TC10TB
Owner's Manual
Xantrex
TM
Truecharge 10TB
Multistage Battery Charger
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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
Email: [email protected]
Phone: 1 800 670 0707 (toll free) 1 604 422 2777 (direct)
Fax: 1 604 420 2145
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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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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 (Ni-
MH) 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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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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•
•
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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4.0 Installation Procedure
To install the Truecharge, you will need to purchase additional items to suit your
particular installation, such as mounting screws, wires, and ring terminals for
terminating the wires. These items are described in the instructions below.
Warning: All wiring must be done in compliance with local and national electrical
codes. Xantrex recommends having the installation wired by a certified electrician.
4.1 Choosing a Location
The Truecharge is designed to be mounted permanently. The location
chosen for mounting can affect its performance and influence safety. The
mounting location must be:
•
Dry. Truecharge must be located where no water or other fluids can
drip or splash on it. When mounting in a boat, be sure that the
Truecharge will not be exposed to bilge water splash.
•
Cool. Do not mount in an area where ambient air temperature is
commonly below 32° F (0° C), or above 105° F (40° C). Like all electronic
equipment, the Truecharge will operate more efficiently if kept
reasonably cool.
•
•
Well ventilated. At least a 4-inch (10 cm) clearance all around the unit
must be provided in order for proper cooling air flow. If mounting in a
closed compartment, ventilation holes to allow free air flow must be
provided.
Safe. To avoid corrosion and for general safety, do not install in the same
compartment as batteries. Although the Truecharge is approved as an
ignition-protected device, it is sensible practice wherever possible to
avoid installing it in any space containing gasoline or propane tanks, a
gasoline engine or associated fuel lines and fittings.
•
•
Relatively close to the batteries. The wires that connect the
Truecharge output to the batteries carry high current. Long runs of the
charger output wires will incur voltage loss and require much heavier
wire size.
Accessible to the vehicle or boat’s AC power system. The best
location is one that keeps both AC and DC wires to a minimum length.
Caution: Fire hazard risk. Do not install the Truecharge in a zero-
clearance compartment. Ensure adequate ventilation is provided.
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4.2 Mounting the Truecharge
Mount the Truecharge using four #8 (or M4) screws. Don’t skimp on either
the number or type of screws. Damage resulting from insecure mounting is
not covered under warranty. Mount on a vertical surface with the terminal
block end below.
4.3 Connecting the DC Wiring
If the Truecharge will be charging two batteries, check that negative
terminals of both batteries have a cable connecting them together, or
individually to a common DC negative bus. The Truecharge cannot be
used to charge a pair of batteries that are completely isolated from each
other.
Warning: To prevent accidental short circuits, sparking, and possible
battery explosion, damage or personal injury, all DC wiring from the
Truecharge to the battery(s) must be completed prior to connecting
AC wiring (see section 4.4).
Table 1 lists wire sizes required, and the ring terminal color code required
to terminate the wires. Wire length shown is total length (combined length
of negative and positive wires). When charging two batteries, use only the
longest positive wire and the negative wire to arrive at the “Total Wire Length”
in the table.
Total DC Wire
Length
Min. Wire Size
(Stranded)
#8 (4mm) Ring
Terminal Color
Code
Feet
0–8
Meters
0–2.5
AWG
14
mm2
2.5
4
Blue
Yellow
Yellow
8–12
12–20
2.5–3.5
3.5–6.0
12
10
6
Table 1.
To avoid polarity errors and possible damage, never use wires of only one color.
Use red insulated wire(s) for positive connection(s) and black insulated wire for
the negative connection.
Follow these steps, and Figure 1, to connect the DC wiring to your battery(s).
Wire sizes listed in the table above are absolute minimums. If there is any
doubt, always use larger wire.
