Xantrex Technology Battery Charger XC1524 User Manual
Owner’s Guide  
Xantrex  
XC3012, XC5012,  
XC1524 and XC2524  
Battery Charger  
12 V / 30 A  
12 V / 50 A  
24 V / 15 A  
24 V / 25 A  
 
Xantrex XC3012, XC5012,  
XC1524 and XC2524  
Battery Charger  
Owner’s Guide  
 
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: 1 800 670 0707 (toll free North America)  
+34 93 470 5330 (Europe)  
1 360 925 5097 (direct and rest of world)  
Fax:  
1-800 994 7828 (toll free North America)  
+34 93 473 6093 (Europe)  
1 360 925 5143 (direct and rest of world)  
Email: [email protected] (North America)  
[email protected] (Europe)  
[email protected] (rest of world)  
Web: www.xantrex.com  
 
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.  
iii  
 
About This Guide  
Conventions Used  
The following conventions are used in this guide.  
WARNING  
Warnings identify conditions or practices that could result in personal injury or loss of life  
CAUTION  
Cautions identify conditions or practices that could result in damage to the unit or other  
equipment.  
Important: These notes describe things which are important for you to know, but not as  
serious as a caution or warning.  
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  
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975-0187-01-01  
 
Important Safety Instructions  
WARNING  
This chapter contains important safety and operating instructions as prescribed by safety  
standards for chargers used in RV and marine applications. Read and keep this Owner’s  
Guide for future reference.  
1. 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.  
v
 
Safety  
8. The XC Series is provided with an AC ground conductor that must be  
connected to the AC input ground and a DC ground stud which must be  
connected to the DC system ground.  
9. For marine applications in the United States, external connections to the  
charger shall comply with the United States Coast Guard Electrical Regulations  
(33CFR183, Sub part 1).  
Explosive Gas and Battery Precautions  
WARNING: Explosion or fire hazard  
1. 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.  
vi  
975-0187-01-01  
 
Safety  
10. Have plenty of fresh water and soap nearby in case battery acid contacts skin,  
clothing, or eyes.  
11. Wear complete eye protection and clothing protection. Avoid touching your  
eyes while working near batteries.  
12. If battery acid contacts skin or clothing, wash immediately with soap and water.  
If acid enters your eye, immediately flood it with running cold water for at least  
twenty minutes and get medical attention immediately.  
13. 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.  
975-0187-01-01  
vii  
 
viii  
 
Contents  
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  
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ix  
 
Contents  
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  
x
975-0187-01-01  
 
Introduction  
1
Chapter 1 describes the XC Series standard features. It  
also provides information to prepare for installation of  
the XC Series.  
 
Introduction  
Xantrex XC3012, XC5012, XC1524 and XC2524 Battery  
Charger Features  
The XC Series provides the following standard features:  
•
three full current rated, independently controlled outputs which enable it to  
charge three different batteries or battery banks. Each bank can be of a different  
battery type, stage of charging, and temperature compensation  
•
one battery temperature sensor (BTS) is included. 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  
1–2  
975-0187-01-01  
 
XC Series Appearance  
XC Series Appearance  
This section describes the parts of the XC Series. Figure 1-2 shows the XC Series.  
2
1
3
Figure 1-1 XC Series  
Item  
Description  
1
2
Remote display for all programming functions and monitoring of the XC Series.  
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  
975-0187-01-01  
1–3  
 
Introduction  
Information Centers of the XC Series  
Remote Display  
This section describes the parts of the remote display of the XC Series. The remote  
display can be rotated 180°, or it can be removed and remotely mounted up to 20 m  
(65 ft) from the XC Series for convenience. Figure 1-2 shows the remote display.  
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.  
2
3
4
5
6
1
7
Figure 1-2 XC Series Remote Display  
Item Description  
1
ON/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  
1–4  
975-0187-01-01  
 
Information Centers of the XC Series  
Item Description  
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
5
Units indicator lights  
Illuminate to show unit of measure for the numeric read-out on the alpha-numeric display  
•
BANK selection push button  
•
•
Press to select a bank during setup  
Press at the same time as MODE to enter or exit equalization mode.  
6
7
TYPE selection push button  
Press to select flooded (lead acid), gel, AGM, or lead calcium batteries.  
•
MODE 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.  
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.  
975-0187-01-01  
1–5  
 
Introduction  
Onboard Status Panel  
This section describes the parts of the onboard status panel of the XC Series.  
Figure 1-3 shows the panel.  
2
3
4
1
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)  
2
3
4
Charger Status - READY  
•
Ready indicator light illuminated indicates all batteries are fully charged, and are now in  
float or rest  
Charger 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  
Charger 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  
followed by  
1–6  
975-0187-01-01  
 
Rear Panel  
Rear Panel  
This section describes the parts of the rear panel of the XC Series. Figure 1-4 shows  
the rear panel.  
9
7
8
11  
2
+ +  
3
4
1
10  
5
6
Figure 1-4 XC Series Rear Panel  
Item  
1
Description  
Remote display communication connector  
2
BTS1 (battery temperature sensor for bank 1) connector  
BTS2 (battery temperature sensor for bank 2) connector  
BTS3 (battery temperature sensor for bank 3) connector  
Battery negative, common for all 3 banks (6 mm stud)  
Battery positive for bank 1 (6 mm stud)  
Battery positive for bank 2 (6 mm stud)  
Battery positive for bank 3 (6 mm stud)  
Fan assembly  
3
4
5
6
7
8
9
10  
11  
Chassis ground (earth) for DC wiring  
AC wiring access panel  
975-0187-01-01  
1–7  
 
Introduction  
Preparing for Installation  
The XC Series is designed to be permanently mounted. Figure 1-1 shows a typical  
installation with three batteries, a BTS and a remote display. It also shows the AC  
and DC wiring and protection devices required for a successful installation.  
9
L
N
G
8
3
2
1
7
5
5
5
6
10  
4
6
6
4
4
Figure 1-5 XC Series System  
1
AC mains source with correct size and type of circuit breaker  
AC input wiring compartment  
2
3
DC negative cable  
4
DC positive cables  
5
DC circuit breaker or DC fuse and disconnect  
Battery or battery bank  
6
7
Engine ground bus or DC negative bus  
Remote display panel  
8
9
Battery temperature sensor (#1 is standard equipment. #2 and #3 are optional)  
DC chassis ground (earth)  
10  
1–8  
975-0187-01-01  
 
Preparing for Installation  
Tools and Materials  
To mount and connect the XC Series you need the following tools:  
•
•
•
•
•
•
10 mm wrench or socket for the DC terminals and ground stud  
Phillips screwdriver for securing the AC wiring compartment cover  
power drill  
drill bit for pilot holes for mounting screws  
wire stripper  
manufacturer's recommended crimp tool for any crimp terminals that are being  
used  
You need the following materials:  
•
3 conductor AC input wiring  
Use the information in “AC Wiring” on page 1–13 and your local electrical  
codes to determine the correct wire and breaker or fuse.  
•
•
AC cable strain relief (if the one included is not sufficient for your local  
electrical code requirements)  
appropriately sized DC cables for each battery, with suitable connectors at the  
battery end  
•
•
•
•
•
appropriately sized DC chassis ground (earth) with suitable connectors  
ring terminals to fit 6 mm (1/4 in.) studs at the charger end  
DC fuse and disconnect or circuit breaker for each battery bank  
mounting hardware, 3 mm (#6) corrosion resistant 6 pieces.  
other means to route and secure AC and DC wiring  
975-0187-01-01  
1–9  
 
Introduction  
Location  
Install the XC Series in a location that meets the following requirements:  
Condition Requirement  
Dry  
The XC Series must be installed in a dry location not subject to rain, spray or splashing  
bilge water.  
Clean  
Cool  
The XC Series should not be exposed to metal filings or any other form of conductive  
contamination.  
The ambient air temperature should be between 0 °C - 50 °C (32 °F - 122 °F) for best  
performance.  
Ventilated There must be at least 76 mm (3 in.) of clearance on each end of the XC Series for air  
flow. Ventilation openings on the unit must not be obstructed. If mounting in a tight  
fitting compartment, the compartment must be ventilated with cut-outs to prevent  
overheating.  
Safe  
This battery charger is ignition protected, so it can be installed in areas containing  
gasoline tanks or fittings which usually require ignition protected equipment. Xantrex  
recommends, however, that it is safest not to install electrical equipment in these areas.  
Close to  
batteries  
The XC Series should be installed as close as possible to the batteries, but not in the  
same compartment to prevent excess corrosion. Avoid excessive cable lengths and use  
the recommended wire sizes. Xantrex recommends <3% wire voltage drop (round  
circuit) on battery cables under full load.  
When planning where and how to mount the XC Series, be sure the installation  
allows the charger to be mounted in one of the permitted vertical or horizontal  
orientations.  
For marine installations, only the mounting configurations with a check mark in  
Figure 1-6 meet the North American and European marine requirements. Marine  
products are required to meet drip tests, to ensure safety in the presence of  
condensation. If you are certain your installation is not subject to moisture,  
configuration d) in Figure 1-6 may be used.  
1–10  
975-0187-01-01  
 
Preparing for Installation  
a)  
c)  
b)  
Vertical - this configuration is unsafe and  
should not be used  
Vertical  
d)  
Vertical - this configuration may be used  
in an environment which is dry and clean  
only (non-marine)  
Horizontal  
Figure 1-6 XC Series Mounting Orientations  
975-0187-01-01  
1–11  
 
