follow, keeping it as short as IP-32 and drip-proof ratings.
possible. Measure and cut the required wire length, after allowing Failure to follow these instructions can result in death or serious
some extra length for connections and to provide slack in the wires for injury.
strain relief.
3. Identify the positive wires, by using color-coded wire, or by marking 6. Insert and slide the rubber boot(s) over the charger end of the DC
both ends of the wire with colored tape, or similar kind of marking. battery cables.
Repeat with a different color for the negative. Most installation codes
recommend coloring the positive red and the negative black.
IMPORTANT: You may find it helpful to label each cable, associating it
with the battery bank it is connected to. For example, bank 1 (–), bank 1
(+), bank 2 (–), and so on.

18 Truecharge2 Series Battery Charger Owner’s Guide

 Installing the Truecharge 2 Battery Charger
7. Install crimp lugs on the charger end of the DC battery cables using the For one battery or bank
crimp manufacturer’s instructions and tool. � Connect the negative cable from the negative terminal on the battery to
the negative DC terminal on the Truecharge2 Battery Charger.
Use a flat washer, a lock washer and a nut (five of each included in the
To charger installation kit) to secure the connection.
For more than one battery or bank
� Connect the negative cable from the negative terminal on the negative
ground bar or bus to the negative DC terminal on the Truecharge2
Battery Charger.
Use a flat washer, a lock washer and a nut (five of each included in the
installation kit) to secure the connection.
9. Tighten the nuts to 2.3 N-m (20 lb-in.) torque and test that the wire is
REVERSE POLARITY DAMAGE secure. Do not over-tighten as this may result in damage to the charger.
Before proceeding to the next step, carefully check the wiring polarity. 10. Connect each positive cable to the correct positive DC terminal on the
Do not reverse the connections. See note below. Truecharge2 Battery Charger.
Failure to follow these instructions can damage the unit and/or Use a flat washer, a lock washer and a nut (five of each included in the
damage other equipment. installation kit) to secure the connection.
11. Tighten the nuts to 2.3 N-m (20 lb-in.) torque and test that the wire is
NOTE: Make sure the positive terminals of the Truecharge2 Battery Charger secure.
will be connected to the correct terminals of the battery (fuses or breakers) 12. Connect the free end of each positive cable assembly to the correct
and from there to the positive terminals of the battery. Make sure the positive terminal of the battery, using sufficient torque as
negative terminal of the Truecharge2 Battery Charger will be connected to recommended by your battery manufacturer.
the battery negative terminal (or DC negative bus).
13. Connect the free end of the negative cable to the negative terminal on
8. Connect the negative cable to the negative DC terminal on the charger. the battery, using sufficient torque as recommended by your battery
See Figure 4, “Configuration for Normal Loads” on page 8. manufacturer.

975-0526-01-02 19
Installing the Truecharge 2 Battery Charger
NOTE: If you are using more than one battery, you will need to connect
the negative cable from each of the batteries to the negative ground bar
or bus. The negative ground bar or bus will then have a single negative
cable connecting to the negative charger terminal.
14. Secure cables in place using tie-wraps or cable straps according to
electrical codes.
15. Slide the rubber boots to cover the DC terminals.

16. If available, route the optional battery temperature sensor (BTS) from
the battery (one which is located in the warmest ambient temperature)
to the charger location.
17. Proceed to “Step 4: Installing AC Wiring”.

20 Truecharge2 Series Battery Charger Owner’s Guide

 Installing the Truecharge 2 Battery Charger
Step 4: Installing AC Wiring
Before connecting AC wiring, make sure the AC source circuit is protected 4. Unscrew the wiring compartment cover from the left rear of the
by a breaker switch of the correct size and type, to comply with the Truecharge2 Battery Charger to expose the AC wiring access hole and
electrical code for your location and application. The current rating of the charger’s AC pigtail leads.
input breaker should not be larger than 20 A for 120 Vac applications and
16 A for 230 Vac applications, but may be required to be lower depending
on the wire size used. wiring compartment
cover

ELECTRICAL SHOCK HAZARD

Disconnect the AC source by turning off the breaker feeding the circuit,
unplugging from shore power and disconnecting any other power sources
(such as a generator).
Failure to follow these instructions will result in death or serious
AC wiring access hole AC pigtail leads
injury.

1. Plan the route that the AC supply wiring will follow from the source 5. Carefully remove 50 – 75 mm (2 – 3 in.) of the outer jacket from the
(usually an AC distribution panel) to the Truecharge2 Battery Charger. AC supply wiring, being careful not to cut or nick the insulation on the
2. Measure and cut the required length of three-conductor (L, N, GND) individual conductors.
cable allowing some extra length for connections and providing some 6. Extend the charger’s AC (L, N, GND) pigtail leads (wires) from the AC
slack. wiring compartment of the charger.
3. Route the AC supply wiring from the charger (in its mounted position)
to the source.

975-0526-01-02 21
Installing the Truecharge 2 Battery Charger
7. Feed the AC supply wiring through the wider end of strain relief and To connect AC wires with the provided crimp-on butt-splice connector:
out the tapered end. a) Make the connections using the provided crimp-on connectors1
or with other approved connectors required by your code, and
tapered end suitable for your installation.
of strain relief
For example, the ABYC Standards and Recommended Practices for Small
Craft prohibit twist-on connectors for AC connections on a boat. For other
AC supply wiring
types of installation, refer to your applicable code.

25 m
m(
1 in
.)
FIRE HAZARD
8. Slide the strain relief on the jacket of the wiring (not on the individual Improperly connected wires may overheat. Exercise care when using any
conductors) approximately 25 mm (1 in.) from the end of the jacket. crimp connector, use the tool specified by the crimp connector
manufacturer, and follow all crimping instructions.
9. Connect the AC supply wires to the Truecharge2 Battery Charger
pigtail wires. Failure to follow these instructions will result in death or serious
NOTE: Connect the line conductor to the AC line, the neutral to the AC injury.
neutral, and the ground to the AC ground. The wires are color coded as
follows: b) Using a wire stripper, carefully strip 8 mm (5/16 in.) from the
ends of the two wires being connected.
Conductor Charger Pigtail AC Supply Wire
Color Code Color Code
Line Black Black (or brown)
Neutral White White (or light blue)
Ground Green with yellow stripe Green with yellow stripe
1.Provided butt-splice connector (catalog number BNYF2) is available
from www.ksterminals.com.

22 Truecharge2 Series Battery Charger Owner’s Guide

 Installing the Truecharge 2 Battery Charger
c) Insert one wire into one end of the butt-splice, until the insulation
hits the internal metal crimp section, insert the butt-splice into the screw to secure the
crimper1, and crimp firmly. The proper location for the crimp is wiring compartment
approximately 1.6 mm (1/16 in.) past where the butt-splice insu- cover
lation tapers down as shown.