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Figure 1. AC and DC Connections
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1. Run 2 (or 3) wires from the Truecharge to the battery(s), and fasten
neatly along their length. Do not connect wires yet. For a single battery
system, use one black wire for the negative connection and one red
wire for the positive connection. For a two battery system, add a second
red wire. Follow local code(s) regarding the use of conduit, wire loom
or other wiring protection.
2. Insert both wire clamps supplied into the two holes in the lower end of
the Truecharge and tighten their locknuts securely. Only one wire clamp
will be used for DC wiring, and the other will be used later in step 4.4 to
clamp the AC wiring.
3. Insert the DC wires through the left hand wire clamp and trim the wires
so about 6" (15 cm) of length protrudes inside the Truecharge wiring
compartment.
4. Strip 5/16" (8 mm) of insulation from wire ends, and crimp a ring terminal
to each wire using the correct crimping tool recommended by the crimp
terminal manufacturer. Use the correct size (color code) of ring terminal
specified in Table 1.
5. Remove the 3 unused terminal block screws in the “DC Output”
compartment. Using these screws, fasten the ring terminal attached to
the black wire to the (-) terminal, and the ring terminal attached to the
red wire to either of the (+) terminals. For a two-battery system, connect
the second red wire to the unused (+) terminal. Terminal screws must
be fully tight. For a single battery system, one of the two (+) terminals
will be unused.
6. Tighten the wire clamp firmly around the wires.
7. Xantrex recommends, and most local installation codes require,
installation of a DC fuse connected to the positive battery terminal of
each battery. Fuse size must not exceed 15 amps.
8. Using suitable battery terminal post connectors (typically, ring terminals
connected through the battery terminal’s clamp bolt), first connect the
red wire to the positive (+) battery post. As a last step, connect the
black wire to the negative (-) battery post. If two batteries are being
connected, connect one red wire to one battery’s (+) post (or battery
fuse, if installed in step 7), and the second red wire to the second
battery’s (+) post (or battery fuse). It doesn’t matter which wire is
connected to which battery. As a last step, connect the black wire to
the nearest negative battery post.
Caution: Battery connections must be made direct to the battery(s) or
to the battery fuses (if installed), and must never be made to a DC
distribution panel or to a battery isolator or similar device.
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4.4 Connecting the AC Wiring
Warning: Shock hazard. AC wiring must be disconnected from all
electrical sources before handling. All AC wiring must be installed
according to local and national electrical wiring codes. Xantrex
recommends having the installation wired by a certified electrician.
The following table lists the standard AC wire color codes and the ring
terminal color code required to terminate the wires inside the Truecharge.
Use only wire that meets local and national AC wiring codes. The Truecharge
is designed to operate from a grounded (3-wire) 120 volt AC circuit. The
circuit must be protected by a 15 ampere circuit breaker, and any switch
placed in series to switch AC power to the Truecharge must be in the “line”
side of the circuit and must be rated for a minimum of 3 amperes.
Connect the AC wiring as follows. Refer also to Figure 1.
AC Circuit
Designation
14 AWG Stranded
Wire Color
#8 (4mm) Ring
Terminal Color Code
Line, or Hot
Neutral
Black
White
Blue
Blue
Green or Green with
Yellow stripe
Ground, or Earth
Blue
Table 2.
1. Run three 14 or 16 AWG wires, one of each color listed in Table 2, or
an approved jacketed cable from the charger to the AC power source
or AC distribution panel, and fasten neatly in place. Do not connect
wires yet. Follow local code(s) regarding the use of conduit, wire loom
or other wiring protection.
2. Insert the AC wires through the right hand wire clamp (previously
installed in step 2, Section 4.3) and trim the wires so about 6" (15 cm)
of length protrudes inside the Truecharge wiring compartment.
3. Strip 5/16" (8 mm) of insulation from wire ends, and crimp a ring terminal
to each wire using the correct crimping tool recommended by the crimp
terminal manufacturer. Use the correct size (color code) of ring terminal
specified in Table 2.