Introduction  
Wiring Requirements  
WARNING  
Wire and fuse sizes are dictated by electrical standards. Different standards apply in  
different countries and different types of installations, for example, boat, home or RV. It is  
the responsibility of the installer to ensure that the installation complies with all applicable  
standards.  
CAUTION  
Ensure that both wires and fuses are correctly sized.  
Maximum continuous current available from the charger may be an additional 6–10% above  
the nominal current rating of the charger. Output current may also vary depending on  
ambient temperature conditions.  
DC Wiring  
The following two tables show some typical wire sizes, based on 3% voltage drop  
(round circuit), 75 °C (167 °F) rated wire and wiring being inside the engine  
compartment – assumed ambient of 50 °C (122 °F).  
Table 1-1 DC Wiring Requirements  
Wire Length  
(maximum length one way)  
Wire Size (AWG and mm2)  
feet  
meters  
1.5  
XC3012  
XC5012  
XC2524  
XC1524  
5
No. 10  
5 mm2  
No. 6  
13 mm2  
No. 10  
5 mm2  
No. 12  
3 mm2  
7.5  
20  
2.25  
6
No. 8  
No. 6  
No. 10  
5 mm2  
No. 12  
3 mm2  
8 mm2  
13 mm2  
No. 6  
13 mm2  
No. 4  
19 mm2  
No. 10  
5 mm2  
No. 12  
3 mm2  
1–12  
975-0187-01-01  
 
Preparing for Installation  
Over-current protection disconnect  
The DC circuit from the battery to the charger must be equipped with a disconnect  
and over-current protection device. The device usually consists of a DC-rated  
circuit breaker, a “fused disconnect”, or a separate fuse and disconnect. These  
devices must be rated for DC voltage and current. Do not substitute devices rated  
only for AC voltage; they may not operate properly.  
The current rating of the DC fuses must be matched to the size of the DC wiring  
used, in accordance with the applicable codes.  
The DC chassis ground (earth) should not be more than one size smaller than the  
DC wiring size selected (see Table 1-1). Refer to your local electrical codes for  
verification.  
AC Wiring  
The AC wiring must meet the following requirements before you install the  
XC Series:  
The AC input wiring for the XC Series should be three-conductor cable, providing a  
line, neutral, and ground conductor (or L1, N, GND) in an outer jacket.  
For example, in North America for 120 VAC use a 14 AWG wire with a 15 A  
breaker; or typically in Europe for 230 VAC use either a 2.5mm2 wire with a 16 A,  
double pole breaker or fuse or use 1.5 mm2 wire with a 10 A, double pole breaker or  
fuse. Note that every jurisdiction will have different requirements, so see the  
regulations for your local jurisdiction to determine which wire size and type is  
correct. A second example:  
•
for marine applications the United States ABYC requires stranded wire, which  
is more robust than solid wire when exposed to vibration  
•
for RV applications, the United States NEC allows solid wire in multi-  
conductor cable, but stranded wire will withstand vibration better.  
The circuit supplying the XC Series must be protected by the correct size and type  
of breaker to meet the code for your local jurisdiction and application. If a fuse is  
used, a disconnect switch is needed ahead of the fuse.  
975-0187-01-01  
1–13  
 
Introduction  
Battery Bank Size Requirements  
The XC Series is designed to work with a minimum battery bank size. Each bank  
should meet the minimum Ah rating shown in Table 1-2.  
Table 1-2 Minimum Battery Bank Size  
Models  
XC 1524  
XC 2524  
XC 3012  
XC 5012  
30  
50  
60  
100  
Minimum Battery  
Bank Size (Ah)  
1–14  
975-0187-01-01  
 
Installation  
2
Chapter 2 provides procedures for installing, testing  
and configuring the XC Series.  
The unit is packed with the following materials:  
•
•
•
•
•
•
•
•
Owner’s Guide  
AC cable strain relief  
Two DC cable boots  
Blank plate for remote display cavity  
One battery temperature sensor (BTS)  
Five #6 lockwashers  
Five #6 flatwashers  
Five #6 nuts  
After unpacking the unit, record the serial number and  
other purchase information on page WA–4 of this  
guide.  
 
Installation  
Installing the XC Series  
WARNING: Shock and Energy Hazards  
Be sure to read the safety guidelines and pay attention to all cautions and warnings  
throughout the installation procedure. The installer is responsible for ensuring compliance  
with the installation codes for your particular application.  
Disconnect all sources of AC and DC power before proceeding.  
Installation Sequence  
To make charger installation quick and easy, Xantrex recommends that the  
installation tasks be performed in the following sequence:  
1. Select charger mounting position and plan AC and DC cable routing (page 1–8)  
2. Install DC cable runs and fuses or breakers (page 2–3)  
3. Make the AC connections at the charger (page 2–4)  
4. Mount the remote display and charger in position (page 2–7)  
5. Make the final DC and then AC cable connections (including earth grounds)  
(page 2–10)  
2–2  
975-0187-01-01  
 
Installing the XC Series  
Pre-Installing DC Wiring  
The procedure for installing the DC wiring applies to a single battery or multiple  
batteries or battery banks.  
WARNING: Shock or arc burn hazard  
To help prevent accidental shorts or sparks, leave the DC disconnects or breakers in the Off  
position or fuses removed from their fuse holders until installation is complete.  
Important: Xantrex recommends that you install the rubber boots over the XC Series DC  
terminals to provide drip protection and increased protection from short circuits. You need  
to install the boots before doing any other DC wiring. See “To install rubber boots:” on  
page 2–14.  
To install DC wiring:  
1. Identify the battery or bank that most frequently becomes deeply discharged.  
This bank will often be a deep cycle battery referred to as the House Bank on a  
boat, as opposed to an engine Start Battery. This high priority bank should be  
connected to bank 1 on the XC Series, which is the default bank.  
2. Plan the route that the DC wires will follow, keeping it as short as possible.  
Measure and cut the required wire length. Allow some extra length for  
connections and to provide slack in the wires.  
Note: The connection to the battery negative circuit may not be at a battery, but  
may be at an engine negative bus or a DC negative bus. If in doubt, consult the  
boat schematics.  
3. Identify the positive wires, by using color-coded wire or by marking both ends  
of the wire with colored tape or similar kind of marking. 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 (–).  
4. Install a DC circuit breaker or fuse/disconnect in each positive cable close to  
each battery. For your applications and jurisdiction, consult your local electrical  
codes regarding the distance between the battery and the disconnect device. Be  
sure the breaker is open or fuse is not inserted at this time.  
975-0187-01-01  
2–3  
 
Installation  
5. Route the wiring to the batteries and to the XC Series, but don’t connect it yet.  
Avoid routing wiring through an electrical distribution panel, battery isolator, or  
other device that will add voltage drops.  
6. Install crimp lugs on each end of the battery cables using the crimp  
manufacturer’s instructions and tool.  
7. Install rubber boots over the charger end of the DC cables.  
Xantrex recommends that you install rubber boots over the XC Series DC  
terminals to provide drip protection. Follow the procedure on page 2–14 to  
install rubber boots.  
8. Route the battery temperature sensor from each battery to the charger location.  
9. Proceed to “Pre-Installing AC Wiring”.  
Pre-Installing AC Wiring  
Before connecting AC wiring, make sure the AC source circuit is protected by a  
breaker switch of the correct size and type, to comply with the electrical code for  
your location and application.  
To install AC wiring:  
1. Disconnect the AC source by turning off the breaker feeding the circuit,  
unplugging from shorepower and disconnecting any other power sources (such  
as a generator).  
2. Plan the route that the AC wiring will follow from the source (usually an AC  
distribution panel) to the XC Series. Measure and cut the required length of  
three-conductor cable.  
For example, in North America for 120 VAC use a 14 AWG wire with a 15 A  
breaker; or typically in Europe for 230 VAC use either a 2.5mm2 wire with a  
16 A, double pole breaker or fuse or use 1.5 mm2 wire with a 10 A, double pole  
breaker or fuse. Note that every jurisdiction will have different requirements, so  
see the regulations for your local jurisdiction to determine which wire size and  
type is correct.  
Allow some extra length for connections and to provide slack.  
3. Make the AC connections to the back of the charger when it is sitting on a table  
or other convenient work surface.  
Route the AC cables to the source after the charger is mounted in position.  
4. Unscrew the wiring compartment cover from the left rear of the XC Series to  
expose the AC wiring access hole.  
2–4  
975-0187-01-01  
 
Installing the XC Series  
5. Install the cable strain relief on the XC Series end of the source AC cable.  
6. Carefully remove 50 – 75 mm (2 – 3 in.) of the outer jacket, being careful not to  
cut or nick the insulation on the individual conductors.  
7. Pull the XC Series pigtail wires out through the access hole.  
8. Thread the source AC cable through the knockout beneath the wiring  
compartment cover and then pull it out through the access hole.  
9. Connect the AC wiring to the XC Series pigtail wires, being sure to connect the  
line conductor to the line, the neutral to the neutral, and the ground to the  
ground. The pigtail wires are color coded as follows:  
Conductor  
Line  
Color code  
Black or brown  
White or blue  
Neutral  
Ground  
Green with yellow stripe  
10. Make the connections with twist-on or crimp-on connectors or with other  
approved connectors suitable for your installation. For example, the ABYC  
Standards and Recommended Practices for Small Craft prohibit twist-on  
connectors for AC connections on a boat. For non-marine installations in  
locations not subject to vibration, either type of connector may be used.  
For marine installations, follow the procedure for installing butt splice  
connectors.  
975-0187-01-01  
2–5  
 