1/16 “

CRIMP TOOL
STRIP 5/16”

AC wiring access hole

with strain relief
d) Repeat Step c for the other end of the butt-splice.
10. When all connections are completed, push the wiring and connectors
inside the AC wiring compartment. 13. If applicable, install the optional remote panel.

11. Place the strain relief on the AC wiring access hole. 14. Connect the AC supply wiring from the charger to the AC panel
feeding the charger.
12. Install the wiring compartment cover to fasten the strain relief and
tighten the screw on top to secure the cover. Do not over-tighten. 15. Connect the line conductor to the breaker, the neutral to the neutral
bus, and the ground to the ground bus.
16. Secure cables in place using tie-wraps or cable straps according to
electrical codes.

1.Use crimper (product number CT-160) from www.panduit.com.

975-0526-01-02 23
Installing the Truecharge 2 Battery Charger
Step 5: Powering Up
Make one last check that all connections are correct and secure.
The Truecharge2 Battery Charger charger may now be powered up.
1. Close the DC disconnect switch or breaker.

EXPLOSION AND/OR FIRE HAZARD

The final connection of the DC battery circuit will generate an arc.
Ensure all areas of the system, including batteries and engine
compartments, are well ventilated prior to making this connection.
Failure to follow these instructions will result in death or serious
injury.

2. Switch the AC power on at the source breaker. It is normal to see a

seven to ten second delay while the charger powers up. During this
time, the indicator LEDs on the onboard display and the remote panel
will illuminate for a second (power on test) before reporting charging
and battery status information.
NOTE: Battery qualification may not be correctly performed if AC
power is switched on first.
NOTE: The onboard display LEDs will also illuminate momentarily
with DC power alone when DC power is applied and the minimum
battery voltage (i.e., the connected batteries) is above 9 V.

24 Truecharge2 Series Battery Charger Owner’s Guide

Installing a Parallel Configuration
A parallel configuration is when two Truecharge2 Battery Chargers are Installing a parallel configuration:
coupled together to increase the output capacity. For example, a 40-amp 1. Follow the installation sequence (from steps 1 through 4) for a single
Truecharge2 Battery Charger can be connected with another 40-amp unit - “Installing the Truecharge 2 Battery Charger” on page 16.
Truecharge2 Battery Charger for a combined 80-amp capacity charger. This
2. In “Step 4: Installing AC Wiring” on page 21, make sure that the two
configuration is possible only with the use of the optional remote panel.
AC input lines come from the same circuit branch, that is, both AC
input lines should have a common circuit breaker.
3. Designate a primary charger and a secondary charger between the two
DAMAGE TO THE BATTERY CHARGER chargers. Remember that only the primary charger or remote panel can
Do not parallel Truecharge2 Battery Chargers together without a be used to configure and operate the parallel system.
Truecharge2 Remote Panel (part number: 808-8040-01). 4. Connect the primary charger’s battery bank 1 to the secondary
Failure to follow these instructions can damage the unit and/or charger’s battery bank 1. Do the same for battery banks 2 and 3.
damage other equipment. NOTE: A maximum of three battery banks can be connected to a
parallel-configured charger system.

Parallel configuration can only be done when the following conditions are 5. Leave any unused DC output/s unconnected.
met: 6. Connect the remote panel’s communications cable to the primary
• Two Truecharge2 Battery Chargers must have the same output charger’s remote port and to the remote panel’s primary port. Do the
voltage rating. Never parallel a 24-volt charger with a 12-volt same for the secondary charger.
charger. 7. Connect the BTS (or battery temperature sensor’s) cable plug to the
• Both Truecharge2 Battery Chargers must connect to a primary charger’s BTS port. Then connect the BTS’s sensor to the
Truecharge2 Remote Panel. battery.
• Both Truecharge2 Battery Chargers must be correctly installed. NOTE: If you have two BTSs, you may connect the two separate cable
plugs to each of the battery chargers’ BTS ports. You may then
connect each of the sensors to two separate batteries. However, during
operation, the BTS that is detecting a higher temperature will be used
for battery temperature compensation.

975-0526-01-02 25
Installing a Parallel Configuration
Powering up after installing a parallel configuration: Fault and Warning Conditions
1. Follow the procedures in “Step 5: Powering Up” on page 24. • When one charger encounters a fault condition, the other charger
remains charging but the remote panel will stop synchronizing the two
2. Observe that the Parallel LED on the remote panel lights up to indicate
chargers’ settings at this point. The remote panel will display the fault
that two chargers are in parallel configuration charging mode.
condition via Fault/Warning LED the same way as the “faulty” charger
displays it on its onboard display.
During Charging • Remote panel’s Fault/Warning LED only clears when fault or warning
The two Truecharge2 Battery Chargers’ output currents are synchronized conditions at both chargers are cleared. The remote panel will resume
during most of the charging cycle. When a battery is approaching a fully synchronizing the two chargers’ settings at this point.
charged state, it is normal to see one charger’s output current drop down
earlier than the other charger. The output current displayed via the remote Exiting parallel operation:
panel lights is the sum of both chargers’ output currents divided by the total
Once the remote panel enters parallel operation, the only way to exit out of
maximum current ratings of both chargers.
it is to completely power down the remote panel by unplugging both of the
communication cables.
When Configuring the Battery Chargers
The secondary charger’s configurations are automatically synchronized
with the primary charger. The configuration can be performed from either
the remote panel or the primary charger’s onboard display. Follow the
exact same procedures as a single charger when configuring the paralleled
chargers.

When Equalizing Batteries

Equalization can be programmed and cancelled through the remote panel.
Equalization can be cancelled through both charger’s onboard display.

26 Truecharge2 Series Battery Charger Owner’s Guide

Installing Batteries
Battery installation should always be treated like a brand new installation. 5. Reconnect the battery cables to the new battery.
This means, that all safety and precautionary guidelines that were followed NOTE: For Negative chassis systems, reconnect the positive cable first,
prior and during the installation of the battery charger, must again be then the negative cable.
followed in order to avoid risks of electrical shock, injury, or death. For Positive chassis systems, reconnect the negative cable first, then
the positive cable.