4. Remove the 3 unused terminal block screws in the “AC Input”
compartment. Using these screws, fasten the ring terminals attached
to the Black “hot” wire to the “L” terminal, the White “neutral” wire to the
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“N” terminal and the Green “ground” wire to the
screws must be fully tight.
terminal. Terminal
5. Tighten the wire clamp firmly around the wires. If a jacketed 3-wire
cable was used, tighten the wire clamp around the end of the cable
jacket, not the individual wires. The cable jacket must protrude slightly
past the wire clamp.
6. Connect the opposite end of the AC power cable or wires, to the AC
power source, again using appropriate connecting terminals. The green
wire connects to the distribution panel “ground”, the white wire to the
system “neutral” and the black wire to the output terminal of a 15-ampere
circuit breaker.
4.5 Selecting the Correct Battery Type
The Truecharge is designed to properly charge all types of lead acid
batteries. A battery selector switch located inside the wiring compartment,
directly under the lower right corner of the front panel label, must be set to
match the type of batteries being charged. The switch is recessed behind
the inner wiring compartment panel to guard against inadvertent changes.
A pointed object such as a ballpoint pen will be needed to reach through a
small access hole to move the switch lever.
Important: The battery selector switch must be set correctly. An
incorrect setting may seriously affect battery life.
•
•
If “Flooded” battery(s) are being charged, slide the switch to the right in
the direction of the “F” stamped into the metal switch panel. Flooded-
type batteries are those that have removable caps for water addition.
If “Sealed” battery(s) are being charged, slide the switch toward the
center of the Truecharge (to the left), in the direction of the “G” stamped
into the metal switch panel. There are two types of sealed batteries:
“Gel” and “Starved-Electrolyte” (or “AGM”). Both types are identified by
having no removable caps where water can be added. Both Gel and
AGM batteries require the switch set to the “G” position.
4.6 Completing the Installation
The Truecharge is now almost ready to begin charging. Prior to switching
on AC power, first double check that the above installation has been
performed correctly, then follow these final steps.
1. Securely attach the metal wiring compartment cover using the four
self-tapping screws supplied.
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2. Review any literature that was supplied with the batteries regarding
battery-specific charging requirements.
3. For “Flooded” batteries, top up the electrolyte level with distilled water.
4. Switch on AC power to the charger, and switch on the 15-amp breaker
installed in section 4.4. Also, switch on the power switch if this optional
item was installed.
5. The “Bulk” status light will switch on, indicating that the Truecharge
has begun charging in bulk charging mode.
6. Read section 5.0 to familiarize yourself with the various modes of
operation of the Truecharge as it brings the battery(s) up to full charge.
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5.0 Operation
5.1 Automatic Charging Sequence
1. When AC power is first switched on, an initialization procedure begins.
The microprocessor checks for excessive voltage at the battery. It then
checks to ensure the internal charger temperature is not greater than
175°F (80°C). If both these conditions are met, and the battery voltage
is lower than the “absorption” voltage (see step 4), the Truecharge
begins “bulk” charging, delivering a full charge to the battery or batteries.
During this charging phase, the majority, or bulk of the charge is returned
to the battery.
2. After approximately 10 seconds, the microprocessor rechecks battery
voltage, to determine if the battery is responding to being charged. If
the battery is not responding, charging is terminated and the initialization
procedure in step 1 is restarted.
3. If the battery is responding, bulk charging at a full 10 amps continues
until the battery voltage rises to just below the point where destructive
battery “gassing” can begin. When this threshold is reached, typically
14.2 to 14.4 volts, depending on battery type and position of the battery
selector switch, the Truecharge enters its absorption charge mode.
4. When the battery voltage under full bulk charge approaches the point
where battery “gassing” can begin, the Truecharge switches over to
“absorption” mode. During this final charging phase, current is
progressively reduced to hold the battery voltage absolutely constant
at 14.2 to 14.4 volts (depending on battery type selected).
