Xantrex BC3012 User manual

12 V / 30 A
12 V / 50 A
24 V / 15 A
24 V / 25 A
Xantrex
BC3012, BC5012,
BC1524 and BC2524
Battery Charger
User Guide
BC_Charger_User.book Page 1 Friday, August 12, 2005 3:31 PM

BC_Charger_User.book Page 2 Friday, August 12, 2005 3:31 PM

Xantrex BC3012, BC5012,
BC1524 and BC2524
Battery Charger
User’s Guide
BC_Charger_User.book Page i Friday, August 12, 2005 3:31 PM

About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with
products from 50 watt mobile units to one MW utility-scale systems for wind, solar, batteries, fuel cells,
microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex
products include inverters, battery chargers, programmable power supplies, and variable speed drives
that convert, supply, control, clean, and distribute electrical power.
Trademarks
Xantrex BC3012, BC5012, BC1524 and BC2524 Battery Charger is a trademark of Xantrex
International. Xantrex is a registered trademark of Xantrex International.
Other trademarks, registered trademarks, and product names are the property of their respective owners
and are used herein for identification purposes only.
Notice of Copyright
Xantrex BC3012, BC5012, BC1524 and BC2524 Battery Charger User’s Guide© August 2005 Xantrex
International. All rights reserved.
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC.
(“XANTREX”)
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF
ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER
DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER
DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF
THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE
ENTIRELY AT THE USER’S RISK.
Date and Revision
August 2005 Revision B
Part Number
975-0188-01-01
Contact Information
Phone: [phone] (toll free North America)
[phone] (Europe)
1 360 925 5097 (direct and rest of world)
Fax: [phone] (toll free North America)
[phone] (Europe)
1 360 925 5143 (direct and rest of world)
Email: [e-mail] (North America)
[e-mail] (Europe)
[e-mail] (rest of world)
Web: www.xantrex.com
BC_Charger_User.book Page ii Friday, August 12, 2005 3:31 PM

iii
About This Guide
Purpose
The purpose of this User’s Guide is to provide explanations and procedures for
operating, maintaining, and troubleshooting the Xantrex BC3012, BC5012,
BC1524 and BC2524 Battery Charger.
Scope
The Guide provides safety guidelines, detailed planning and setup information, as
well as information about operating and troubleshooting the unit. It does not
provide details about particular brands of batteries. Consult individual battery
manufacturers for this information.
Audience
The Guide is intended for anyone who needs to operate the Xantrex BC3012,
BC5012, BC1524 and BC2524 Battery Charger.
Organization
This Guide is organized into 3 chapters and 1 appendix:
Chapter 1, “Introduction”: Chapter 1 describes the BC Series standard features and
lists the procedures to configure the BC Series.
Chapter 2, “Operation”: Chapter 2 describes the operating states of the BC Series
and provides procedures for charging a battery and performing an equalization.
Chapter 3, “Troubleshooting”: Chapter 3 contains information on error codes and
procedures for troubleshooting your BC Series charger.
Appendix A, “Specifications”: Appendix A details the specifications for the
BC Series.
BC_Charger_User.book Page iii Friday, August 12, 2005 3:31 PM

About This Guide
iv 975-0188-01-01
Conventions Used
The following conventions are used in this guide.
This Guide contains information for four versions of the BC Series.
The Xantrex BC3012 Battery Charger (12 V, 30 A) will be referred to as the
BC3012 when it is being referenced individually.
The Xantrex BC5012 Battery Charger (12 V, 50 A) will be referred to as the
BC5012 when it is being referenced individually.
The Xantrex BC1524 Battery Charger (24 V, 15 A) will be referred to as the
BC1524 when it is being referenced individually.
The Xantrex BC2524 Battery Charger (24 V, 25 A) will be referred to as the
BC2524 when it is being referenced individually.
When the Xantrex BC3012, BC5012, BC1524 and BC2524 Battery Chargers are
being referenced together, they will be referred to as the BC Series.
Related Information
You can find more information about Xantrex Technology Inc. as well as its
products and services at www.xantrex.com
WARNING
Warnings identify conditions or practices that could result in personal injury or loss of life
CAUTION
Cautions identify conditions or practices that could result in damage to the unit or other
equipment.
Important: These notes describe things which are important for you to know, but not as
serious as a caution or warning.
BC_Charger_User.book Page iv Friday, August 12, 2005 3:31 PM