IMPORTANT: If the new battery is different from the old one in chemistry,
ELECTRICAL SHOCK HAZARD temperature, or size, remember to re-configure the battery settings
Disconnect both AC and DC power from the battery charger before accordingly. See “Setting the Battery Temperature without a BTS” on page
attempting before replacing old or defective batteries and even installing 32 and “Configuring the Battery Bank Type” on page 34.
new batteries.
Failure to follow these instructions will result in death or serious
injury.
Input Voltage Operating and Derating
To replace an old battery: When AC input is within the lower range between 90–108 Vac, the
1. Turn off the AC source by disconnecting the AC line and/or opening Truecharge2 Battery Charger derates to 80% of maximum current.
the AC source disconnect. However, when AC input increases above 108 Vac up to 265 Vac,
2. Switch off all devices operating from currently installed batteries. maximum current returns to 100% capacity. Furthermore, the Truecharge2
3. Disconnect the battery cables from the old battery. Battery Charger will continue to operate at 100% of maximum current.
NOTE: For Negative chassis systems, disconnect the negative cable
first, then the positive cable.
For Positive chassis systems, disconnect the positive cable first, then
the negative cable.
Inspect all AC and DC cables for damage and repair, if necessary.
4. Replace the old battery with the new battery.

975-0526-01-02 27
Installing Batteries

Multi-Stage Charging NOTE: Not to scale. For illustration purposes only. Remote panel
(optional)
Most Truecharge2 Battery Charger models have three outputs that share the
full rated current enabling it to charge three different batteries or battery
banks that either have the same chemistry or can tolerate the same charge AC source
sequence and thresholds. The Truecharge2 Battery Charger can perform L
either three-stage charging (Bulk, Absorption, and Float) or two-stage N
charging (Bulk and Absorption). G

IMPORTANT: The battery banks are not galvanically isolated from each L
other. They share a common negative as shown in the diagram below. N
not
The negative bus to chassis connection as shown below may not be suitable G BTS applicable in
in some applications. NOTE: In some jurisdictions a
double-pole breaker may be
(optional) Australia/
New
required.
Zealand

IMPORTANT: Do not use the Negative bus to Truecharge2 Battery

Charger chassis connection in Australia/New Zealand markets.

Negative bus
Battery banks

Figure 8 Typical Three-Battery Installation

28 Truecharge2 Series Battery Charger Owner’s Guide

 Installing Batteries
Three-Stage Charging
The three-stage charging mode employs the following sequence: Bulk, Vbat = Vabs
for 1 minute
lout < 10% lrating
for 1 minute
Absorption, and Float. During the Bulk stage the batteries are accepting a Battery Voltage
Vbat = Vgas Vbat < 12.5 V
constant maximum current. In the Absorption stage, the battery voltage is for 1 minute for 15 minutes

held constant and the current declines. A battery will “gas” (produce
hydrogen and oxygen) when its voltage exceeds the “gassing” voltage. Vgas 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,
Charge
start

however, is able to provide current to its full rating to power auxiliary DC

ABS ABS
loads on the battery. BULK CC CV FLOAT

The charger will restart the charging cycle in the Bulk stage if the lowest
battery voltage of the three banks drops below 12.5 V (12 Vdc chargers) or
25 V (24 Vdc chargers) for 15 minutes. After seven days, the charger will
automatically restart charging in order to refresh the batteries. ABS CV timeout
Time

max 5 hrs
Start of FLOAT timeout
max 7 days
charging cycle
Total ABS timeout
max 8 hrs

Figure 9 Three-Stage Charging Process

975-0526-01-02 29
Installing Batteries

Two-Stage Charging
Vbat = Vabs
lout < 10% lrating
for 1 minute
The two-stage charging mode employs the following sequence: Bulk and Battery Voltage
for 1 minute
Vbat = Vgas
Absorption. It runs similar to the three-stage sequence except that there is for 1 minute
no float stage; after the absorption stage the charger stops providing current
to the battery and the charger output drops to 9 V (12 Vdc chargers) or 18V
(24 Vdc chargers). In this manner, DC loads draw power supplied by
Vgas voltage

batteries and the charger enters a “rest or standby stage.” Like the three- GO TO BULK when
stage sequence, the charger will restart the charging cycle in the Bulk stage Charge
Vbat < 12.5 V for
15 minutes
if the lowest battery voltage of the three banks drops below 12.5 V (12 Vdc start

chargers) or 25 V (24 Vdc chargers) for 15 minutes. After seven days, the ABS ABS REST
charger will automatically restart charging in order to refresh the batteries. BULK CC CV (Standby)

Time
ABS CV timeout
max 5 hrs
Start of REST (Standby)
charging cycle timeout max 7 days
Total ABS timeout
max 8 hrs

Figure 10 Two-Stage Charging Process

30 Truecharge2 Series Battery Charger Owner’s Guide

 Installing Batteries
Charging Voltage Setpoints Battery Qualification
The Truecharge2 Battery Charger charging process is designed to make the The Truecharge2 Battery Charger will perform a battery qualification on
battery or battery banks reach the following voltage setpoints. each application of AC (or DC > 9 V [for 12-volt batteries]; DC > 18 V [for
24-volt batteries]), to determine if battery banks are present and healthy.
Table 5 Charging Maximum Voltages for 12-volt chargers To force a battery detection sequence,
Battery Absorption Float (Volts) Equalization 1. Turn off AC and DC.
Type (Volts) (Volts) 2. Wait approximately 20 seconds or until all lights on the charger or
Flooded 14.4 13.5 16.0 remote have gone out.
GEL 14.2 13.8 not applicable 3. Turn on DC.
AGM 14.3 13.4 not applicable 4. Turn on AC.
The charger will then perform a battery detection.
Lead-Calcium 15.5 13.5 16.0
The Truecharge2 Battery Charger charges all banks at the same time but the
bank in most need of charging is the one that receives the most charge. For
Table 6 Charging Maximum Voltages for 24-volt chargers
example, if Bank 1 and Bank 2 are both charged, but Bank 1 has a load and
Battery Absorption Float (Volts) Equalization Bank 2 does not, then the charger may rarely charge Bank 2.
Type (Volts) (Volts)
Flooded 28.8 27.0 32.0 Temperature Considerations
GEL 28.4 27.6 not applicable
Xantrex strongly recommends that you purchase and install the optional
AGM 28.6 26.8 not applicable
Battery Temperature Sensor (BTS) to protect your battery and improve
Lead-Calcium 31.0 27.0 32.0 charging accuracy. Attach the BTS to the warmest battery.
If no BTS is connected, the charger defaults to the Battery Temp. selection
on the onboard display as well as on the optional remote panel.

