Xantrex XC3012 User manual

Xantrex
XC3012, XC5012,
XC1524 and XC2524
Battery Charger
12 V / 30 A
12 V / 50 A
24 V / 15 A
24 V / 25 A
Owner’s Guide
XC_Charger_Owner.book Page 1 Friday, August 12, 2005 3:23 PM

XC_Charger_Owner.book Page 2 Friday, August 12, 2005 3:23 PM

Xantrex XC3012, XC5012,
XC1524 and XC2524
Battery Charger
Owner’s Guide
XC_Charger_Owner.book Page i Friday, August 12, 2005 3:23 PM

About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with
products from 50 watt mobile units to one MW utility-scale systems for wind, solar, batteries, fuel cells,
microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex
products include inverters, battery chargers, programmable power supplies, and variable speed drives
that convert, supply, control, clean, and distribute electrical power.
Trademarks
Xantrex XC3012, XC5012, XC1524 and XC2524 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 XC3012, XC5012, XC1524 and XC2524 Battery Charger Owner’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
975-0187-01-01
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
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iii
About This Guide
Purpose
The purpose of this Owner’s Guide is to provide explanations and procedures for
installing, operating, maintaining, and troubleshooting the Xantrex XC3012,
XC5012, XC1524 and XC2524 Battery Charger.
Scope
The Guide provides safety guidelines, detailed planning and setup information,
procedures for installing the charger, as well as information about operating and
troubleshooting the unit. 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 install and operate the Xantrex
XC3012, XC5012, XC1524 and XC2524 Battery Charger. Installers should be
certified technicians or electricians.
Organization
This Guide is organized into 4 chapters and 1 appendix:
Chapter 1, “Introduction”: Chapter 1 describes the XC Series standard features. It
also provides information to prepare for installation of the XC Series.
Chapter 2, “Installation”: Chapter 2 provides procedures for installing, testing and
configuring the XC Series.
Chapter 3, “Operation”: Chapter 3 describes the operating states and provides
procedures for charging a battery and performing an equalization.
Chapter 4, “Troubleshooting”: Chapter 4 contains information on error codes and
procedures for troubleshooting your XC Series charger.
Appendix A, “Specifications”: Appendix A details the specifications for the
XC Series.
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About This Guide
iv 975-0187-01-01
Conventions Used
The following conventions are used in this guide.
This Guide contains information for four versions of the XC Series.
The Xantrex XC3012 Battery Charger (12 V, 30 A) will be referred to as the
XC3012 when it is being referenced individually.
The Xantrex XC5012 Battery Charger (12 V, 50 A) will be referred to as the
XC5012 when it is being referenced individually.
The Xantrex XC1524 Battery Charger (24 V, 15 A) will be referred to as the
XC1524 when it is being referenced individually.
The Xantrex XC2524 Battery Charger (24 V, 25 A) will be referred to as the
XC2524 when it is being referenced individually.
When the Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Chargers are
being referenced together, they will be referred to as the XC 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.
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v
Important Safety Instructions
1. Before installing or using the Xantrex XC3012, XC5012, XC1524 or XC2524
Battery Charger (XC Series), read all instructions and cautionary markings on
the XC Series, the batteries, and all appropriate sections of this guide.
2. Do not expose the XC 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 XC 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 XC 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 XC 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 XC Series
with damaged or substandard wiring.
6. Do not disassemble the XC Series. It contains no user-serviceable parts.
Attempting to service the XC Series yourself may result in a risk of electrical
shock or fire.
NOTE: Disassembling the XC Series will void your warranty.
7. To reduce the risk of electrical shock, disconnect both AC and DC power from
the XC Series before attempting any maintenance or cleaning or before
working on any circuits connected to the XC Series. Turning the XC Series off
using the remote display will not reduce this risk.
WARNING
This chapter contains important safety and operating instructions as prescribed by safety
standards for chargers used in RV and marine applications. Read and keep this Owner’s
Guide for future reference.
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Safety
vi 975-0187-01-01
8. The XC Series is provided with an AC ground conductor that must be
connected to the AC input ground and a DC ground stud which must be
connected to the DC system ground.
9. For marine applications in the United States, external connections to the
charger shall comply with the United States Coast Guard Electrical Regulations
(33CFR183, Sub part 1).
Explosive Gas and Battery Precautions
1. Read this guide and follow the instructions exactly before installing or using
your XC 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 XC 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
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Safety
975-0187-01-01 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 to reduce the possibility of
causing 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.
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viii
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975-0187-01-01 ix
Important Safety Instructions
Explosive Gas and Battery Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vi
FCC Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vii
1 Introduction
Xantrex XC3012, XC5012, XC1524 and XC2524 Battery Charger Features - - - - - - 1–2
XC Series Appearance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Information Centers of the XC Series- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Remote Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Onboard Status Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Rear Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7
Preparing for Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8
Tools and Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9
Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10
Wiring Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–12
DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–12
AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13
Battery Bank Size Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14
2 Installation