v
Important Safety Instructions
1. Before installing or using the Xantrex BC3012, BC5012, BC1524 or BC2524
Battery Charger (BC Series), read all instructions and cautionary markings on
the BC Series, the batteries, and all appropriate sections of this guide.
2. Do not expose the BC Series to rain, snow, spray, or bilge water. To reduce risk
of fire hazard, do not cover or obstruct the ventilation openings. Do not install
the BC Series in a zero-clearance compartment. Overheating may result.
3. Use only attachments recommended or sold by Xantrex. Doing otherwise may
result in a risk of fire, electric shock, or injury to persons.
4. The BC Series is designed to be permanently connected to the AC and DC
electrical systems. Xantrex recommends that all wiring be done by a certified
technician or electrician to ensure compliance with the local and national
electrical codes relevant to your installation. It is the responsibility of the
installer to ensure that the installation of the BC Series complies with all
relevant electrical codes.
5. To avoid a risk of fire and electric shock, make sure that existing wiring is in
good condition and that wire is not undersized. Do not operate the BC Series
with damaged or substandard wiring.
6. Do not disassemble the BC Series. It contains no user-serviceable parts.
Attempting to service the BC Series yourself may result in a risk of electrical
shock or fire.
NOTE: Disassembling the BC Series will void your warranty.
7. To reduce the risk of electrical shock, disconnect both AC and DC power from
the BC Series before attempting any maintenance or cleaning or before working
on any circuits connected to the BC Series. Turning off will not reduce this risk.
WARNING
This chapter contains important safety and operating instructions as prescribed by UL and
CSA standards for chargers used in residential, RV, marine and automotive applications.
Read and keep this Owner’s Guide for future reference.
BC_Charger_User.book Page v Friday, August 12, 2005 3:31 PM

Safety
vi 975-0188-01-01
8. The BC Series is provided with an AC ground conductor that must be
connected to the AC input ground and a DC ground stud which must be
connected to the DC system ground.
9. For marine applications in the United States, external connections to the
charger shall comply with the United States Coast Guard Electrical Regulations
(33CFR183, Sub part 1).
Explosive Gas and Battery Precautions
1. Read this guide and follow the instructions exactly before installing or using
your BC Series.
2. Follow all instructions published by the battery manufacturer and the
manufacturer of the equipment in which the battery is installed.
3. Working in the vicinity of lead-acid batteries is dangerous. Batteries generate
explosive gases during normal operation.
4. The BC Series has been approved as Ignition Protected. It may be installed in
areas containing gasoline tanks and fittings which require Ignition Protected
equipment. Xantrex recommends, nevertheless, that it is safest not to install
electrical equipment in these areas.
5. Make sure the area around the battery is well ventilated.
6. Never smoke or allow a spark or flame near the engine or batteries.
7. Use caution to reduce the risk of dropping a metal tool on the battery. It could
spark or short circuit the battery or other electrical parts and could cause an
explosion.
8. Remove all metal items, like rings, bracelets, and watches when working with
lead-acid batteries. Lead-acid batteries produce a short circuit current high
enough to weld metal, causing a severe skin burn.
9. Have someone within range of your voice or close enough to come to your aid
when you work near a lead-acid battery.
WARNING: Explosion or fire hazard
BC_Charger_User.book Page vi Friday, August 12, 2005 3:31 PM

Safety
975-0188-01-01 vii
10. Have plenty of fresh water and soap nearby in case battery acid contacts skin,
clothing, or eyes.
11. Wear complete eye protection and clothing protection. Avoid touching your
eyes while working near batteries.
12. If battery acid contacts skin or clothing, wash immediately with soap and water.
If acid enters your eye, immediately flood it with running cold water for at least
twenty minutes and get medical attention immediately.
13. If you need to remove a battery, always remove the ground terminal from the
battery first. Make sure all accessories are off so you don’t cause a spark.
FCC Information
This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference in a residential
installation. This equipment generates, uses, and can radiate radio frequency energy
and, if not installed and used in accordance with the instructions, may cause
harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular
installation. If this equipment does cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by one or more of the following
measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which
the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
BC_Charger_User.book Page vii Friday, August 12, 2005 3:31 PM