975-0526-01-02 31
Installing Batteries
Setting the Battery Temperature without a BTS
NOTE: Cold is for battery temperature below 5 °C (41 °F). Warm
(default setting) is for battery temperature between 5 and 30 °C (41
and 86 °F). Hot is for battery temperature above 30 °C (86 °F). See
RISK OF BATTERY DAMAGE Table 7, “Battery Temperature Compensation Levels” on page 32 to
Do not set a battery temperature that is lower than the actual temperature see how output voltage is offset by varying the temperature selection.
in the absence of a BTS as this may cause the battery to be overcharged.
Similarly, do not set a battery temperature that is higher than the actual Table 7 Battery Temperature Compensation Levels
temperature in the absence of a BTS as this may result in under-charging
the battery. Recommended
Temperature for battery Voltage added for temperature
Failure to follow these instructions can damage the unit and/or
Selection temperature of: compensation offset from 25 °C
damage other equipment.
Cold below 5 °C Flooded/PbCa/ 0.675
(41 °F) Gel
NOTE: Always be aware of the temperature setting, observe the battery’s
actual temperature and adjust the Battery Temperature setting accordingly. AGM 0.525
For varying conditions, use the Warm setting.
Warm between Flooded/PbCa/ 0
To configure the battery temperature: 5 and 30 °C Gel
NOTE: By default, the Battery Temp. is set to Warm. (41 and 86 °F)
1. Press and hold the Battery Temp. Select button for three seconds to AGM 0
advance to the next setting. Hot above 30 °C Flooded/PbCa/ -0.27
2. Select the appropriate battery temperature setting. (86 °F) Gel
The LEDs will indicate which of the three types is being selected:
AGM -0.21
Warm, Hot, or Cold.

32 Truecharge2 Series Battery Charger Owner’s Guide

 Installing Batteries
Operating DC Loads
When the Truecharge™ 2 Battery Charger is operating, DC loads such as
fans and lights may vary in speed or intensity. This is normal. The
Truecharge™ 2 Battery Charger will not harm any load connected to it as
long as the load can withstand the following maximum voltages:
• 16 V for 12-volt chargers,
• 32 V for 24-volt chargers.

975-0526-01-02 33
Configuring the Truecharge2 Battery Charger
Once the charger is connected to at least one battery bank and to AC, it is
live and it may be configured. The indicator LEDs on the onboard display
will illuminate for a second (power on test) before reporting charging and
battery status information.

Configuring the Charger Mode

NOTE: By default, the Charger Mode is set to 3-Stage.
1. Press and hold the Charger Mode Select button for three seconds to
advance to the next setting.
2. Select the proper charger mode.
The LEDs will indicate which of the two modes is being selected:
three-stage (default) or two-stage.

Configuring the Battery Bank Type

Figure 11 Onboard Display Panel
NOTE: By default, the battery type is set to Flooded.
1. Press and hold the Battery Type Select button for three seconds to
advance to the next setting.
2. Select the proper battery type.
The LEDs will indicate which of the five types is being selected:
Flooded (default), GEL, Lead Calc., AGM, and Custom. The Custom
setting is indicated when all four battery type LEDs are illuminated.
This setting should only be used if a custom algorithm has been
programmed by Xantrex or a designated OEM.

34 Truecharge2 Series Battery Charger Owner’s Guide

Charging Batteries
Before you start to charge batteries read the “Important Safety Instructions” The charger can be in one of eight different situations which will be
on page iii and follow all safety precautions when working with batteries. indicated on the onboard display in the Charger Status LEDs:
To charge your batteries:
1. If possible, disconnect any heavy loads on the batteries being charged, Mode Charger Status LED—ON
by opening disconnect switches or by switching the loads off.
Bulk Charging
2. Connect the batteries to the charger by closing the DC disconnect
switches. Absorption Charging
NOTE: The onboard display LEDs will light up for a second. Standby or Rest (two-stage charging) Ready
3. Ventilate the area around the battery thoroughly during charging.
Float (three-stage charging) Ready and Charging
Review the charging instructions supplied by the manufacturer of your
batteries and follow all safety precautions and the required steps. Equalize (in progress) Equalize (solid light)
4. Apply AC power to the Truecharge2 Battery Charger by: Equalize Equalize (flashing)
• closing the AC breaker or (waiting for absorption to end)
• turning the generator on.
Fault Faulta (solid light)
All onboard display indicator LEDs will illuminate for one second
(power on test) as the initialization sequence runs. Warning Faulta (flashing)
After initialization, the indicator LEDs will display present status and
a.In combination with one or more flashing Charging Output % LEDs.
settings. At this point, changes in Battery Type, Battery Temperature,
and/or Charger Mode can then be applied.
These settings are stored in memory (even when all power sources are
disconnected) and need not be entered after every initialization.
During charging, the Charging Output (%) LEDs will show the total
current being delivered to the battery bank as well as any DC load
applied. The charger fan may activate as well.
5. After charging is completed, reconnect all loads to the battery.

975-0526-01-02 35
Charging Batteries
After charging is complete, the Truecharge2 Battery Charger enters into one
of these modes:
Float mode When the ready and charging indicator LEDs both
illuminate, all batteries are fully charged and ready for use. If you selected
the three-stage charging mode, the Truecharge2 Battery Charger is in float
mode and will maintain the batteries’ charge.
Standby mode Or Rest mode. If you selected the two-stage charging
mode, the ready indicator LED shows the charger is now in rest mode and is
continuously checking battery voltage.
With either charging mode, the Truecharge2 Battery Charger will begin a
charging cycle:
• seven days after the last completed cycle, or
• when the minimum battery terminal voltage drops to below 12.5 V
(12 V chargers) or 25 V (24 V chargers) for 15 minutes, or
• when AC is disconnected for more than 15 minutes and then
reconnected.

36 Truecharge2 Series Battery Charger Owner’s Guide

Equalizing Flooded Batteries
In the following conditions the Truecharge2 Battery Charger will not enter
equalization mode:
• the battery type is set to GEL or AGM
RISK OF BATTERY DAMAGE
• any battery is not fully charged (all three battery banks must be
The Truecharge2 Battery Charger will only equalize flooded lead-acid or
charged to float or rest stage before equalization can be activated on
lead-calcium batteries. It does not enter equalization when the battery
type is set to sealed lead-acid batteries (GEL or AGM) since they will be any bank)1
damaged by this process. Use the correct settings for your battery types. • there is an active fault on the battery you are trying to charge
Xantrex recommends that you run a complete normal charge cycle on the
Failure to follow these instructions can damage the unit and/or
batteries before you equalize them.
damage other equipment.