Installation  
To connect AC wires with the crimp-on butt-splice connector:  
Important: You must exercise care when crimping butt-splice connectors. Use the  
crimp tool recommended by the manufacturer for the connector used.  
a) Using a wire stripper, carefully strip 8 mm (5/16 in.) from the ends of the  
two wires being connected.  
b) 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 crimping tool,  
and crimp firmly. The proper location for the crimp is approximately  
1.6 mm (1/16 in.) past where the butt-splice insulation tapers down as  
shown.  
1/16 “  
CRIMP TOOL  
STRIP 5/16”  
c) Repeat Step b for the other end of the butt-splice.  
11. Push the AC cable strain relief into the electrical junction box hole until it snaps  
into place.  
12. When all connections are completed, push the wiring and connectors inside the  
wiring compartment. Install the wiring compartment cover and fasten with the  
supplied blunt-tip screws and lockwashers.  
2
1
13. Proceed to “Mounting the Remote Display”.  
2–6  
975-0187-01-01  
 
Installing the XC Series  
Mounting the Remote Display  
WARNING: Shock hazard  
Even if you intend to leave the remote display in the shipped orientation in the XC Series,  
you must remove the remote display and secure it in place by removing the non-stick  
backing on the rear and pressing the remote display flanges in place. If you do not use the  
non-stick backing, the XC Series will not be drip protected.  
To accommodate the charger mounting orientation, the remote display can be  
removed and turned 180 ° for readability. If you intend to mount the display  
remotely, up to 20 m (65 ft), remove the display before mounting the charger and  
secure the blank plate to cover the display socket on the unit.  
CAUTION  
Ensure you are placing the display in the correct orientation before removing the adhesive  
backing. The adhesive tape for attaching the remote is extremely strong and you may be  
unable to remove it without damaging the display or other equipment.  
To remove the display:  
1. Unplug the display cable from the telephone-type connector on the back of the  
unit.  
2. Release the display cable from the retaining clips on the underside of the unit.  
3. Remove the remote display from the charger and read and then remove the  
warning label that is attached to it.  
To secure the display or blank plate on the unit:  
1. Choose the display orientation that is appropriate for the charger orientation.  
2. Remove the adhesive backing on the back of the display or blank plate .  
3. Line up the display or blank plate with the display socket, making sure it is in  
the chosen orientation.  
4. Firmly press the flanges in place. Do not press in the middle of the display.  
5. Route the display’s North American style telephone-type cable under the unit  
and plug the cable into the bottom connector on the rear panel of the unit.  
975-0187-01-01  
2–7  
 
Installation  
To remotely mount the display:  
1. Remove the display as described on page 2–7.  
2. Secure the blank plate in the display socket as described.  
3. Ensure that the extension cable used for the remote display is long enough to  
suit the installation. A standard North American style, 4 conductor (RJ-11)  
telephone cable extender is adequate.  
4. Use the enclosed mounting template to cut a hole for the display in the chosen  
mounting surface.  
Take care that there is nothing behind the surface for you to damage.  
5. Feed the remote display extension cable through the hole and route it to the  
charger. Be careful not to damage the telephone connector locking tab when  
routing the cable. You can use some tape to protect the locking tab from  
catching on something and breaking off when routing the cable.  
6. Remove the adhesive backing on the back of the display.  
7. Line up the display with the mounting hole.  
8. Firmly press the flanges in place. Do not press in the middle of the display.  
9. Once the XC Series is mounted, plug the cable into the bottom connector on the  
rear panel of the XC Series.  
10. Proceed to “Mounting”.  
Mounting  
Mount the XC Series using the mounting slots provided.  
For marine installations, only the mounting configurations with a check mark in  
Figure 1-6 on page 1–11 meet the North American and European requirements.  
This is to ensure that any moisture that may be present will not enter the XC Series.  
Important: Be sure to measure your AC and DC cables and plan the routing of the cables  
before drilling the pilot holes for mounting the XC Series.  
To mount the XC Series:  
1. Keep the carton and packing material in case you need to return the XC Series  
for servicing.  
2. Ensure that you have selected a mounting surface that is clear, flat and allows  
for a minimum of 76 mm (3 in.) of clearance on each end for fan circulation.  
2–8  
975-0187-01-01  
 
Installing the XC Series  
3. Secure the enclosed mounting template to the mounting surface with tape.  
4. Drill the six pilot holes for the mounting screws, taking care that there is  
nothing behind the surface that can be damaged by the drill.  
5. Mount the XC Series using corrosion resistant, #6 (3 mm) round, pan head (or  
similar) screws.  
The top two keyhole-style mounting holes can be used to hold the XC Series in  
place while fastening the bottom four screws. For secure, permanent mounting,  
use all six mounting slots.  
Grounding  
WARNING: Electric shock hazard  
Do not make an ungrounded installation. Have an electrician install a properly grounded  
circuit if one is not available. Improper connection can result in risk of an electric shock.  
The XC Series Battery Charger must be grounded to reduce the risk of electrical  
shock. The AC input ground wire of the charger must be properly connected to  
ground in accordance with the applicable electrical codes, this is usually a ground  
terminal in the AC distribution panel where the branch circuit originates.  
Xantrex recommends that you install a DC chassis ground (earth) from the ground  
stud on the XC Series to the engine negative bus or DC ground bus. The DC chassis  
ground (earth) should not be more than one size smaller than the power conductors,  
and must be rated for the battery fuses that are used to protect the DC wiring. Refer  
to your local electrical codes to verify if this is required in your jurisdiction or in  
your application.  
Proceed to “Final Connections”.  
975-0187-01-01  
2–9  
 
Installation  
Final Connections  
Once the DC cables, AC cables and XC Series are all in place the final connection  
may be made.  
Figure 2-1 shows the connection order.  
4
3 2 1  
14  
8
15  
5
10  
9
11  
13  
6
7
12  
Figure 2-1 DC Wiring Connection Order  
2–10  
975-0187-01-01  
 
Installing the XC Series  
Final DC Connections  
WARNING: Shock hazard  
Make sure that the DC fuse or circuit breaker is still open.  
To make the last DC connections:  
1. Connect the negative cable from the negative terminal on the battery (if you are  
using only one battery or bank), or the negative ground bar or bus (if you are  
using more than one battery or bank), to the negative DC terminal on the  
XC Series (Figure 2-1). Use a flatwasher, a lockwasher and a nut (5 included in  
the installation kit) to secure the connection.  
Tighten the nuts to 3 N-m (30 lb-in.) torque and test that the wire is secure.  
2. Connect each positive cable to the correct positive DC terminal on the  
XC Series (Figure 2-1). Use a flatwasher, a lockwasher and a nut (5 included in  
the installation kit) to secure the connection.  
Tighten the nuts to 3 N-m (30 lb-in.) torque and test that the wire is secure.  
3. Connect the free end of each positive cable to the correct positive terminal of  
the battery, using sufficient torque as recommended by your battery  
manufacturer.  
4. Connect the free end of the negative cable to the negative terminal on the  
battery, using sufficient torque as recommended by your battery manufacturer.  
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.  
5. Before proceeding, carefully check the wiring polarity – make sure the positive  
terminals of the XC Series are connected to the correct terminals of the battery  
(fuses or breakers) and from there to the positive terminals of the battery. Make  
sure the negative terminal of the XC Series is connected to the battery negative  
terminal (or engine negative bus/DC negative bus). Do not reverse the  
connections.  
6. Install the DC chassis ground (earth) from the ground stud on the XC Series to  
the engine negative bus or DC ground bus.  
7. Connect the BTS cable and the remote display cable to the rear of the charger.  
975-0187-01-01  
2–11  
 
Installation  
8. Secure cables in place using tie-wraps, P-clamps or cable straps according to  
electrical codes. Coil and tie any extra BTS or remote display extension cable.  
9. The DC breakers may be closed or fuses inserted at this time.  
Final AC Connections  
To make the last AC connections:  
1. Complete the installation by routing the AC cable to the AC source.  
2. Connect the AC cable to the AC disconnect breaker and ground in accordance  
with the color codes on page 2–5.  
3. Secure cables in place using tie-wraps, P-clamps or cable straps according to  
electrical codes.  
Powering Up  
Make one last check that all connections and connectors are secure.  
The XC Series charger may now be powered up. Switch the AC power on at the  
source breaker. It is normal to see a 7-10 second delay while the unit powers up.  
During this time, the indicator lights on the onboard status panel and the remote  
display will not display any information.  
At very low AC source voltages (for example, less than 105 VAC) the start up time  
will increase proportionally up to as much as 40 seconds.  
2–12  
975-0187-01-01  
 
Installing Optional Accessories  
Installing Optional Accessories  
The XC Series ships with a battery temperature sensor (BTS) and drip protection  
rubber boots for the DC cables.  
Battery Temperature Sensor  
Xantrex strongly recommends that you install a Battery Temperature Sensor (BTS)  
to protect your battery and improve charging accuracy. 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 with your XC Series and additional battery temperature  
sensors may be purchased separately.  
To install a BTS:  
1. Switch off all devices operating from the battery.  
2. Connect the ring terminal on the sensor directly on to the negative battery stud,  
or affix the double-sided adhesive backing (included) to the sensor back and  
attach the sensor to the side of the battery to be monitored.  
3. Route the sensor cable to the charger and plug it into the bank 1 (default if using  
only one BTS), bank 2 or bank 3 connector on the rear panel.  
975-0187-01-01  
2–13  
 