viii
BC_Charger_User.book Page viii Friday, August 12, 2005 3:31 PM

975-0188-01-01 ix
Important Safety Instructions
Explosive Gas and Battery Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi
FCC Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vii
1 Introduction
Xantrex BC3012, BC5012, BC1524 and BC2524 Battery Charger Features- - - - - - - 1–2
BC Series Appearance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Information Centers of the BC Series- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Onboard Status Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Optional Remote Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
Rear Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7
Battery Bank Size Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8
Battery Temperature Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8
Configuring the BC Series - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9
Configuring with DIP Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9
Configuring with Remote Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–11
2 Operation
About Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Multiplex 3-Stage Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Sequential 2-Stage Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Charging Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Charging Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Equalizing Flooded Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
Transitioning the BC Series to On, Disabled or Off - - - - - - - - - - - - - - - - - - - - - - 2–11
Accessing Charger Information- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Reading Onboard Status Indicator Lights and Remote Display - - - - - - - - - - - 2–12
Remote Display Reporting While Charging and Equalizing - - - - - - - - - - - - - 2–14
Remote Display Reporting While Battery Monitoring - - - - - - - - - - - - - - - - - 2–14
Remote Display Reporting While Disabled - - - - - - - - - - - - - - - - - - - - - - - - 2–15
Using A Generator As Source Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–16
Contents
BC_Charger_User.book Page ix Friday, August 12, 2005 3:31 PM

Contents
x 975-0188-01-01
3 Troubleshooting
Care and Maintenance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Indicator Light Flashing Sequences- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Error Messages on Optional Remote Display - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Problem Solving - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
A Specifications
Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2
AC Input Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3
Temperature Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4
Protection Features- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4
Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–5
Warranty and Product Information - - - - - - - - - - - - - - - - - - - - - - - - - - WA–1
BC_Charger_User.book Page x Friday, August 12, 2005 3:31 PM

1Introduction
Chapter 1 describes the BC Series standard features
and lists the procedures to configure the BC Series.
BC_Charger_User.book Page 1 Friday, August 12, 2005 3:31 PM

Introduction
1–2 975-0188-01-01
Xantrex BC3012, BC5012, BC1524 and BC2524 Battery
Charger Features
The BC Series provides the following standard features:
• three full current rated, independently controlled outputs which enable it to
charge three different batteries or battery banks. Each bank can be of a different
battery type, stage of charging, and temperature compensation
• one battery temperature sensor (BTS) is included. Optional BTSs may be
purchased for the other two outputs, to provide complete optimal battery
charging to each battery or bank
• battery monitoring functions while in float mode or rest mode
• correct charging voltage for your batteries when connected to almost any single
phase AC power outlet in the world
The BC Series provides the following protection features:
• true “fuseless” reverse polarity protection to guard against continuous reverse
battery polarity without charger damage
• AC over voltage protection shutdown
• over temperature protection shutdown
• electronic current limiting for protection against short circuit on the unit’s
output
• built-in protection against accidental connection to a higher battery voltage, up
to 24 VDC
• battery temperature compensation to 0 °C (32 °F) (with BTS installed)
• ignition protected rating, enabling installation in engine spaces
• isolated design to reduce shock hazard
• automatic charge resumption after AC power interruption
BC_Charger_User.book Page 2 Friday, August 12, 2005 3:31 PM

BC Series Appearance
975-0188-01-01 1–3
BC Series Appearance
This section describes the parts of the BC Series. Figure 1-3 shows the BC Series.
Figure 1-1 BC Series
Item Description
1 Configuration DIP switches and equalize push button
2 Onboard status panel for monitoring charger status and charging current at the
BC Series.
3 Mounting flanges
2
3
1
BC_Charger_User.book Page 3 Friday, August 12, 2005 3:31 PM

Introduction
1–4 975-0188-01-01
Information Centers of the BC Series
Onboard Status Panel
This section describes the parts of the onboard status panel of the BC Series.
Figure 1-2 shows the panel.
Figure 1-2 BC Series Status Panel
Item Description
1 Charge Current
• Displays the output charge current in % for the bank being charged
• 100% indicator light flashes to indicate battery temperature too high (> 50 °C, 122 °F)
• 10% indicator light flashes to indicate battery temperature too low (< 0 °C, 32 °F)
• 25% indicator light flashes to indicate that a battery has been disqualified (see page 2–4)
2Charger Status - READY
• Ready indicator light illuminated indicates all batteries are fully charged, and are now in
float or rest
3Charger Status - CHARGING
• Charging indicator light illuminated indicates unit is performing a normal charge cycle
• Charging indicator light flashing indicates that the unit is performing an equalization cycle
4Charger Status - FAULT
• Fault indicator light continuously illuminated indicates any fault condition that prevents
the BC Series from charging one or more batteries, but is not a charger failure - optional
remote display shows details of fault
• Fault indicator light flashing indicates the BC Series has experienced a charger failure -
optional remote display shows
err followed by CHf
1
2
3
4
BC_Charger_User.book Page 4 Friday, August 12, 2005 3:31 PM