EXPLOSION HAZARD
• The battery generates explosive gases during equalization. Follow all
RISK OF BATTERY DAMAGE
of the battery safety precautions listed in this guide.
You must monitor the battery specific gravity throughout equalization to
• Ventilate the area around the battery thoroughly using ventilators with
determine the end of the equalize cycle.
brushless motors and ensure that there are no sources of flame or
Failure to follow these instructions can damage the unit and/or sparks in the vicinity.
damage other equipment.
Failure to follow these instructions will result in death or serious
injury.
The Truecharge2 Battery Charger cannot automatically determine when to
stop the equalization of a battery. The one hour time-out is intended as a
safety feature to require the user to continually re-activate it as necessary
after checking batteries manually, but may not be sufficiently short to
prevent battery damage.
1.In this case an equalization cycle can be programmed to start once the charge cycle
is done.

975-0526-01-02 37
Equalizing Flooded Batteries
Performing An Equalization NOTE: If battery acid contacts skin or clothing, wash immediately with soap
and water. If acid enters your eye, immediately flood it with running cold
water for at least twenty minutes and get medical attention immediately.

To equalize your batteries:

RISK OF EQUIPMENT DAMAGE
• Turn off or disconnect all DC loads on the battery during IMPORTANT: Remember that all connected batteries will undergo the
equalization. equalization. If only one bank is intended to undergo equalization then the
• Do not equalize if the level of equalization voltage (see note below) other banks must be disconnected prior to equalization.
does not comply with the battery manufacturer’s recommendation
1. Check the battery electrolyte level. If necessary, refill with distilled
Failure to follow these instructions can damage the unit and/or water only. All the cells should have similar electrolyte levels. If the
damage other equipment. levels are widely different, it will influence the relative concentration
of acid, thereby affecting the specific gravity measurements. If
NOTE: The voltage applied to the battery during equalization may be above distilled water is added, batteries must undergo a complete charge
safe levels for some loads but the absolute maximum is 16 V for 12-volt cycle.
chargers and 32 V for 24-volt chargers within operational temperature 2. Program or initiate an equalize cycle. Equalization will begin if all
range. banks are in either float or rest mode.

IMPORTANT: If equalization is programmed prior to float or rest mode,

the Equalize LED will flash and equalization will start prior to reaching
EXPLOSION, FIRE, AND BURN HAZARDS float or rest mode.
Always wear proper, non-absorbent gloves, complete eye protection, and
clothing protection. Avoid touching your eyes and wiping your forehead
while working near batteries. See following note.
Failure to follow these instructions can result in death or serious
injury.

38 Truecharge2 Series Battery Charger Owner’s Guide

 Equalizing Flooded Batteries
3. Press and hold for five seconds the Charger Mode Select button and
Battery Temp Select button at the same time to put the Truecharge2
Battery Charger into equalization mode.
IMPORTANT: The onboard display and remote panel buttons will not
allow selection of equalization for AGM and GEL batteries.

When the charger is performing the equalization, the Equalize LED

illuminates as a solid light. It will flash intermittently when
programmed prior to reaching float or rest mode.
4. Monitor the specific gravity of each cell of the battery during
equalization with a battery hydrometer.
NOTE: The equalization cycle is preset to last for one hour. It is not
possible to program another equalization cycle when the present cycle
has not ended yet.
Carefully check the specific gravity of each cell and repeat the
equalization cycle until they all meet the battery manufacturer’s
specifications for specific gravity or until the specific gravity stabilizes
relative to each other for an hour.
The charger automatically exits equalization to float mode or rest
mode after one cycle. To manually exit equalization mode early, repeat
Step 3.
5. Check the battery electrolyte level. If necessary, refill with distilled
water only and repeat a normal charge cycle.

975-0526-01-02 39
Transitioning the Charger to ON, Standby, or Disabled
There are two ways to turn ON the Truecharge2 Battery Charger:
• Connect the batteries to the charger (i.e., charger is on standby) then
connect AC power at the source. If the batteries are not fully charged
then charging begins immediately. If the batteries are fully charged ELECTRICAL SHOCK HAZARD
then charging will go to either standby (two-stage) or float (three- • Do not disassemble the battery charger. Internal capacitors remain
stage). charged for five minutes after all power is disconnected.
• Disconnect both AC and DC power from the battery charger before
Or, attempting any maintenance or cleaning or working on any circuits
connected to the battery charger. See note below.
• Press ON/STANDBY on the optional remote panel while batteries and Failure to follow these instructions will result in death or serious
AC power are both connected to the charger (from Standby). injury.
The charger begins to charge the batteries from Standby.
There is only ONE way to safely turn the Truecharge2 Battery Charger
There are two ways to put the Truecharge2 Battery Charger in off (Disable):
Standby (see Warning below): � Disconnect the AC power at the source and disconnect all DC
• Disconnect AC power at the source (i.e., only the batteries are batteries.
connected) or This is the only state where the Truecharge2 Battery Charger is completely
• Press ON/STANDBY on the optional remote panel while batteries and de-energized.
AC power are both connected to the charger (from ON). When the Truecharge2 Battery Charger is disabled, the optional remote
The charger stops charging but continues to monitor the batteries. panel is inactive.

40 Truecharge2 Series Battery Charger Owner’s Guide

Accessing Charger Information
The Truecharge2 Battery Charger provides a lot of information about the
status of the charger and the batteries.
F
u
C
h
R
e
Type of fault and warning
s g
m
Charging Output (%) LEDs
e r

Charging Output (%)

Reading Onboard Display LEDs <5 5 10 20 40 60 80 100 Charging Output (%) values
Fault LED
The Fault LED works in conjunction with the Charging Current (%) LEDs. Fault
The icons at the top row above the Charging Current (%) LEDs represent
the various types of fault and warning conditions. For example, a Figure 12 Charging Output (%) and Fault LEDs
temperature warning is represented by a thermometer icon.
Table 9, “Interpreting Fault and Warning Indicators” on page 43
The Charging Current (%) LEDs will normally illuminate as a solid
summarizes the various fault conditions that might occur during the
progress bar when they are indicating the amount of output charging
operation of the charger.
current. If any of the LEDs start to flash intermittently at the same time that
the Fault LED is either solid or flashing, a fault or warning condition is
indicated. Reporting While Charging or Equalizing
IMPORTANT: A warning condition notifies the user of an impending After configuring the charger and during charging, the onboard display
problem and will not stop the charger from charging, while a fault panel (and the optional remote panel, if installed) will show the following
condition will stop the charger from charging the battery. information about the charger and the battery:
• Charging Output Current
• Charger Status
• Battery Status (available on the optional remote panel only)
If there is a fault or warning related to one of the banks, the fault or warning
information will display in the form of illuminating or flashing Fault
indicator LEDs. Charging for all banks will stop and will only resume once
the fault condition is cleared. However, charging will continue during
warning conditions.

