Xantrex Technology TC10TB User Manual

TC10TB
Owner's Manual
Xantrex
TM
Truecharge 10TB Multistage Battery Charger
Table of Contents
1.0 Introduction .............................................................................. 1
Truecharge ............................................................................... 2
2.1 General Safety Precautions ......................................................2
2.2 Safety Precautions for Working Around Lead Acid Batteries ....3
3.0 Design Features ....................................................................... 4
3.1 Microprocessor Controlled 3-Step Charging .............................4
3.2 Switchmode Power Conversion Technology ............................. 5
3.3 Safety Features ........................................................................ 5
4.0 Installation Procedure .............................................................. 6
4.1 Choosing a Location .................................................................6
4.2 Mounting the Truecharge.......................................................... 7
4.3 Connecting the DC Wiring ........................................................7
4.4 Connecting the AC Wiring ...................................................... 10
4.5 Selecting the Correct Battery Type ......................................... 11
4.6 Completing the Installation ..................................................... 11
5.0 Operation ............................................................................... 13
5.1 Automatic Charging Sequence ............................................... 13
5.2 Charging Sequence Initiation ..................................................14
5.3 Front Panel Indicators ............................................................ 14
6.0 Charging Times...................................................................... 15
7.0 Care and Maintenance ........................................................... 16
8.0 Output Protection Fuse Replacement .................................... 17
9.0 Troubleshooting ..................................................................... 18
10.0 Limited Warranty (USA and Canada Only) .......................... 20
11.0 Specifications ....................................................................... 22
Notice of Copyright
Xantrex Truecharge 10TB Multistage Battery Charger © October 2002 Xantrex International. All rights reserved.
Truecharge is a 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
October 2002, Revision 2
Part Number
445-0091-01-01Rev. 2
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
Truecharge 10TB Owner’s Manual
1.0 Introduction
Thank you for purchasing the Xantrex Truecharge™ 10TB Automatic Battery Charger. The Truecharge 10TB is part of an advanced family of battery chargers from Xantrex. It is specifically designed for charging high performance deep-cycle lead acid batteries from 25 to 200 ampere-hour capacity. Using the latest high frequency switchmode power conversion technology, the Truecharge 10TB outperforms traditional battery chargers several times its size, even under conditions of marginal AC power. Its sophisticated proprietary microprocessor charging algorithms ensure your batteries are always at maximum charge, while preventing battery damage due to overcharging.
Read this manual before installing or using the Truecharge and save it for future reference.
The following main topics are covered in this manual:
Important safety information
Installation and operating instructions
General principles of operation.
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Truecharge 10TB Owner’s Manual
2.0 Important Safety Instructions … Before You
Install the Truecharge
Incorrect installation or operation of the Truecharge may result in hazardous conditions. We urge you to pay special attention to all CAUTION and WARNING statements. CAUTION statements identify conditions or practices that may result in damage to the Truecharge or to other equipment. WARNING statements identify conditions that may result in personal injury or loss of life. Failure to follow instructions in this manual may result in personal injury and/or damage to the Truecharge.
2.1 General Safety Precautions
1. Do not expose the Truecharge to rain, snow, spray or bilge water splash.
2. All wiring must comply with local and national electrical codes. Use only the wire sizes specified in the installation instructions. Xantrex recommends having the installation wired by a certified electrician.
3. The Truecharge contains shock and energy hazards. Do not disassemble. There are no user-serviceable parts inside.
4. Disconnect all AC and DC power at its source prior to cleaning or removing the wiring cover to access wiring terminals or the internal fuse.
5. Switch off AC power before connecting or disconnecting DC wiring or battery connections.
6. Charge only 12-volt lead acid batteries. Never attempt to charge other types such as Nickel-Cadmium (Ni-Cad), or Nickel-Metal Hydride (Ni­MH) batteries. Never attempt to charge any other voltage of lead acid battery such as 6-volt or 24-volt types. These batteries may burst, causing personal injury and damage.
7. The Truecharge can only be used as a power source when it is connected to a battery.
8. Using attachments not recommended or sold by Xantrex may result in risk of fire, shock or personal injury.
9. Although the Truecharge is approved as an ignition-protected device, avoid installing it in any space containing gasoline or propane tanks, a gasoline engine or associated fuel lines and fittings.
10. Do not install the Truecharge in a zero-clearance enclosure. Overheating may result. Mount correctly and maintain the clearance around the unit, as detailed in the installation instructions.
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Truecharge 10TB Owner’s Manual
11. Ensure existing wiring is in good electrical condition, and that AC wiring size is 14 AWG or larger and less than 100 feet long. Do not operate charger with damaged or substandard wiring. This will avoid risk of fire and electric shock.