Information Centers of the BC Series
975-0188-01-01 1–5
Optional Remote Display
This section describes the parts of the optional remote display of the BC Series. The
remote display can be mounted up to 65 ft (20 m) from the BC Series for
convenience. The remote display may already be installed with your BC Series, or
you may purchase one and install it. Figure 1-3 shows the remote display.
A “press and hold” action on the remote display means that the button must be held
down for more than 2 seconds in order to send the instruction. A “press” action on
the remote display means that the button must be pressed and released before 2
seconds have elapsed.
Figure 1-3 BC Series Remote Display
Item Description
1ON/STANDBY push button
• Press to turn on or disable the charger while AC power is connected
• Press and hold to apply selection when in setup or equalization mode
• Press to show battery bank voltages when AC is disconnected
2 Battery bank indicator lights
• Illuminate to show which bank has been selected for setup or status display
• Illuminate during a fault or warning to show which bank has the fault or warning, or
illuminate all three if the charger itself has the fault or warning
3 Alpha-numeric display shows
• Configuration
• Fault or warning messages (see Table 3-2 on page 3–4)
• Battery bank voltage and current
• Type of charging (2 stage or 3 stage)
• State of charge
1
2 3 4 5
7
6
BC_Charger_User.book Page 5 Friday, August 12, 2005 3:31 PM

Introduction
1–6 975-0188-01-01
The indicator lights and display are also used to indicate error codes. See Chapter 3,
“Troubleshooting” for a list of faults and how to clear them.
4 Units indicator lights
• Illuminate to show unit of measure for the numeric read-out on the alpha-numeric display
5BANK selection push button
• Press to select a bank during setup
• Press at the same time as MODE to enter or exit equalization mode.
6TYPE selection push button
• Press to select flooded (lead acid), gel, AGM, or lead calcium batteries.
7MODE selection push button
• Press to select charging state during setup: 2 stage or 3 stage.
• Press at the same time as BANK to enter or exit equalization mode.
• Press and hold to enter setup.
Item Description
BC_Charger_User.book Page 6 Friday, August 12, 2005 3:31 PM

Rear Panel
975-0188-01-01 1–7
Rear Panel
This section describes the parts of the rear panel of the BC Series. Figure 1-4 shows
the rear panel.
Figure 1-4 BC Series Rear Panel
Item Description
1 Optional remote display communication connector
2 BTS1 (battery temperature sensor for bank 1) connector
3 BTS2 (battery temperature sensor for bank 2) connector
4 BTS3 (battery temperature sensor for bank 3) connector
5 Battery negative, common for all 3 banks (6 mm stud)
6 Battery positive for bank 1 (6 mm stud)
7 Battery positive for bank 2 (6 mm stud)
8 Battery positive for bank 3 (6 mm stud)
9 Fan assembly
10 Chassis ground (earth) for DC wiring
11 AC wiring access panel
1
4
3
2
8
7
9
11 10 65
BC_Charger_User.book Page 7 Friday, August 12, 2005 3:31 PM

Introduction
1–8 975-0188-01-01
Battery Bank Size Requirements
The BC Series is designed to work with a minimum battery bank size. Each bank
should meet the minimum Ah rating shown in Table 1-1.
Battery Temperature Sensors
Xantrex strongly recommends that you install a Battery Temperature Sensor (BTS)
to protect your battery and improve charging accuracy. It is best to use a separate
BTS with each individual battery bank, to provide optimal charging and protection
of each bank. If no BTS is connected, the charger defaults to the charging
conditions for 40 °C (104 °F). At this temperature the charging voltage is lower to
keep batteries from overcharging; charging will be slower and the batteries will be
slightly undercharged.
One BTS is provided with your BC Series, and additional battery temperature
sensors may be purchased separately.
Table 1-1 Minimum Battery Bank Size
BC 1524 BC 2524 BC 3012 BC 5012
Minimum Battery
Bank Size (Ah)
30 50 60 100
BC_Charger_User.book Page 8 Friday, August 12, 2005 3:31 PM