975-0526-01-02 41
Accessing Charger Information
Reporting Without AC Power or While on To interrupt or cease the charging process, disconnect the AC power source
from the charger. If you have the optional remote panel, you can put the
Standby charger in Standby mode by pressing the ON/STANDBY button to interrupt
the charging process.
If AC power has been disconnected or if you have used the optional remote
panel to place the Truecharge2 Battery Charger on Standby mode, the Table 8 Charger Status LED Sequences
onboard display (and the optional remote panel, if installed) LEDs will be
turned off to conserve battery power. However, present settings and battery Charger Status LED Charger status
status can be viewed momentarily by pressing the Status button on the Activity
optional remote panel to initialize a view cycle that will show the status of Ready LED The charger is in standby (or rest) mode of two-
the batteries. illuminates solid stage charging. All batteries have been fully
The remote panel LEDs will turn off after 30 seconds of inactivity. charged.
Ready and Charging The charger is in float mode of three-stage
Indicator LEDs on the Onboard Display Panel LEDs illuminate charging. All batteries have been fully charged.
solid
All indicator LEDs on the Onboard Display panel (and the optional remote Charging LED The charger is charging in bulk or absorption
panel, if installed) will illuminate for one second when AC or DC power is illuminates solid mode
supplied to the Truecharge2 Battery Charger or when the charger is turned
on using the ON/STANDBY button on the remote panel. A “power on” test Equalize LED flashes The charger will perform an equalization cycle
indicates that the charger is now receiving AC power, and all LEDs are after the absorption stage.
functioning. Equalize LED The charger is currently implementing an
The Truecharge2 Battery Charger will recover from fault conditions illuminates solid equalization cycle for all batteries.
automatically when the cause of the fault or warning has disappeared. Fault LED flashes A warning condition. See “Interpreting Fault and
Under fault conditions, the charging process will be stopped, allowing Warning Indicators” on page 43.
either the charger or the battery or both to return within acceptable
Fault LED A fault condition. See “Interpreting Fault and
operating ranges. See “Specifications” on page 54 for more information on
illuminates solid Warning Indicators” on page 43.
normal operating ranges.

42 Truecharge2 Series Battery Charger Owner’s Guide

 Accessing Charger Information

Table 9 Interpreting Fault and Warning Indicators

Fault or Warning Solution

Temp Fan AC Battery Fuse Charger Remote Fault

F C R
Condition e
u h
s g
e r m

AC input out of range • Check AC connections. Change to a more stable AC

fault (<85 V or >265 V) power source and check that the voltage and voltage
frequency are within acceptable operating range. See
“Specifications” on page 54.
High Battery Temp fault • Check the batteries. Do not charge a battery that is
(>70°C) rated other than 12 V nominal for all 12-volt chargers
or 24 V nominal for all 24-volt chargers. Check that
the battery type and temperature settings match the
actual battery and its conditions.
• Disconnect or turn off other charging sources such as
an alternator or the charger on a generator with an
electric start.
• Allow the battery (or batteries) to cool to normal
operating temperature. See “Specifications” on page
54.

Flashing LED Solid LED

975-0526-01-02 43
Accessing Charger Information
Table 9 Interpreting Fault and Warning Indicators

Fault or Warning Solution

Temp Fan AC Battery Fuse Charger Remote Fault
F C R
Condition e
u h
s g
e r m

Low Battery Temp fault • Check the batteries. Do not charge a frozen battery.
(< -25°C) Charging a frozen battery may present a risk of
explosion. Check that the battery type and
temperature settings match the actual battery.
• Allow the battery (or batteries) to warm up to a
temperature that is above freezing before charging.
See “Specifications” on page 54.
High Battery voltage • Discontinue charging or disconnect AC power source
fault from supplying power to the charger.
(>16.5V for 12-volt • Disconnect voltage sensitive DC loads from DC
chargers) supply to prevent damage.
(>33V for 24-volt • If the DC bus voltage is still measuring high after AC
chargers) power has been disconnected, call a qualified and
certified electrician.
High Charger Temp • Allow the Truecharge2 Battery Charger to cool while
fault the AC is connected so the fan stays on.
• Improve ventilation or install the charger in a cooler
location.
Loss of Remote • Reconnect the communication cable to the port. It
Connection warning takes about 15 seconds to re-establish
communication.

Flashing LED Solid LED

44 Truecharge2 Series Battery Charger Owner’s Guide

 Accessing Charger Information
Table 9 Interpreting Fault and Warning Indicators

Fault or Warning Solution

Temp Fan AC Battery Fuse Charger Remote Fault
F C R
Condition e
u h
s g
e r m

Reverse Polarity Fuse • Check for reverse battery polarity (negative

fault connected to negative, positive connected to positive
is correct) at battery and charger output terminals.
• Disconnect AC and DC sources before replacing the
fuse(s) on the charger. See “Replacing the DC Output
Fuse” on page 48.
Internal fault • Call Xantrex for support.

Flashing LED Solid LED

975-0526-01-02 45
Using A Generator As Source Power
The Truecharge2 Battery Charger can be run from a regular AC power
source or from an alternate power source such as a generator. Refer to “AC
Input Specifications” on page 54 for AC input current draw to determine
the size of generator you need. Many generators provide output voltage that
is modified sine wave or modified square wave (MSW) rather than the true
sine wave (TSW) that your utility provides.
If a generator needs to run on full load capacity to supply charging current
to the battery via the battery charger, its output frequency and amplitude
may become unstable. This scenario can cause the battery charger to
shutdown. Using the current limiting feature1 from the remote panel can
help avoid this scenario.
The Truecharge2 Battery Charger may be used with MSW generators but its
lifetime may be reduced somewhat depending on the severity of any peak
voltage overshoots, and the severity of waveshape rise times.

1.See “Configuring the Maximum Output Current Percentage of the Charger” on the
Truecharge2 Remote Panel Owner’s Guide.

46 Truecharge2 Series Battery Charger Owner’s Guide

Maintaining the Charger
Periodically, disconnect all AC and DC sources and check all DC and AC
wiring connections to be sure they have not loosened or deteriorated. Also
check all cable clamps to ensure they are tightly fastened.
ELECTRICAL SHOCK HAZARD Loose battery terminals and lugs exposed to open air corrode rapidly. The
Do not disassemble the battery charger. See note below. corrosion appears as a white powder or granular foam on the terminals and
Failure to follow these instructions will result in death or serious any nearby exposed metal parts. If it contacts your skin, it will cause burns
injury. unless you rinse it off immediately.
To clean battery terminals, follow the recommendations and procedures of
NOTE: The Truecharge2 Series Battery Charger contains no user- the battery manufacturer.
serviceable parts with the exception of the DC output fuse(s) which are
user-replaceable. See “Replacing the DC Output Fuse” on page 48 for
instructions. For obtaining service other than replacing the fuse, contact
customer support for guidance.