Installation  
Drip Protection Rubber Boots  
Xantrex recommends that you install the supplied rubber boots over the XC Series  
DC terminals to provide drip protection.  
To install rubber boots:  
1. Before making the DC connections to the charger, feed the rubber boot over the  
charger end of the DC cables.  
2. Perform all other DC connections as described in “To install DC wiring:” on  
page 2–3.  
3. After the DC cables are connected to the charger, slide the boot up the cables  
and over the DC terminals. If you are only using one battery, slide the spare  
boots over the unused DC terminals.  
2–14  
975-0187-01-01  
 
Configuring the XC Series  
Configuring the XC Series  
Once the charger is connected to a battery on bank 1 or to AC, it is live and it may  
be configured. There will be a short delay of about 15 seconds before the remote  
display begins reporting. The remote display will use this time to query the charger  
for the current operating conditions.  
If AC was already applied, ensure that the charger is in on by pressing ON/STANDBY  
if necessary.  
To configure the battery bank type:  
1. Press and hold MODE until  
(setup) is displayed.  
2. Press TYPE to select the battery type configuration programming mode.  
The XC Series will default to Bank 1 and will show the present battery type  
setting.  
3. Press BANK repeatedly to select which bank you are setting up. The bank  
indicator light will illuminate to show which bank has been selected.  
4. Press TYPE repeatedly to select the battery type for each bank. When you have  
selected a battery type that is different from the present configuration, the bank  
indicator light flashes.  
Set the TYPE according to the table below:  
If your battery is  
then select  
Flooded Lead Acid (has removable caps intended for refilling)  
GEL (any sealed type except AGM)  
Absorbed Glass Mat (AGM)  
Lead Calcium  
Custom (if pre-configured at factory)  
5. Press and hold ON/STANDBY until  
is displayed to store the selected battery  
type. If  
is displayed, verify that you are setting the correct battery type and  
try again.  
6. Repeat steps 1 through 4 for all banks attached to the XC Series. Each time  
is displayed for a newly programmed battery type, the charger exits the  
programming mode.  
7. At any time during setup, you can press ON/STANDBY once to cancel the current  
change and return to charging or battery monitoring.  
975-0187-01-01  
2–15  
 
Installation  
To configure the charging type:  
1. Press and hold MODE until  
(setup) is displayed.  
2. Press MODE to select 2-stage ( ) or 3-stage ( ) charging. When you have  
selected a charging type that is different from the present configuration, the  
bank indicator light flashes.  
See “About Charging” on page 3–2.  
3. Press and hold ON/STANDBY until  
is displayed to store the selected mode.  
4. At any time during setup, you can press ON/STANDBY once to cancel the current  
change and return to charging or battery monitoring.  
2–16  
975-0187-01-01  
 
Operation  
3
Chapter 3 describes the operating states and provides  
procedures for charging a battery and performing an  
equalization.  
 
Operation  
About Charging  
The XC Series has three full current rated, independently controlled outputs which  
enable it to charge three different batteries or battery banks. Each output can  
accommodate any one of the four allowable battery types, regardless of what  
battery types are connected to the other outputs. Each output can be in a different  
stage of charge, ralative to the other banks; for exampe, Bank 1 in float, Bank 2 in  
absorption and Bank 3 in bulk. Each bank can accommodate a separate battery  
temperature sensor. The XC Series can also perform either multiplex (3 stage)  
charging, or sequential (2 stage) charging.  
Important: The battery banks are not galvanically isolated from each other. They share a  
common negative.  
Multiplex 3-Stage Charging  
In multiplex charging mode the charger will check all qualified battery banks every  
15 seconds to determine which bank is most in need of charging. That bank will  
then be charged for the next 15 seconds. Every 15 minutes the charger will query all  
outputs and detect which battery banks are present and healthy.  
The multiplex charging mode employs the 3-stage charging algorithm: Bulk,  
Absorption, and Float. During the Bulk stage the battery is accepting high current.  
In the Absorption stage the battery voltage is held constant and the current declines.  
A battery will also "gas" (produce hydrogen and oxygen) during this stage. 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, however, is able to provide current to  
its full rating to power DC loads on the battery. In float, if batteries are very new or  
a battery is on the low end of the size range and if it is fully charged to the point  
where it will not accept any more current, then the charger will enter an adaptive  
float/no float behaviour where it will alternate between float charging ( ) and  
resting the battery ( ).  
The charger will restart the charging cycle in the Bulk stage if the battery voltage  
drops below 12.5 V (12 V units) or 25 V (24 V units) for 15 minutes. After 21 days,  
the charger will automatically restart charging in order to refresh the batteries.  
3–2  
975-0187-01-01  
 
About Charging  
Sequential 2-Stage Charging  
In sequential charging mode the charger will check all battery banks every 15  
minutes to determine which banks are present, healthy, and in most in need of  
charge. The bank most in need of charge will then be charged for the next 15  
minutes.  
The sequential charging mode employs the 2-stage charging algorithm. It is the  
same as the 3-stage algorithm except that there is no float stage; after the absorption  
stage the charger stops providing voltage and current to the battery and enters a  
"rest stage". Like the 3-stage algorithm, the charger will restart the charging cycle in  
the Bulk stage if the battery voltage drops below 12.5V (12 V units) or 25 V (24 V  
units) for 15 minutes. After 21 days, the charger will automatically restart charging  
in order to refresh the batteries.  
Charging Overview  
The XC Series will perform a battery detection sequence every 15 minutes, or on  
reapplication of AC, to determine which battery banks are present and healthy.  
If you connect a battery when AC is disconnected, the remote will not recognize it  
until the unit has performed a battery detection with AC applied.  
To force a battery detection sequence,  
1. Turn off AC.  
2. Wait approximately 20 seconds or until all lights on the charger or remote have  
gone out .  
3. Turn on AC.  
The charger will then perform a battery detection when AC is reapplied  
The charger does not charge the banks in a pre-determined sequence. The bank  
most in need of charging is the one that receives the charge. For example, if Bank 1  
and Bank 2 are both charged, but Bank 1 has a load and Bank 2 does not, then the  
charger may rarely charge Bank 2.  
975-0187-01-01  
3–3  
 
Operation  
Disqualified Batteries  
The XC Series can identify when a battery will not accept a charge (battery is  
damaged) or when it is fully charged (healthy) and does not require further charge.  
Batteries that will not accept a charge will be removed (disqualified) from the  
charging sequence until all banks are checked again (every 15 minutes). A damaged  
battery will continue to be disqualified each cycle and the charger will not waste  
energy trying to charge it. Under some conditions it is also possible that a healthy  
battery that is fully charged but unable to accept current (for example, at the  
moment it transitions from Absorption to Float or Rest) will be deemed unable to be  
charged and temprarily removed from the charging sequence. The charger will enter  
an adaptive float/no float behaviour where it will alternate between float charging  
(
) and resting the battery ( ) and the 25% Charge Current indicator light on  
the onboard status panel will flash. The battery will be evaluated every 15 minutes  
and added back to the charging sequence when it is later able to accept charge.  
If disqualification occurs during Bulk or Absorption, the battery is damaged or  
there is another charging source present other than the charger itself. The remote  
display will show  
and the 25% Charge Current indicator light on the onboard  
status panel will flash.  
Measuring Battery Voltage  
Use a voltmeter that has a stated accuracy of 0.5% or better on DC voltage. Place  
the probes of the meter directly on the studs or plates of the charger terminals. Do  
not probe on the wire lugs or other places in the battery wiring system as this will  
introduce error into the measurement: the charger monitors battery voltage as  
measured at the charger terminals.  
Temperature Considerations  
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.  
3–4  
975-0187-01-01  
 
About Charging  
Things to be aware of  
When the XC Series is operating, fans and lights (DC loads) may vary in speed or  
intensity. This is normal. The XC Series will not harm any load connected to it as  
long as there is a battery present on that bank.  
When you initially turn the XC Series on and configure it, it is possible that some  
banks may be disqualified. Because the charger is able to detect unhealthy batteries  
and disqualify them, batteries that may have appeared healthy before will now be  
correctly identified as needing attention.  
Perform these disqualification checks in the order shown:  
1. Wait 15 minutes for the next battery detection cycle. The warning may be  
temporary.  
2. Verify that the battery meets the minimum AmpHour rating (XC1524: 30 Ah,  
XC2524: 50 Ah, XC3012: 60 Ah, XC5012: 100 Ah)  
3. Try adding a small DC load.  
4. Replace the battery.  
975-0187-01-01  
3–5  
 
Operation  
Charging Batteries  
Before you start to charge batteries read the “Important Safety Instructions” on  
page v and follow all safety precautions when working with batteries.  
To charge your batteries:  
1. If possible, disconnect all loads from the battery, by opening a disconnect  
switch, or by switching the loads off.  
2. Ventilate the area around the battery thoroughly. Review the charging  
instructions supplied by the manufacturer of your batteries and take any steps  
required.  
3. Apply AC power to the XC Series by closing the AC breaker and/or applying  
shorepower or turning the generator on. The indicator lights will blink as an  
initialization sequence runs, lasting typically 10 seconds. After initialization the  
charging indicator light illuminates.  
During charging, the charging current indicator lights show the total current  
being delivered to the selected battery bank as well as any DC load applied.  
4. Re-connect all loads to the battery, by closing a disconnect switch, or by  
switching the loads on.  
The batteries can be in one of six different stages:  
Mode  
Remote Display  
Bulk mode  
Absorption mode  
Rest mode (2-stage charging)  
Float mode (3-stage charging)  
Equalize mode  
Battery fault  
3–6  
975-0187-01-01  
 
