Introduction5
Truecharge 10 Features5
Theory of Operation7
Important Safety Instructions10
Permanent Installation13
Battery Charging Safety15
Grounding and AC Power Cord Connection Instructions16
Operating Instructions17
Care and Maintenance19
Troubleshooting20
Warranty Terms21
Specifications25
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.
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 10Features
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
5
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.
7
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 gassingvoltage—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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