The Truecharge2 Battery Charger contains solid-state electronic

components that require no maintenance. The best care you can give the
charger is to protect it from contact with liquids, spray, or fumes which may
cause corrosion and by keeping the air intake vent clean and free from any
obstructions.
Disconnect all AC and DC power and clean the outside of the case and
wiring with a damp cloth. Wear protective gloves, if you suspect it has
come in contact with battery fluid, salt water, gasoline or oil, or other
corrosive material. Do not operate if the charger contains moisture of any
kind.

975-0526-01-02 47
Replacing the DC Output Fuse
3. Pull out the blown fuse(s) gently, using the provided fuse puller.
NOTE: The fuse puller is located on the inside of the fuse cover.
4. Install a brand new fuse(s) with same type and rating as the old one.
IMPROPER INSTALLATION BY AN UNQUALIFIED INSTALLER
See “Fuse Replacement Ratings” on page 49.
Xantrex recommends that the installer should have knowledge and
experience in installing electrical equipment, knowledge of the applicable 5. Replace the fuse cover making sure that it aligns and fits perfectly,
installation codes, and awareness of the hazards involved in performing leaving no space for moisture or small debris to enter the
electrical work and how to reduce those hazards. compartment.

Failure to follow these instructions can damage the unit and/or 6. Tighten the screw on the fuse cover but do not over-tighten.
damage other equipment. 7. Fix the reverse polarity fault which caused the fuse to blow prior to
reconnecting all AC and DC sources to the charger.
8. Reconnect all AC and DC sources to the charger.

ELECTRICAL SHOCK HAZARD

Disconnect all AC and DC sources to the charger and wait five minutes
for internal voltage and energy levels to reduce to safe levels.
Failure to follow these instructions will result in death or serious
injury.

To replace the DC Output Fuse:

1. Locate the fuse cover on the charger’s top panel (see “Front Panel” on
page 3).
2. Loosen the screw on the fuse cover using a Phillips screwdriver.
NOTE: The screw will not separate from the cover.

48 Truecharge2 Series Battery Charger Owner’s Guide

 Replacing the DC Output Fuse
Fuse Replacement Ratings

RISK OF EQUIPMENT DAMAGE

For continued protection, replace only with Littelfuse® type 257 (or
equivalent) with ratings as shown below.
Failure to follow these instructions can damage the unit and/or
damage other equipment.

Model Amperage Voltage

TC2012 30 A (green) 32 Vdc
TC4012 2×30 A (green) 32 Vdc
TC6012 3×30 A (green) 32 Vdc
TC1024 15 A (blue) 32 Vdc
TC2024 15 A (blue) 32 Vdc
TC3024 40 A (amber) 32 Vdc

975-0526-01-02 49
Troubleshooting
In the event that you have a problem with your Truecharge2 Battery
Charger, the following tables will help you to identify the problem and offer
possible solutions to the problem.

Symptom Symptom
Indicator LEDs do not illuminate when charger is connected to an AC The initial power up display test is not performed upon connection of
power source. battery or batteries.

Possible Cause Solution Possible Cause Solution

No power at AC source Ensure that power is available at Truecharge2 Battery Charger Check quality of battery connection and
charger AC input and it is within does not detect battery for one of wires.
acceptable range. the following reasons: Ensure correct polarity (negative
• poor connection connected to negative, positive
Defective AC wiring or Wiring must be inspected and replaced • reverse polarity connection connected to positive).
switches/breakers by a qualified installer. (blown fuse) In case there is an accompanying fault,
• damaged wiring check the type of fault from
Remote panel has been used to Press the On/Standby button on the • open DC breaker or external “Interpreting Fault and Warning
put the charger into Standby remote panel to turn the charger on. fuse Indicators” on page 43.
mode. • battery voltage is below 9 V

50 Truecharge2 Series Battery Charger Owner’s Guide

 Troubleshooting
Symptom Symptom
Fault indicator LED illuminates. Temp and Battery indicator Truecharge2 Battery Charger completes a charging cycle, but the battery
LEDs flash. voltage seems too low.

Possible Cause Solution

EXPLOSION HAZARD Battery has a shorted cell. Disconnect AC to the charger and
Never charge a frozen battery. check the battery voltage approximately
one hour later.
Failure to follow these instructions can result in death or serious
NOTE: If the charger is functioning
injury.
properly but the charge cycles fail to
bring the resting voltage up above
10 V for 12-volt chargers and 20 V for
Possible Cause Solution 24-volt chargers, then this confirms the
battery has a damaged or shorted cell.
Battery temperature is either too If battery is too hot, allow battery to
hot or too cold for safe charging. cool. Improve ventilation or install in a Replace battery.
cooler location. The battery has reached the end of its
useful life and can no longer accept a
If the optional remote panel is charge.
available, you may reduce the output
current using the Set Max Output
button.

If battery is too cold, allow batteries to

warm up.

975-0526-01-02 51
Troubleshooting
Symptom Symptom
The Truecharge2 Battery Charger appears to be taking too long to charge The Truecharge2 Battery Charger appears to have quickly charged the
battery. Ready indicator LED does not illuminate after 24 hours of battery. Ready indicator LED illuminates sooner than expected.
charging.
Possible Cause Solution
Possible Cause Solution
Battery capacity is too low for Use a lower capacity charger.
Battery capacity is too high for Use a higher capacity charger. the Truecharge2 Battery Charger Using the optional remote panel (if
the Truecharge2 Battery Charger model. installed), reduce the output current
model. delivered to the smaller battery.

Load connected to battery is Disconnect all loads or switch loads off. Battery has a damaged cell or Replace battery.
draining charge current so that has reached the end of its useful
battery does not recharge. life.

Battery has a damaged cell or Replace battery.

has reached the end of its useful
life.

The remote panel Max Output Increase the Max Output setting.
setting is too low for the battery
capacity.

52 Truecharge2 Series Battery Charger Owner’s Guide

 Troubleshooting
Symptom
The Truecharge2 Battery Charger will not perform equalization.

Possible Cause Solution

Battery is the wrong type, or set Determine if the battery type is set to
to the wrong type to equalize. GEL or AGM. These battery types
cannot be equalized.

Not all batteries are fully The charger will wait for all batteries to
charged. be in float stage of three-stage charging
or rest stage of two-stage charging
before attempting to equalize (the ready
indicator LED will illuminate).

An active fault is present on the Clear the active fault by disconnecting

bank you are attempting to the AC power source and finding the
equalize. cause of the fault from “Interpreting
Fault and Warning Indicators” on page
43.