Charging Batteries  
After charging is complete, the XC Series enters into one of these modes:  
Float mode When the ready indicator light illuminates, all batteries are fully  
charged and ready for use. If you selected the 3-stage charging mode, the XC Series  
is in float mode and will maintain the batteries’ charge.  
Rest mode If you selected the 2-stage charging mode, the ready indicator light  
shows the charger is now in rest mode and is checking battery voltage and elapsed  
time since the last charge cycle.  
With either charging mode, the XC Series will begin a charging cycle 21 days after  
the last cycle, or when battery voltage drops to below 12.5 V (12 V units) or 25 V  
(24 V units) for 15 minutes.  
975-0187-01-01  
3–7  
 
Operation  
Equalizing Flooded Batteries  
About Equalizing  
The XC Series equalizes only flooded lead-acid or lead-calcium batteries. It does  
not equalize sealed lead-acid batteries since they can be damaged by this process.  
In the following conditions the remote display will show and the XC Series will  
not enter equalization mode:  
•
•
the battery type is set for Gel or AGM  
any battery is not fully charged (all three battery banks must be charged to float  
or rest stage before equalization can be activated on any bank)  
•
there is an active fault on the battery you are trying to charge  
Xantrex recommends that you run a normal charge cycle on the batteries before you  
equalize them.  
WARNING: Explosion hazard  
During equalization, the battery generates explosive gases. Follow all the battery safety  
precautions listed in this guide. Ventilate the area around the battery thoroughly and ensure  
that there are no sources of flame or sparks in the vicinity  
CAUTION: Risk of battery damage  
The XC Series cannot automatically determine when to stop the equalization of a battery.  
You must monitor the battery specific gravity throughout equalization to determine the end  
of the equalize cycle. 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.  
3–8  
975-0187-01-01  
 
Equalizing Flooded Batteries  
Performing An Equalization  
Turn off or disconnect all DC loads on the battery during equalization. The voltage  
applied to the battery during equalization may be above the safe levels for some  
loads.  
To equalize your batteries:  
1. Check the battery electrolyte level. If necessary, refill with distilled water only.  
All the cells should have similar electrolyte levels. If the levels are widely  
different, it will influence the relative concentration of acid, thereby affecting  
the specific gravity measurements.  
2. Verify that all banks are in either float or rest mode.  
3. Press MODE and BANK at the same time.  
4. Press BANK to select which bank you wish to equalize. The bank indicator light  
will flash to show which bank has been selected.  
5. Press and hold ON/STANDBY to put the XC Series into equalization mode.  
You can cancel the equalization request by pressing ON/STANDBY once.  
If the battery cannot be equalized, the display will show  
Check that the battery is flooded and in float mode.  
.
6. When the charger is in equalize mode, the display will show  
.
7. Monitor the specific gravity of each cell of the battery during equalization with  
a battery hydrometer.  
The equalize cycle will terminate in one hour.  
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.  
8. The charger automatically exits equalization to float mode or rest mode after 1  
hour. To manually exit equalization mode early, press MODE and BANK at the  
same time and then press and hold ON/STANDBY.  
You can cancel the manual exit request by pressing ON/STANDBY once.  
9. When equalization has finished, check the battery electrolyte level. If  
necessary, refill with distilled water only.  
975-0187-01-01  
3–9  
 
Operation  
Transitioning the XC Series to On, Disabled or Off  
There are two ways to turn the XC Series on:  
•
•
connect AC power at the source  
press ON/STANDBY on the remote display if AC is still connected.  
There are two ways to disable the XC Series:  
WARNING: Shock hazard  
The XC Series still has live voltage while disabled. Even when AC power is removed, if the  
XC Series is connected to a battery on bank 1, the unit will take power from the battery. The  
only time the XC Series is de-energized completely is when both AC and DC are  
disconnected.  
•
•
disconnect AC power at the source  
press ON/STANDBY on the remote display.  
The XC Series continues to monitor the batteries, but will not charge them.  
There is only one way to safely turn the XC Series off:  
•
disconnect the AC power at the source and disconnect all DC batteries.  
This is the only state where the XC Series is completely discharged.  
When the XC Series is disabled or off, the remote display is inactive.  
3–10  
975-0187-01-01  
 
Accessing Charger Information  
Accessing Charger Information  
The XC Series can give you a lot of information about the status of the charger and  
the batteries.  
Reading Remote Display and Onboard Status Indicator Lights  
The remote display and onboard status panel show what is happening during the  
charging process and are also helpful in troubleshooting. Refer to Chapter 4,  
“Troubleshooting” for more information about interpreting the remote display and  
onboard status indicator lights.  
The remote display is designed to report on the active status of the charger. While  
the unit is charging, the remote display reports only on the battery being charged at  
that moment. It does not report the status of other batteries.  
The Ready light on the onboard status indicator panel only illuminates when all  
connected banks have reached float ( ) of 3-stage charging or rest ( ) of 2-  
stage charging. If one of the three batteries has been disqualified before it reaches  
float/rest stage, while the others have reached float ( ) of 3-stage charging or rest  
(
) of 2-stage charging, the Ready light on the onboard status indicator panel will  
not illuminate.  
975-0187-01-01  
3–11  
 
Operation  
Table 3-1 Reading XC Series Status  
Remote  
Charger Status  
Display Onboard Status Indicator Lights  
Charging in bulk or absorption mode.  
or Charging indicator light illuminates  
Remote display shows scrolling display of charging  
state, battery voltage in volts and charging current in  
amps.  
Indicator lights indicate the charging current in % of  
full charge. At transition points when the current is  
changing, two indicator lights may flash alternately,  
then settle into the new charging current reading.  
Equalizing.  
Charging indicator light flashes  
Charging indicator light flashes once every four  
seconds if bank 1 is being equalized, twice every four  
seconds if bank 2 is being equalized, and three times  
every four seconds if bank 3 is being equalized.  
Float mode of three stage charging or rest mode of  
two stage charging.  
All batteries have been fully charged.  
or Ready indicator light illuminates  
or 25% current indicator light flashes  
A battery has been disqualified while in float mode of  
three stage charging or rest mode of two stage  
charging.  
A battery has been disqualified while in bulk or  
absorption mode.  
25% current indicator light flashes  
Fault indicator light illuminates  
Non-charger fault condition.  
Any fault condition that prevents the charger from  
charging one or more banks, but is not a charger  
failure. Remote display shows details of fault.  
(example)  
3–12  
975-0187-01-01  
 
Accessing Charger Information  
Table 3-1 Reading XC Series Status  
Remote  
Charger Status  
Display Onboard Status Indicator Lights  
Battery too hot fault  
Fault indicator light illuminated  
100% current indicator light flashes  
Battery too cold fault  
Fault indicator light illuminated  
10% current indicator light flashes  
Charger fault condition.  
Fault indicator light flashes  
The charger is damaged, contact service.  
Reporting While Charging or Equalizing  
After configuration, the XC Series defaults to a scrolling display. As long as there  
are no faults or errors to report, the remote will display the following information,  
in order, for the bank presently being charged:  
•
•
•
Charging Stage  
Battery Voltage  
Charger Current  
If there is a fault or warning related to one of the banks, the fault or warning  
information will display in the scrolling display before the charging state for the  
bank presently being charged. Charging for banks not in fault will continue (see  
“Error Messages on Remote Display” on page 4–4). Charging for the bank in fault  
will resume once the fault condition is cleared.  
975-0187-01-01  
3–13  
 
Operation  
Reporting While Battery Monitoring  
The XC Series is considered to be battery monitoring if it is experiencing a charger  
level fault. If there is a charger level fault (affecting all banks), all charging will be  
suspended until the charger fault is resolved (see “Error Messages on Remote  
Display” on page 4–4).  
The remote will display all of the following, in order:  
•
•
•
•
•
•
•
•
•
•
•
•
•
Highest level charger fault or warning (if present)  
Bank 1 Highest level bank fault or warning (if present)  
Bank 1 Charging Stage  
Bank 1 Battery Voltage  
Bank 1 Charger Current  
Bank 2 Highest level bank fault or warning (if present)  
Bank 2 Charging Stage  
Bank 2 Battery Voltage  
Bank 2 Charger Current  
Bank 3 Highest level bank fault or warning (if present)  
Bank 3 Charging Stage  
Bank 3 Battery Voltage  
Bank 3 Charger Current  
Reporting While Disabled  
If AC power has been disconnected or if you have used the remote display to  
disable the XC Series the unit is considered to be disabled. The remote display is  
also disabled at this time.  
While the XC Series is disabled, you may wish to see the present status of the  
banks.  
To view the present status of the banks:  
◆ Press ON/STANDBY.  
If AC power is disconnected, the remote display will show one cycle (similar to the  
battery monitor cycle) for each bank that was qualified as present and healthy  
during the last battery detection cycle. The remote display will turn itself off after  
one complete cycle.  
3–14  
975-0187-01-01  
 
Accessing Charger Information  
◆ Press ON/STANDBY on the optional remote display to initialize another  
cycle.  
If AC power is connected, the XC Series will turn on, check which battery  
banks are present and healthy, and begin charging.  
While the XC Series is off, and a fault is present, the remote display will  
turn itself on approximately once per minute to show the fault and then turn  
itself off.  
Using A Generator As Source Power  
The XC Series can be run from a regular power source or from an alternate  
power source such as a generator. Refer to Appendix A, “Specifications” for  
AC input 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.  
The XC Series may be used with MSW generators but the lifetime may be  
reduced somewhat depending on the severity of any peak voltage  
overshoots, and the severity of waveshape risetimes.  
975-0187-01-01  
3–15  
 
3–16  
 
Troubleshooting  
4
Chapter 4 contains information on error codes and  
procedures for troubleshooting your XC Series  
charger.  
 