Installing the XC Series - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Installation Sequence - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2
Pre-Installing DC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3
Pre-Installing AC Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4
Mounting the Remote Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7
Mounting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9
Final Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Final DC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Final AC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Powering Up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12
Contents
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Contents
x 975-0187-01-01
Installing Optional Accessories- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13
Battery Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13
Drip Protection Rubber Boots - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14
Configuring the XC Series- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–15
3 Operation
About Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Multiplex 3-Stage Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Sequential 2-Stage Charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Charging Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Charging Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6
Equalizing Flooded Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Transitioning the XC Series to On, Disabled or Off - - - - - - - - - - - - - - - - - - - - - - 3–10
Accessing Charger Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11
Reading Remote Display and Onboard Status Indicator Lights - - - - - - - - - - - 3–11
Reporting While Charging or Equalizing - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13
Reporting While Battery Monitoring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–14
Reporting While Disabled - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–14
Using A Generator As Source Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–15
4 Troubleshooting
Care and Maintenance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2
Indicator Light Flashing Sequences- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3
Error Messages on Remote Display- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
Problem Solving - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7
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
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1Introduction
Chapter 1 describes the XC Series standard features. It
also provides information to prepare for installation of
the XC Series.
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Introduction
1–2 975-0187-01-01
Xantrex XC3012, XC5012, XC1524 and XC2524 Battery
Charger Features
The XC Series provides the following standard features:
• three full current rated, independently controlled outputs which enable it to
charge three different batteries or battery banks. Each bank can be of a different
battery type, stage of charging, and temperature compensation
• one battery temperature sensor (BTS) is included. 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
• invertable remote display panel which can also be removed from the charger
and mounted up to 20 m (65 ft) away for remote control and monitoring
The XC 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
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XC Series Appearance
975-0187-01-01 1–3
XC Series Appearance
This section describes the parts of the XC Series. Figure 1-2 shows the XC Series.
Figure 1-1 XC Series
Item Description
1 Remote display for all programming functions and monitoring of the XC Series.
2 Onboard status panel for monitoring charger status and charging current at the
XC Series when the remote display is mounted remotely from the charger.
3 Mounting flanges
2
1
3
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Introduction
1–4 975-0187-01-01
Information Centers of the XC Series
Remote Display
This section describes the parts of the remote display of the XC Series. The remote
display can be rotated 180°, or it can be removed and remotely mounted up to 20 m
(65 ft) from the XC Series for convenience. Figure 1-2 shows the remote display.
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 1-2 XC 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
1
2 3 4 5
7
6
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Information Centers of theXC Series
975-0187-01-01 1–5
The indicator lights and display are also used to indicate error codes. See Chapter 4,
“Troubleshooting” for a list of faults and how to clear them.
3 Alpha-numeric display shows
• Configuration
• Fault or warning messages (see Table 4-2 on page 4–4)
• Battery bank voltage and current
• Type of charging (2 stage or 3 stage)
• State of charge
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
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Introduction
1–6 975-0187-01-01
Onboard Status Panel
This section describes the parts of the onboard status panel of the XC Series.
Figure 1-3 shows the panel.
Figure 1-3 XC Series Onboard Status Panel
Item Description
1 Charge Current
• Displays the output charge current in % of charger maximum 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 3–4)
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 XC Series from charging one or more batteries, but is not a charger failure - remote
display shows details of fault
• Fault indicator light flashing indicates the XC Series has experienced a charger failure -
remote display shows
err followed by CHf
1
2
3
4
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Rear Panel
975-0187-01-01 1–7
Rear Panel
This section describes the parts of the rear panel of the XC Series. Figure 1-4 shows
the rear panel.
Figure 1-4 XC Series Rear Panel
Item Description
1 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
++
2
Bank 3 Bank
1
4
3
2
8
7
9
11
10 65
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Introduction
1–8 975-0187-01-01
Preparing for Installation
The XC Series is designed to be permanently mounted. Figure 1-1 shows a typical
installation with three batteries, a BTS and a remote display. It also shows the AC
and DC wiring and protection devices required for a successful installation.
Figure 1-5 XC Series System
1 AC mains source with correct size and type of circuit breaker
2 AC input wiring compartment
3 DC negative cable
4 DC positive cables
5 DC circuit breaker or DC fuse and disconnect
6 Battery or battery bank
7 Engine ground bus or DC negative bus
8 Remote display panel
9 Battery temperature sensor (#1 is standard equipment. #2 and #3 are optional)
10 DC chassis ground (earth)
L
N
G
123
4
4
4
5
5
5
6
6
6
7
8
9
10
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