975-0526-01-02 53
Specifications
NOTE: Specifications are subject to change without prior notice.

AC Input Specifications
Physical Specifications
Base Unit Dimensions: L × W × H AC input voltage range
TC2012, TC4012 250×170×70 mm (9.84×6.70×2.76 in.) Nominal: 120 Vac, 230 Vac, 240 Vac
Full Performance: 104 – 265 Vac ±4 Vac
TC1024, TC2024 250×170×70 mm (9.84×6.70×2.76 in.)
Automatic derating to
TC6012, TC3024 340×170×90 mm (13.38×6.70×3.54 in.) 80% output: 90 – 108 ±4 Vac
Weight
Max. AC input current
TC2012, TC4012 2.2 kg (4.8 lbs)
TC2012: 3.9 A
TC1024, TC2024 2.2 kg (4.8 lbs) TC4012: 7.7 A
TC6012, TC3024 4.5 kg (9.9 lbs) TC6012 11.6 A
AC input connections Three color-coded No. 16 AWG wires (L, N, TC1024: 3.9 A
GND) minimum 152 mm (6 in.) long in a TC2024: 7.7 A
separate AC wiring enclosure with 21.3 mm TC3024 11.6 A
(0.84 in.) hole provision for connection of a
Power factor at rated 0.95
½ inch North American "trade size" strain
load
relief (included).
AC input connections IEC 60320 C14 male connector receptacle Frequency 47 – 63 Hz
(IEC models only) Efficiency – peak
DC output Four M6 studs (3 positives and 1 common 12/24-volt units: 80% @ 120 Vac
connections negative) for battery cable ring terminals and 12/24-volt units: 84% @ 230 Vac
one M6 mm DC equipment ground
Surge protection Line-to-neutral surge protector rated at
275 Vac

54 Truecharge2 Series Battery Charger Owner’s Guide

 Specifications
DC Output Specifications DC Output Specifications
Number of isolated battery 3 separated outputs Normal operating output
bank outputs range
12-volt units: 0 – 16 Vdc
DC output voltage range
24-volt units: 0 – 32 Vdc
including dead battery
charging voltage
12-volt units: 0 – 16 Vdc Maximum DC output
24-volt units: 0 – 32 Vdc current (total)
TC2012: 20 +10% A
TC4012: 40 +10% A
Maximum equalization
TC6012 60 +10% A
voltage
TC1024: 10 +10% A
12-volt units: 16 Vdc
TC2024: 20 +10% A
24-volt units: 32 Vdc
TC3024: 30 +10% A
Absorption voltage:
Voltage accuracy (no load)
12-volt units 24-volt units
12-volt units: 14.4 ±0.1 Vdc @ 25 °C (77 °F)
25 °C (77 °F) 25 °C (77 °F)
24-volt units: 28.8 ±0.2 Vdc @ 25 °C (77 °F)
Flooded 14.4 ±0.1 28.8 ±0.2
GEL 14.2 ±0.1 28.4 ±0.2
Nominal battery voltage AGM 14.3 ±0.1 28.6 ±0.2
12-volt units: 12 Vdc Lead-calcium 15.5 ±0.1 31.0 ±0.2
24-volt units: 24 Vdc

975-0526-01-02 55
Specifications

DC Output Specifications DC Output Specifications

Float voltage: Voltage regulation Uncompensated load voltage
12-volt units 24-volt units regulation
25 °C (77 °F) 25 °C (77 °F) < 0.1Vdc drop from 0 Amps to rated
Flooded 13.5 ±0.1 27.0 ±0.2 current output at charger output
GEL 13.8 ±0.1 27.6 ±0.2 terminals (adds in series with
AGM 13.4 ±0.1 26.8 ±0.2 recommended 3% limit for user's
Lead-calcium 13.5 ±0.1 27.0 ±0.2 battery cable voltage drop).

Equalize mode current 50% rated output ±6%

Equalize mode—maximum Environmental Specifications

output voltage Operating range 0 – 60 °C (32 – 140 °F)
12-volt units: 16 ±0.1 Vdc with up to 80% current derating
24-volt units: 32 ±0.2 Vdc above 40 °C (104 °F) and
up to 50% current derating
Off-state current draw above 50 °C (122 °F)
(without remote installed) <35 mA dc Storage –40 to 80 °C (–40 to 176 °F)

Humidity 5 – 95%, RH non-condensing

56 Truecharge2 Series Battery Charger Owner’s Guide

 Specifications
Protection Features Protection Features
Battery reverse polarity Protected by replaceable DC output Battery under-temperature Charger shuts down if battery
fuses protection temperature below –25 °C (–13 °F) is
sensed by the battery temperature
Over-voltage limits The Truecharge2 Battery Charger will
sensor (BTS).
stop charging if the output voltage is
above
16.6 ±0.5 Vdc for 12 Vdc units,
33.2 ±0.1 Vdc for 24 Vdc units.
Output current limit
TC2012: 20 +10% A
TC4012: 40 +10% A
TC6012: 60 +10% A
TC1024: 10 +10% A
TC2024: 20 +10% A
TC3024: 30 +10% A
Over-temperature Shutdown at 65 ±5 °C (149 ±9 °F)
(measured internally)
Restart at 60 ±5 °C (140 ±9 °F)
Battery over-temperature Charger shuts down if battery
protection temperature above 70 °C (158 °F) is
sensed by the battery temperature
sensor (BTS).

975-0526-01-02 57
Specifications

Regulatory Approvals
Safety
North America NRTL listed to CSA E60335-2-29, UL1236 including the
marine supplement, and UL1564.
ABYC E11 - Alternating Current and Direct Current
Electrical Systems on Boats, and
ABYC A31 - Battery Chargers and Inverters.
European Union CE marked for the Low Voltage Directive 2014/35/EU,
(complying with EN60335-1 and EN60335-2-29 Battery
Chargers).
EN 28846 - Small Craft Electrical Devices, Protection
against ignition of surrounding flammable gases.
Australia/New RCM marked to AS/NZS 60335.1 and AS/NZS
Zealand 60335.2.29 including Australian/New Zealand deviations.
EMC
North America Class B according to FCC Part 15B and ISED Canada
ICES-003.
European Union CE marked for the EMC Directive 2014/30/EU
(complying with EN55014-1 (Class B), EN55014-2,
EN61000-3-2, and EN61000-3-3).
Environmental
European Union CE marked for the RoHS Directive 2011/65/EU
(complying with EN50581).

58 Truecharge2 Series Battery Charger Owner’s Guide

www.xantrex.com
(Toll Free USA/Canada) +1 800 670 0707
(Outside USA/Canada) +1 408 987 6030

975-0526-01-02 Rev E Printed in China.