12. Do not operate the charger if it has received a sharp blow, been dropped or damaged in any way. A damaged charger must be taken to qualified service personnel for repair.
2.2 Safety Precautions for Working Around Lead Acid Batteries
WARNING! Explosion hazard.
Batteries generate explosive gases during normal operation. Follow these precautions, and those published by the battery manufacturer, to reduce the risk of explosion.
1. Never smoke or allow a spark or flame in the vicinity of a battery.
2. Ensure the battery compartment is well ventilated, in accordance with all codes applicable to the installation.
3. For flooded batteries, check acid level periodically and fill with distilled water per manufacturer’s instructions, to reduce the remaining space in the cells where explosive gases can collect.
4. Never attempt to charge a frozen battery.
CAUTION! Batteries contain corrosive materials and present a safety hazard.
1. Wear eye protection and protective clothing.
2. If battery acid or corrosive by-products contact skin or clothing, wash immediately with soap and water. In the event of eye contact, immediately flush with running water for 20 minutes, then seek prompt medical attention.
3. Always ensure someone is nearby to help you in the event of an emergency.
4. Remove personal metal items such as rings, watches, bracelets etc. and be careful not to drop metal or tools on the battery. Contact to the battery terminals may result in a short circuit, causing severe burns or triggering an explosion.
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Truecharge 10TB Owner’s Manual
3.0 Design Features
The design of the Truecharge incorporates numerous features that traditional battery charger designs cannot match. Key features and their benefits to the user are as follows.
3.1 Microprocessor Controlled 3-Stage Charging
Truecharge provides fast, complete charging without sacrificing battery life. The sophisticated 3-Stage charging algorithms executed by the Truecharge’s microprocessor compensate for conditions that normally cause less sophisticated chargers to deliver an improper charge. The Truecharge’s advanced design eliminates design compromises inherent in old-fashioned chargers and provides the following benefits.
Full 10-amp charge is delivered for the duration of the “Bulk Charge”
period, until the battery nears full charge. Traditional chargers deliver full rated current only when the battery is nearly discharged, rapidly “tapering” off to a much lower value. Because its charge current does not taper off during bulk charging, the 10-amp rated Truecharge 10TB can fully charge a battery in about half the time a traditional 10-amp rated charger would take.
Automatic switchover to “Absorption Charge” mode as the battery nears
full charge. In this mode, output voltage is held absolutely constant to ensure the battery “absorbs” its full charge. The Truecharge’s microprocessor constantly monitors charging current, and signals that the battery has reached full charge when current falls to a predetermined low value. Precision control is key to ensuring full charge is delivered in minimum time, while ensuring longest possible battery life.
Automatic switchover to “Float Charge” mode when the battery has
reached 100% charge. In this mode, the Truecharge’s output voltage now reduces to a level designed to ensure the battery maintains its full charge. Precision long-term control of this voltage is key to ensuring full battery charge is maintained without electrolyte loss and battery damage due to excessive gassing (“boiling”) of the battery acid. The Truecharge can be left permanently connected without risk of battery damage.
Ability to fully monitor and charge two separate batteries. The most
discharged battery receives the highest charging current.
Automatic restarting of the charging sequence when battery capacity
begins to fall as loads are switched on. This ensures your battery is always at maximum charge even when power is being drawn from it.
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Truecharge 10TB Owner’s Manual
Automatic restarting of the charging sequence if 21 days has passed
since the last charging cycle has occurred. This eliminates reduced battery capacity problems caused by normal internal battery leakage.
Automatic restarting of the charging sequence each time AC power is
reconnected.
3.2 Switchmode Power Conversion Technology
The Truecharge employs advanced high frequency switchmode power conversion circuitry resulting in these benefits.
Much smaller size and lower weight as compared to traditional 10-amp
chargers.
Totally silent operation, without the buzz or hum traditional chargers
often generate.
High efficiency solid state circuitry, resulting in minimum heat generation.
Full charging capability even when the AC line voltage has fallen to 90
volts, where many other chargers no longer function.
Pure DC output without the current pulsations common to traditional
chargers. This results in increased battery life and eliminates the “buzz” traditional chargers often cause on audio equipment operating from the battery.
3.3 Safety Features
These advanced safety features come built into the Truecharge.
Isolated design. Charger output is galvanically isolated from the AC
power line to eliminate electrolysis problems on boats.
Overheat protection. The Truecharge shuts down before its internal
temperature rises to dangerous levels that may be caused by poor ventilation or high ambient temperatures, and automatically restarts after cooling.
Installer error protection. Output short circuit and reverse battery polarity
protected.
Protected against damage that could otherwise result from connecting
to a 24 volt battery.
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