Troubleshooting  
Care and Maintenance  
WARNING: Risk of electric shock  
The XC Series contains no user serviceable components. Attempting any kind of service  
will void your warranty. Contact your dealer or the manufacturer for service information.  
The XC Series contains solid-state electronic components that require no  
maintenance. The best care you can give the unit is to protect it from contact with  
liquids, spray, or fumes which may cause corrosion. Disconnect all AC and DC  
power and clean the outside of the case and wiring with a damp cloth if you suspect  
it has come in contact with battery fluid, salt water, gasoline or oil, or other  
corrosive material. Periodically, 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.  
Loose battery terminals and lugs exposed to open air corrode rapidly. The corrosion  
appears as a white powder or granular foam on the terminals and any nearby  
exposed metal parts. If it contacts your skin, it will cause burns unless you rinse it  
off immediately. Most textiles that are exposed to this corrosive eventually dissolve.  
To clean battery terminals:  
1. Disconnect all loads and charging sources.  
2. Using the appropriate tool, remove the negative battery cable first and re-install  
it last.  
3. To remove any stubborn residue, sprinkle baking soda directly on the area,  
scrub with a wet toothbrush (or other soft-bristle brush), add water as required,  
and then rinse.  
CAUTION  
Take care not to allow any washing solution to enter the battery filling caps in the case of a  
flooded battery, as any contamination into a cell will chemically damage it.  
4. Reconnect the battery cable terminals to the battery lugs and tighten.  
5. After tightening the cables, evenly coat all the exposed metal surfaces of the  
battery terminals and lugs with liquid neoprene. If liquid neoprene is not  
available, use a light coating of anti-corrosion grease or other sealant. Do not let  
anything come between the mating surfaces of the lugs and terminals.  
4–2  
975-0187-01-01  
 
Indicator Light Flashing Sequences  
Indicator Light Flashing Sequences  
Table 4-1 Indicator Light Sequences on the XC Series  
Activity  
Charger status  
Charging indicator light illuminates The unit is charging in bulk or absorption mode  
Charging indicator light flashes  
The unit is performing the equalization charge.  
(Charging indicator light flashes once every four  
seconds if bank 1 is being equalized, twice every  
four seconds if bank 2 is being equalized, and  
three times every four seconds if bank 3 is being  
equalized)  
Ready indicator light illuminates  
Fault indicator light illuminates  
The unit is either in float mode of three stage  
charging or rest mode of two stage charging. All  
batteries have been fully charged.  
Any fault condition that prevents the charger from  
charging one or more banks, but is not a charger  
fault condition - remote display shows details of  
fault. Example:  
(battery reverse  
polarity detected)  
Fault indicator light flashes  
Charger fault condition - remote display shows  
followed by  
. The charger is damaged,  
contact service.  
Charging current indicator lights  
illuminate  
These lights indicate the charging current. At  
transition points when the current is changing, two  
indicator lights may flash alternately, then settle  
into the new charging current reading.  
Charging current indicator lights  
flash  
100% indicator light flashes to indicate battery  
temperature too high warning (> 50 °C, 122 °F)  
10% indicator light flashes to indicate battery  
temperature too low warning (< 0 °C, 32 °F)  
25% indicator light flashes to indicate that a  
battery has been disqualified (see page 3–4)  
Charging current indicator lights  
flash,  
Fault indicator light illuminated  
100% indicator light flashes to indicate battery  
temperature too high fault (> 55 °C, 131 °F)  
10% indicator light flashes to indicate battery  
temperature too low fault (< -20 °C, -4 °F)  
975-0187-01-01  
4–3  
 
Troubleshooting  
Error Messages on Remote Display  
Table 4-2 Error Messages  
Onboard Status Panel  
Display Indicator lights  
Fault  
Solution  
Red fault indicator light  
Fault  
A fault has been detected. The fault code  
flashing or illuminated  
will be shown immediately after  
.
AC Low  
Warning  
Check AC connections, check AC  
availability at source.  
Red fault indicator light  
illuminated  
Reverse  
Polarity  
Reverse Polarity Battery connected.  
Check connections. Ensure correct  
polarity (negative connected to negative,  
positive connected to positive).  
Red fault indicator light  
flashing  
Charger  
Hardware  
Fault  
Call for service.  
Over-  
temperature  
Warning  
Allow the XC Series to cool. Improve  
ventilation or install in cooler location. If  
the temperature increases, the XC Series  
will enter the fault level and stop  
functioning.  
Red fault indicator light  
illuminated  
Over-  
temperature  
Shutdown  
Allow the XC Series to cool. Improve  
ventilation or install in cooler location.  
Green 10% indicator light  
flashes  
Display green bank indicator  
light for affected battery bank  
illuminated  
Battery Too  
Allow batteries to warm up before  
Cold Warning attempting to charge again. Charging a  
battery that has frozen is a potential  
explosion hazard. If the temperature  
drops, the XC Series will enter the fault  
level and stop charging the affected bank.  
4–4  
975-0187-01-01  
 
Error Messages on Remote Display  
Table 4-2 Error Messages  
Onboard Status Panel  
Display Indicator lights  
Fault  
Solution  
Red fault indicator light  
illuminated  
Green 10% indicator light  
flashes  
Battery Too  
Cold  
Shutdown  
Allow batteries to warm up before  
attempting to charge again. Charging a  
battery that has frozen is a potential  
explosion hazard.  
Display green bank indicator  
light for affected battery bank  
illuminated  
25% current indicator light  
flashes  
Battery  
Disqualified  
Warning  
Wait 15 minutes for the next battery  
detection cycle. The warning may be  
temporary.  
Verify that the battery meets the minimum  
AmpHour rating (XC1524: 30 Ah,  
XC2524: 50 Ah, XC3012: 60 Ah,  
XC5012: 100 Ah)  
Try adding a small DC load.  
Replace the battery.  
Display green bank indicator Over Voltage  
Check battery. Do not charge a battery  
rated at more than 12 volts nominal  
(XC3012, XC5012) or 24 volts nominal  
(XC1524, XC2524).  
light for the affected battery  
bank illuminated  
Shutdown  
Warning  
Disconnect or turn off other charging  
sources such as the alternator or the  
charger on a generator with electric start.  
If the warning level escalates without  
being corrected, the XC Series enter the  
fault level and stop charging the affected  
bank.  
Red fault indicator light  
illuminated  
Display green bank indicator  
light for the affected battery  
bank illuminated  
Over Voltage  
Shutdown  
Check battery. Do not charge a battery  
rated at more than 12 volts nominal  
(XC3012, XC5012) or 24 volts nominal  
(XC1524, XC2524).  
Disconnect or turn off other charging  
sources such as the alternator or the  
charger on a generator with electric start.  
975-0187-01-01  
4–5  
 
Troubleshooting  
Table 4-2 Error Messages  
Onboard Status Panel  
Display Indicator lights  
Fault  
Solution  
Green 100% indicator light  
flashes  
Display green bank indicator  
light for the affected battery  
bank illuminated  
Battery too  
Hot Warning  
Allow battery to cool. Improve ventilation  
or install in cooler location. It may  
indicate a shorted cell in the battery or  
excessive water loss. If the temperature  
increases, the XC Series will enter the  
fault level and stop charging the affected  
bank.  
Red fault indicator light  
illuminated  
Green 100% indicator light  
flashes  
Battery too  
Allow battery to cool. Improve ventilation  
Hot Shutdown or install in cooler location. It may  
indicate a shorted cell in the battery or  
excessive water loss.  
Display green bank indicator  
light for affected battery bank  
illuminated  
Cannot apply The operation you have tried to execute  
change  
cannot be completed.  
Red fault indicator light  
illuminated  
No batteries  
detected  
The charger did not detect any batteries.  
4–6  
975-0187-01-01  
 
Problem Solving  
Problem Solving  
If the remote display is not functioning, troubleshoot your XC Series using the  
tables below. In the event that you have a problem with your XC Series, the  
following tables will help you to identify the problem and offer possible solutions to  
the problem.  
Symptom  
Indicator lights do not illuminate when charger is connected to AC power.  
Possible Cause  
Solution  
No power at AC source and no Ensure that power is available at the source and a  
battery connected on bank 1  
Defective AC wiring  
Charger level fault  
battery or bank is connected on bank 1  
Replace wiring  
Call for service  
Symptom  
Fault indicator light illuminates. XC Series stops functioning.  
Possible Cause  
Solution  
XC Series does not detect battery Check quality of battery connection and wires.  
for one of following reasons:  
Ensure correct polarity (negative connected to  
negative, positive connected to positive).  
•
•
•
poor connection  
reverse polarity connection  
damaged wiring  
XC Series internal temperature  
too hot  
Allow the XC Series to cool. Improve ventilation or  
install in cooler location.  
975-0187-01-01  
4–7  
 
