Double Your Charging Power with TRUEcharge3 Parallel Configuration: Step-by-Step Guide

If you have a large battery bank and you are looking to speed up charging, a parallel configuration with two TRUEcharge3 chargers is an ideal solution. By combining the output currents of two chargers, you essentially double the charging power, reducing downtime and ensuring that your power system is ready for action. This guide provides an in-depth look at the setup and installation process, with a focus on essential safety and functionality requirements.

Why Choose a Parallel Configuration?

In a parallel setup, two TRUEcharge3 chargers work in sync to provide a combined output current. For example, pairing two 40-amp TRUEcharge3 chargers results in an 80-amp charging capacity, ideal for larger battery banks that demand higher power to reach full charge quickly. Note: Parallel configuration requires the TRUEcharge3 Remote Panel (PN: 808-8040-10), which synchronizes the two chargers and ensures smooth, reliable operation.

Installation Pre-requisites

Before diving into the installation, ensure the following conditions are met to avoid equipment damage or inefficient operation:

Matching Output Voltage and Current: Both chargers must have the same output voltage and current rating. For instance, pair two 12V 40A chargers or two 24V 30A chargers, but never a 12V with a 24V or 20A with an 30A.

Remote Panel Requirement: Both chargers must be connected to the TRUEcharge3 Remote Panel to function in parallel.

Correct Mounting and Wiring: Install each charger securely and per the setup guide to prevent any operational issues.

Step-by-Step Guide for Setting Up a Parallel Configuration

Step 1: Mount the Chargers Securely

Choose a well-ventilated, dry location for each charger. Mount them following the specific instructions provided below:

• Connecting the DC Chassis Ground
• Locate the Ground Stud: Each charger has a dedicated ground stud for DC grounding.
• Connect to Ground Bus: Attach each charger’s ground stud to the ground bus using a flat washer, lock washer, and nut from the installation kit.
• Tighten: Secure the ground connection by tightening the nuts to 2.3 N-m (20 lb.-in.) torque. Avoid over-tightening, this may damage the equipment or compromise the connection.

Install DC Wiring

• Plan the Wiring Route: Plan a direct path for the DC wiring from each charger to the battery banks, ensuring a safe and efficient setup.
• Label Wires: Clearly mark positive and negative cables. Use red for positive and black for negative, as recommended by standard marine codes.
• Install Circuit Breakers: Place a DC circuit breaker or fused disconnect in each positive cable, close to the battery’s positive terminal.
• Connect the Wires: Route the cables from the chargers directly to the battery banks, avoiding intermediate devices that could cause voltage drops. Attach each wire securely to prevent looseness or shorts.

Install AC Wiring

• Route AC Wiring: Plan the route from the power source to each charger, ensuring the cables remain undamaged and properly secured.
• Prepare the Wires: Strip the outer insulation from the AC wiring, taking care to avoid damaging the inner conductors.
• Connect the AC Wires: Attach the AC supply wiring (L, N, G) to each charger, using the color-coded pigtail leads provided. Ensure that each connection is secure.
• Use a Double-Pole Breaker: Connect both chargers to the same AC circuit branch with a double-pole breaker. This setup synchronizes the chargers and helps avoid potential issues with unsynchronized currents.

Initial Power-Up for Parallel Setup

• Switch on DC Power: Start by closing the DC disconnect switches or breakers.
• Turn on AC Power: Next, turn on the AC breaker. You should see a brief delay as the chargers initialize, indicated by flashing LEDs on each unit.

Step 2: Designate Primary and Secondary Chargers

Once the chargers are powered up, select one as the primary charger and the other as the secondary. Only the primary charger (charger connected to the primary terminal on the remote panel) or the remote panel itself should be used to configure and control the parallel system.

Step 3: Configuring the Battery Banks

Connect Battery Banks: Link the positive and negative terminals of the primary charger’s battery bank 1 to the secondary charger’s battery bank 1. Repeat this step for battery banks 2 and 3.

Leave Unused Outputs Unconnected: Disconnect any unused DC outputs from both chargers to avoid accidental connections

Step 4: Connecting the Remote Panel

Connect Communication Cables: Attach the remote panel’s communication cables to the primary charger’s remote port (labeled Primary) and to the secondary charger’s remote port.

Connect Battery Temperature Sensor: If you’re using a Battery Temperature Sensor (BTS), connect it to the primary charger’s BTS port. For dual BTSs, connect one to each charger. The BTS with the higher detected temperature will manage temperature adjustments.

Powering Up and Synchronizing the Chargers

Power On the Chargers: Once all connections are in place, turn on both the DC and AC power sources.

Observe Parallel LED: The Parallel LED on the remote panel will light up, indicating the chargers are synchronized and functioning in parallel.

During charging, the remote panel displays the combined output of both chargers. As your battery nears a full charge, one charger may reduce its output sooner than the other—this is normal and helps prevent overcharging.

Configuring and Operating the Parallel Setup

You can configure and monitor both chargers through the primary charger or the remote panel. The settings on the secondary charger will automatically synchronize with the primary charger, allowing for consistent and easy management.

Battery Equalization during Parallel Charging

Equalization can be programmed and monitored from the remote panel, ensuring balanced charge distribution across battery banks.

Fault and Warning Monitoring

If one charger encounters a fault, the other continues operating. The remote panel will display the fault condition, stopping synchronization temporarily until the issue is resolved.

Exiting Parallel Operation

To exit parallel mode, completely power down the chargers and disconnect both communication cables from the remote panel.

Setting up TRUEcharge3 chargers in a parallel configuration provides a flexible, powerful charging solution for larger battery banks. By following this guide and meeting all prerequisites, you’ll be able to safely and effectively double your charging capacity, ensuring your batteries stay healthy and ready for your next adventure.