Xantrex Technology TC10 User Manual

TC10
Owner’s Manual
Xantrex Truecharge 10
TM
Battery Charger
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Table of Contents
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Xantrex Truecharge 10 Battery Charger © November 2002 Xantrex International. All rights reserved. Truecharge is a registered trademark of Xantrex International. Xantrex is a registered trademark of Xantrex International.
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
November 2002, Revision 3
Part Number
445-0071-01-01 rev. 3
Contact Information
Web: www.xantrex.com Email: CustomerService@xantrex.com Phone: 1 800 670 0707 (toll free)
1 604 422 2777 (direct)
Fax: 1 604 420 2145
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Introduction
Your Xantrex Truecharge 10 is an advanced battery charger designed specifically for today’s high performance deep-cycle lead-acid batteries. It provides charging performance that simple marine and automotive chargers are unable to provide.
The Truecharge 10 is designed to recharge 12 volt lead-acid batteries with capacities from 25 amp hours to 200 amp hours. If you wish to charge batteries with capacities greater than 200 amp hours, Xantrex’s Truecharge 20 or Truecharge 40 chargers will be better choices.
To get the full benefit of the Truecharge 10’s capabilities, please read and follow the instructions in this manual. This manual covers both the TC10 115 VAC model and the international TC10i 230 VAC model. TC10i input specifications are shown in parentheses. Pay special attention to the Important Safety Instructions in this manual and to the CAUTION and WARNING statements in this manual and on the Truecharge 10.
Truecharge 10 Features
The Truecharge 10 is a true “smart charger” that automatically provides the correct charge cycle for modern sealed (“gel”) or flooded (“wet”) lead-acid batteries.
Microprocessor Controlled Three-Step Charging
Experts and battery manufacturers recommend that lead-acid batteries be charged with a three-step charge cycle to provide a fast, complete charge. The microprocessor in the Truecharge 10 precisely regulates the voltage and current delivered to the battery, accurately charging without risk of overcharging and battery damage.
Proprietary software algorithms compensate for a variety of conditions which “fool” less sophisticated chargers into delivering an improper charge.
Truecharge 10 10-Amp Continuous Rating
The Truecharge 10 will deliver its rated 10 ampere charging current for most of the charging cycle. The charger only reduces the charging current below this continuous rating level when the battery is approaching full charge. Many other chargers only deliver their rated
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charging current for a short initial part of the charge cycle. Charging current decreases rapidly (“tapers off”) as the battery charges.
Because it delivers rated current over most of the charge cycle, your Truecharge 10 will charge your batteries faster than many other chargers rated at 20 amperes or more.
Wide Voltage Range Operation
Now you can give your battery a top-quality charge even when your AC power isn’t top quality. The Truecharge 10 precisely maintains the correct charging voltage for your battery when the AC line voltage drops as low as 90 VAC, or rises as high as 135 VAC (200 to 260 VAC for the international 230 VAC model). A surge protector in the Truecharge 10 protects it, and your 12-volt circuits, from surges and spikes on the AC power line.
Selector Switch for Battery Type
The Truecharge 10 has a selector switch that allows you to set the charger for the charging characteristics of the new sealed lead-acid “gel” batteries, or for the charging characteristics of conventional flooded batteries. By setting the switch correctly before you begin charging your battery, you will be ensuring that it receives the best possible charge.
Extensive Protection Features
The Truecharge 10 will not begin delivering current until it detects that it has been properly connected to a battery. You will have fewer worries about accidental sparks as you make your connections to the battery. The Truecharge 10 will not deliver current if it detects a reverse polarity connection, a short circuit, or connection to a battery with incorrect voltage. The Truecharge 10 will also shut down if it becomes overheated because of inadequate ventilation.
Isolated Design
The DC battery charging circuits of the Truecharge 10 are electrically isolated by a transformer from the AC power source circuits. This improves your personal safety and ensures that there will be no electrolysis problems when charging batteries on a boat.
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Theory of Operation
High Frequency Power Converter
The Truecharge 10 uses modern high frequency switching power circuits to convert the alternating current from the utility line to the low voltage direct current required to charge the battery. The circuits are similar to those used in power supplies for computers and other modern electronic equipment.
The alternating current from the utility line is first rectified by diodes to produce a high voltage direct current.
This direct current is switched at a very high frequency (approximately 75 kHz) to produce pulses of current which are stepped down to a lower voltage by a small high frequency transformer. The low voltage pulses of current from the secondary side of the transformer are rectified and smoothed to create a continuous direct current which is sent to the battery.
The power switching is performed by power MOSFET transistors. These transistors also control the charging current and voltage through a process called pulse width modulation (PWM). The average value of the voltage or current is controlled by varying the lengths of the pulses of current. Shorter duration pulses result in lower voltage and current while longer duration pulses result in higher voltage or current.
The advanced power conversion technology in the Truecharge 10 gives you several benefits:
A charger that is smaller and lighter than most other chargers
with similar capabilities. The Truecharge 10 is easy to carry with you and can be stored or installed in small compartments.
A totally silent charger. There is none of the “hum” or “buzz”
commonly associated with chargers based on older technology.
Non-pulsing charging current. While the Truecharge 10 uses
current pulses internally, the output current is filtered so that it is very smooth. This is the ideal current for charging lead-acid batteries. Many other chargers produce a pulsating charging current that does not recharge the battery to its maximum potential.
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Three-Step Charging Process
Modern lead-acid batteries will last longer and charge faster if they are charged in a particular sequence known as a three-step charge. The Truecharge 10 implements the three-step charging process.
In the first step, known as the bulk charge, the Truecharge 10 delivers its rated current (10 A) until the battery voltage approaches its gassing voltage—typically around 14.4 volts. The bulk charge step restores about 75% of the battery's charge.
The gassing voltage is the voltage at which the electrolyte in the battery begins to break down into hydrogen and oxygen gases. Under normal circumstances, a battery should not be charged at a voltage above its gassing voltage since this will cause the battery to lose electrolyte and dry out over time. Therefore the Truecharge 10 transfers to the next step, known as the absorption charge.
During the absorption charge, the charging voltage is held constant near the gassing voltage and the charging current is steadily decreased. When the charging current has decreased to approximately one ampere, the battery is fully charged. At this point, the Truecharge 10 transfers to its final step, known as the float charge.
The float charge is a maintenance mode in which the Truecharge 10 output voltage is reduced to a lower level, typically about 13.5 volts, to maintain the battery's charge without losing electrolyte through gassing. Unlike many other chargers, the Truecharge 10 can be left connected to your battery indefinitely without risk of overcharging.
The voltage levels mentioned in the paragraphs above are dependent on the type of battery (sealed vs. flooded) and on the temperature of the battery. The Truecharge 10 is equipped with selector switches to allow you to set it for your battery type and temperature.
Charger Operating Sequence
The microprocessor in the Truecharge 10 is constantly checking to ensure that the charger is working properly.
Once AC power is connected to the Truecharge 10, the microprocessor begins by checking whether a battery is connected properly to the charger. The Truecharge 10 will only start charging if the following
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