Troubleshooting  
Symptom  
Fault indicator light flashes. XC Series stops functioning.  
Possible Cause  
XC Series hardware failure  
Solution  
Call for service  
Symptom  
Symptom  
Symptom  
Fault indicator light illuminates. 100% indicator light flashes.  
Possible Cause  
Solution  
Battery temperature is too hot for  
safe charging.  
Allow battery to cool. Improve ventilation or  
install in cooler location. It may indicate a shorted  
cell in the battery or excessive water loss.  
Fault indicator light illuminates. 10% indicator light flashes.  
Possible Cause  
Solution  
Battery temperature is too cold for  
safe charging.  
Allow batteries to warm up before attempting to  
charge again. Charging a battery that has frozen is  
a potential explosion hazard.  
XC Series completes a charging cycle, but the battery voltage seems (about 2 volts)  
too low.  
Possible Cause  
Solution  
Battery has a shorted cell.  
Check the battery.  
Verify you are attempting to charge a battery correctly  
rated at 12 volts nominal (XC3012, XC5012) or 24  
volts nominal (XC1524, XC2524). Re-check the  
battery voltage with all loads removed and the battery  
is at rest for about an hour.  
4–8  
975-0187-01-01  
 
Problem Solving  
Symptom  
The XC Series appears to be taking too long to charge battery. Ready indicator light  
does not illuminate after 24 hours of charging.  
Possible Cause  
Solution  
Battery capacity is too high for the Use a higher capacity charger.  
XC Series model.  
Load connected to battery is  
draining charge current so that  
battery does not recharge.  
Disconnect load or switch load off.  
Battery has a damaged cell.  
Replace battery.  
Symptom  
The XC Series will not transition to equalization mode.  
Possible Cause  
Solution  
Battery is the wrong type, or set to Verify battery type is set to Gel or AGM. These  
the wrong type to equalize.  
battery types cannot be equalized.  
Not all batteries are fully charged.  
Wait for all batteries to be in float (  
) of 3-stage  
charging or rest (  
) of 2-stage charging before  
attempting to equalize (the ready indicator light will  
illuminate).  
An active fault is present on the  
Clear the active fault (see Table 4-2 on page 4–4)  
bank you are attempting to equalize.  
975-0187-01-01  
4–9  
 
4–10  
 
Specifications  
A
Appendix A details the specifications for the  
XC Series.  
 
Specifications  
Physical Specifications  
Dimensions  
Base unit:  
367 mm x 240 mm x 106 mm  
14.45 in. x 9.45 in. x 4.17 in.  
Remote Display: 118 mm x 41 mm x 32 mm  
4.65 in. x 1.6 in. x 1.26 in.  
Weight  
5.7 kg (12.6 lbs)  
AC input connections Two color-coded No. 16 AWG wires (L, N) and one  
No. 18 AWG (G) minimum 152 mm (6 in.) long in a separate  
AC wiring enclosure with 21.3 mm (0.84 in.) hole provision for  
connection of a ½ inch North American "trade size" cable clamp  
or conduit hub or international PG 13.5 or PG16 or M20 gland or  
cable strain relief fitting.  
DC output connections Four right-angle M6 studs (3 positives and 1 common  
negative) for battery cable ring terminals and one M6 mm DC  
equipment ground  
Electrical Specifications  
Number of battery bank outputs  
3 isolated, independently controlled outputs  
Nominal battery voltage  
12 V units: 12 VDC  
24 V units: 24 VDC  
Normal operating output range  
12 V units: 0 – 16 VDC  
24 V units: 0 – 32 VDC  
Nominal operating AC voltage  
Rated DC output current (total)  
110 – 240 VAC  
XC3012: 30 A (up to 15 V)  
XC5012: 50 A (up to 15 V)  
XC1524: 15 A (up to 30 V)  
XC2524: 25 A (up to 30 V)  
Absorption voltage (in VDC for  
XC3012 and XC5012)  
(Multiply VDC by 2 to get the  
absorption voltage for XC1524  
and XC2524)  
50 °C (122 °F)  
13.7  
25 °C (77 °F) <0 °C (32 °F)  
Flooded  
Gel  
AGM  
14.4  
14.2  
14.3  
15.5  
15.1  
14.9  
14.8  
16.0  
13.5  
13.8  
Lead-calcium 14.8  
A–2  
975-0187-01-01  
 
AC Input Specifications  
Float voltage (in VDC for XC3012  
and XC5012)  
(Multiply VDC by 2 to get the  
float voltage for XC1524 and  
XC2524)  
50 °C (122 °F)  
12.8  
25 °C (77 °F) <0 °C (32 °F)  
Flooded  
Gel  
AGM  
13.5  
13.8  
13.4  
13.5  
14.2  
14.5  
13.9  
14.2  
13.1  
12.9  
Lead-calcium 12.8  
Equalize mode current  
50% rated output  
Equalize mode—maximum output XC3012: 16.0 VDC  
voltage  
XC5012: 16.0 VDC  
XC1524: 32.0 VDC  
XC2524: 32.0 VDC  
Off-state current draw (with  
remote installed)  
XC3012:  
XC5012:  
XC1524:  
XC2524:  
<20 mA  
<20 mA  
<15 mA  
<15 mA  
AC Input Specifications  
AC input voltage range  
100 – 260 VAC at full power  
90 – 105 VAC at 80% restricted load  
Note: Charger may not start with input voltage  
<100 VAC  
Maximum AC input current  
at 100 VAC  
at 184 VAC  
XC3012: 6 AAC  
XC5012: 10 AAC  
XC1524: 6 AAC  
XC2524: 10 AAC  
XC3012: 4.3 AAC  
XC5012: 5.7 AAC  
XC1524: 4.3 AAC  
XC2524: 5.7 AAC  
Power factor at rated load  
Frequency  
≥0.95  
47 – 63 Hz  
Efficiency – peak  
12 V units: 80% @ 120 VAC, 83% @ 230 VAC  
24 V units: 85% @ 120 VAC, 87% @ 230 VAC  
Surge protection  
Line-to-neutral surge protector rated at 275 VAC  
975-0187-01-01  
A–3  
 
Specifications  
Temperature Specifications  
Nominal ambient  
Operating range  
Current de-rating  
Storage  
25 °C (77 °F)  
0 – 50 °C (32 – 122 °F)  
approx. 2% (Imax) / °C (50 – 65 °C) (122 – 149 °F)  
-40 – 80 °C (-40 – 176 °F)  
Humidity  
5 – 95%, RH non-condensing  
Protection Features  
Battery reverse polarity  
No damage incurred by reverse polarity.  
Safe non-operating battery voltage 35 VDC maximum  
Over-voltage limits  
Output current limit  
Over-temperature  
The XC Series will stop charging any bank that has a  
voltage greater than + 0.5 V over the temperature  
compensated absorption voltage. It will restart when  
this voltage is + 0.2 V.  
XC3012: 30 – 33 ADC  
XC5012: 50 – 55 ADC  
XC1524: 15 – 16.5 ADC  
XC2524: 25 – 27.5 ADC  
Internal charger temperature is measured. Unit shuts  
down and restarts as follows:  
•
•
Over-temperature shutdown at 75 °C (167 °F)  
Over-temperature restart at 70 °C (158 °F)  
Current derating in ambient  
temperatures  
Rated current to 50 °C (122 °F)  
2%/ °C derating above 50 °C (122 °F)  
Battery over-temperature  
protection  
Battery temperature, as sensed by the battery  
temperature sensor (if installed), results in the  
charger no longer charging the individual battery or  
bank at a battery temperature of 55 °C (132 °F).  
A–4  
975-0187-01-01  
 
Approvals  
Approvals  
Safety  
CSA/NRTL approved to CSA107.2 and UL1236, including the marine  
supplement, ignition protection, and UL1564  
EN60335-1, EN60335-2-29 Battery Chargers  
ISO 8846: Ignition Protection for Small Craft  
ABYC E11 - Alternating Current and Direct Current Electrical Systems on  
Boats  
ABYC A20 - Battery Charging Devices  
NFPA70/1996 US NEC for home and RV installation requirements  
EMC  
Other  
FCC Class B  
CE marked, meeting EMC Directive 89/336/EEC (referencing EN55014-1,  
EN55014-2, EN61000-3-2, EN61000-3-3, EN61000-4-2, EN61000-4-3,  
EN61000-4-4, EN61000-4-5, EN61000-4-6, EN61000-4-11)  
CISPR25 (similar to SAE J1113-41) Class 1 on DC outputs  
KKK-A-1822 Rev D - Federal Specification for the Star-of-Life Ambulance  
975-0187-01-01  
A–5  
 
A–6  
 
Warranty and Product Information  
Limited Warranty for:  
Xantrex XC3012 Battery Charger  
Xantrex XC5012 Battery Charger  
Xantrex XC1524 Battery Charger  
Xantrex XC2524 Battery Charger  
"XC Series"  
What does this warranty cover and how long does it last? This Limited Warranty is provided by  
Xantrex Technology Inc. ("Xantrex") and covers defects in workmanship and materials in your Xantrex XC Series  
product. This warranty lasts for a Warranty Period of 24 months from the date of purchase at point of sale to you,  
the original end user customer. This Limited Warranty is transferable to subsequent owners but only for the  
unexpired portion of the Warranty Period.  
What will Xantrex do? Xantrex will, at its option, repair or replace the defective product free of charge,  
provided that you notify Xantrex of the product defect within the Warranty Period, and provided that Xantrex  
through inspection establishes the existence of such a defect and that it is covered by this Limited Warranty.  
Xantrex will, at its option, use new and/or reconditioned parts in performing warranty repair and building  
replacement products. Xantrex reserves the right to use parts or products of original or improved design in the  
repair or replacement. If Xantrex repairs or replaces a product, its warranty continues for the remaining portion of  
the original Warranty Period or 90 days from the date of the return shipment to the customer, whichever is greater.  
All replaced products and all parts removed from repaired products become the property of Xantrex.  
For United States and Canada returns, Xantrex covers both parts and labor necessary to repair the product, and  
return shipment to the customer via a Xantrex-selected non-expedited surface freight within the contiguous United  
States and Canada. Alaska and Hawaii are excluded. Contact Xantrex Customer Service for details on our freight  
policy for return shipments outside of the contiguous United States and Canada.  
How do you get service? If your product requires troubleshooting or warranty service, contact your dealer. If  
you are unable to contact your dealer, or the dealer is unable to provide service, contact Xantrex directly at:  
Phone:  
Fax:  
1 800 670 0707 (toll free North America)  
+34 93 470 5330 (Europe)  
1 360 925 5097 (direct and rest of world)  
1-800 994 7828 (toll free North America)  
+34 93 473 6093 (Europe)  
1 360 925 5143 (direct and rest of world)  
Email:  
[email protected] (North America and rest of world)  
[email protected] (Europe)  
Direct returns may be performed according to the Xantrex Return Material Authorization Policy described in your  
product manual. For some products, Xantrex maintains a network of regional Authorized Service Centers. Call  
Xantrex or check our website to see if your product can be repaired at one of these facilities.  
In any warranty claim, dated proof of purchase must accompany the product and the product must not have been  
disassembled or modified without prior written authorization by Xantrex.  
Proof of purchase may be in any one of the following forms:  
•
•
•
The dated purchase receipt from the original purchase of the product at point of sale to the end user, or  
The dated dealer invoice or purchase receipt showing original equipment manufacturer (OEM) status, or  
The dated invoice or purchase receipt showing the product exchanged under warranty  
975-0187-01-01  
WA–1  
 
Warranty and Product Information  
What does this warranty not cover? This Limited Warranty does not cover normal wear and tear of the  
product or costs related to the removal, installation, or troubleshooting of the customer's electrical systems. This  
warranty does not apply to and Xantrex will not be responsible for any defect in or damage to :  
a) the product if it has been misused, neglected, improperly installed, physically damaged or altered, either  
internally or externally, or damaged from improper use or use in an unsuitable environment;  
b) the product if it has been subjected to fire, water, excessive corrosion, biological infestations, or input voltage  
that creates operating conditions beyond the maximum or minimum limits listed in the Xantrex product  
specifications including high input voltage from generators and lightning strikes;  
c) the product if repairs have been done to it other than by Xantrex or its authorized service centers (hereafter  
"ASCs");  
d) the product if it is used as a component part of a product expressly warranted by another manufacturer;  
e) the product if its original identification (trade-mark, serial number) markings have been defaced, altered, or  
removed.  
DISCLAIMER OF WARRANTY  
THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN  
CONNECTION WITH YOUR XANTREX PRODUCT AND IS, WHERE PERMITTED BY LAW, IN LIEU OF  
ALL OTHER WARRANTIES, CONDITIONS, GUARANTEES, REPRESENTATIONS, OBLIGATIONS AND  
LIABILITIES, EXPRESS OR IMPLIED, STATUTORY OR OTHERWISE IN CONNECTION WITH THE  
PRODUCT, HOWEVER ARISING (WHETHER BY CONTRACT, TORT, NEGLIGENCE, PRINCIPLES OF  
MANUFACTURER'S LIABILITY, OPERATION OF LAW, CONDUCT, STATEMENT OR OTHERWISE),  
INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY,  
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY IMPLIED WARRANTY OF  
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED  
UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE  
PERIOD STIPULATED UNDER THIS LIMITED WARRANTY.  
IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR  
CONSEQUENTIAL DAMAGES, LOSSES, COSTS OR EXPENSES HOWEVER ARISING WHETHER IN  
CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND,  
ANY LOSS OR DAMAGE TO PROPERTY, ANY PERSONAL INJURY, ANY DAMAGE OR INJURY  
ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE, OR THE INCORRECT INSTALLATION,  
INTEGRATION OR OPERATION OF THE PRODUCT.  
Exclusions If this product is a consumer product purchased in the United States, federal law does not allow an  
exclusion of implied warranties. To the extent you are entitled to implied warranties under federal law, to the extent  
permitted by applicable law they are limited to the duration of this Limited Warranty. Some states do not allow  
limitations or exclusions on implied warranties or on the duration of an implied warranty or on the limitation or  
exclusion of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not apply to you.  
This Limited Warranty gives you specific legal rights. You may have other rights which may vary depending on the  
country, province, or state.  
WITHOUT LIMITING THE GENERALITY OF THE FOREGOING, UNLESS SPECIFICALLY AGREED TO  
BY IT IN WRITING, XANTREX  
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY  
TECHNICAL OR OTHER INFORMATION PROVIDED IN MANUALS OR OTHER DOCUMENTATION  
PROVIDED BY IT IN CONNECTION WITH THE PRODUCT; AND  
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES,  
WHETHER SPECIAL, 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.  
WA–2  
975-0187-01-01  
 
WARNING: LIMITATIONS ON USE  
Please refer to your product user manual for limitations on uses of the product. Specifically, please note that the  
Xantrex Battery Charger is not intended for use in connection with life support systems and Xantrex makes no  
warranty or representation in connection with any use of the product for such purposes.  
Xantrex Technology, Inc.  
8999 Nelson Way  
Burnaby, British Columbia  
Canada  
V5A 4B5  
Return Material Authorization Policy  
If your product requires warranty service, please contact your dealer first. If you are unable to contact your dealer,  
or your dealer is unable to provide service, contact Xantrex.  
Before returning a product directly to Xantrex you must obtain a Return Material Authorization (RMA) number and  
the correct factory "Ship To" address. Product shipments will be refused and returned at your expense if they are  
unauthorized returned without an RMA number clearly marked on the outside of the shipping box, if they are  
shipped collect, or if they are shipped to the wrong location.  
When you contact Xantrex to obtain service, please have your instruction manual ready for reference and be  
prepared to supply:  
•
•
•
•
The serial number of your product  
Information about the installation and use of the unit  
Information about the failure and/or reason for the return  
A copy of your dated proof of purchase  
When you ship:  
1.  
Package the unit safely, preferably using the original box and packing materials. Please ensure that your product is shipped  
fully insured in the original packaging or equivalent. This warranty will not apply where the product is damaged due to  
improper packaging.  
Include the following:  
2.  
•
•
•
•
The RMA number supplied by Xantrex Technology Inc clearly marked on the outside of the box.  
A return address where the unit can be shipped. Post office boxes are not acceptable.  
A contact telephone number where you can be reached during work hours  
A brief description of the problem  
Please contact Xantrex for details of the freight policy for your country of purchase. For United States and Canada  
returns, ship the unit prepaid to the address provided by your Xantrex customer service representative.  
If you are returning a product to a Xantrex facility in North America from outside of the USA or Canada: In  
addition to the above, you MUST include return freight funds and are fully responsible for all documents, duties,  
tariffs, and deposits.  
If you are returning a product to a Xantrex Authorized Service Center (ASC): A Xantrex return material  
authorization (RMA) number is not required. However, you must contact the ASC prior to returning the product or  
presenting the unit to verify any return procedures that may apply to that particular facility.  
975-0187-01-01  
WA–3  
 
Warranty and Product Information  
Information About Your System  
As soon as you open your Xantrex XC3012, XC5012, XC1524 or XC2524 Battery Charger package, record the  
following information and be sure to keep your proof of purchase.  
_________________________________  
_________________________________  
_________________________________  
❐
❐
❐
Serial Number  
Purchased From  
Purchase Date  
If you need to contact Customer Service, please record the following details before calling. This information will  
help our representatives give you better service.  
___________________________________________  
___________________________________________  
___________________________________________  
___________________________________________  
___________________________________________  
___________________________________________  
❐
❐
❐
❐
❐
❐
Type of installation  
Length of time charger has been installed  
Battery/battery bank size  
Battery type (e.g. flooded, sealed gel cell, AGM)  
DC wiring size and length  
Description of light indicators or remote display  
readout  
___________________________________________  
___________________________________________  
❐
❐
Appliances operating when problem occurred  
Description of problem  
___________________________________________  
_________________________________________________________________________________________  
_________________________________________________________________________________________  
WA–4  
975-0187-01-01  
 
 
Xantrex Technology Inc.  
Phone: 1 800 670 0707 (toll free North America)  
+34 93 470 5330 (Europe)  
1 360 925 5097 (direct and rest of world)  
Fax:  
1-800 994 7828 (toll free North America)  
+34 93 473 6093 (Europe)  
1 360 925 5143 (direct and rest of world)  
Email: customerservice@xantrex.com (North America)  
support.europe@xantrex.com (Europe)  
customerservice@xantrex.com (rest of world)  
Printed in Canada  
975-0187-01-01  
 

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