5. When charging current drops below 1 amp, this signals that the battery
is fully charged. If a Gel or AGM battery type is being charged, the
Truecharge now switches immediately into its “float” charge mode. If
the battery being charged is a Flooded type, the Truecharge continues
the absorption charge mode for one additional hour, then switches into
float charge mode.
6. Once in float charge mode, the Truecharge reduces its charging voltage
to the precision-controlled “float” voltage value. This maintains the
battery indefinitely at 100% charge, yet creates negligible gassing or
electrolyte loss.
7. If the microprocessor detects the charger has been in absorption mode
for more than 8 hours, it automatically switches into float mode. This
feature protects the battery against situations where a light load
connected to the battery prevents the charger current from dropping
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below the 1-amp threshold that would normally trigger the transition to
float mode.
5.2 Charging Sequence Initiation
The Truecharge always begins, or restarts, the above charging sequence
by initiating a bulk charge. If the battery is only slightly discharged, the
Truecharge will quickly switch into absorption mode, then eventually enter
float mode once fully charged. The conditions that will cause the Truecharge
to start, or restart high current bulk charging are as follows.
1. If, due to an external load consuming current or due to internal battery
leakage, the battery terminal voltage falls to 12.5 volts for more than
15 minutes, a new charging cycle will begin.
2. If 21 days have passed since the last charging cycle, a new charging
cycle is automatically begun. This protects against slowly diminishing
capacity that can occur due to normal internal battery leakage.
3. Each time AC power is connected or reconnected, the charging
sequence is restarted.
5.3 Front Panel Indicators
Three front panel charging status lights are provided to allow monitoring of
battery charging status. Referring to charging modes described in section
5.1, the status light functions are as follows.
•
Sequential flashing of all three lights for several seconds, when AC
power is first switched on, indicate the automatic initialization procedure
is in progress.
•
•
•
Yellow “Bulk” status light. Indicates the bulk charging mode is in
progress. Charging current is 8 to 10 amps.
Yellow “Absorption” status light. Indicates the Truecharge has switched
into absorption mode. Current is 1 to 8 amps.
Green “Float/Ready” status light. Indicates that batteries are fully
charged, and the Truecharge has switched into float mode. Charging
current drops to a maintenance level of less than 1 amp.
In addition, the status lights also report an automatic safety shutdown code.
•
Both “Ready/Float” and “Bulk” lights flash simultaneously. This indicates
that the battery voltage is dangerously high and the Truecharge has
shut down. This condition is generally caused by a poorly regulated engine
alternator, or generator, simultaneously charging the battery.
•
“Bulk” light only flashes. This indicates the Truecharge has shut down
due to overheating caused by poor ventilation.
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6.0 Charging Times
The time taken for the Truecharge to fully recharge the battery(s) connected to it
depends on many factors such as, the size (capacity in amp hours) of the battery (or
total capacity if two batteries are connected), and how deeply the battery(s) are
discharged. The following simple formula can be used to establish the approximate
expected charging time.
Total Ah of Battery(s) x Depth of Discharge
Approx. Charging time in hrs
=
900
Where “Depth of Discharge” is the percentage of charge that has been used (0% is
fully charged, and 100% is completely discharged).
As an example, for a Group 27 size battery with a rated capacity of 80 amp hours
that is 75% discharged, the formula becomes:
80 x 75
Approx. Charging time in hrs
6.7 Hours
=
=
900
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7.0 Care and Maintenance
The Truecharge requires very little care and essentially no maintenance. Provided
the location and mounting instructions have been followed, and the Truecharge is
not exposed to corrosive fumes from batteries, water or similar liquids, it will continue
to function indefinitely with no additional maintenance. Should any of the above
liquids contact the Truecharge, immediately switch off and disconnect the AC power
and wipe the unit thoroughly with a damp cloth. Dry the unit with a dry cloth then let
it sit for several hours to allow residual water to evaporate before reconnecting AC
power.
Warning: Do not disassemble the Truecharge for cleaning, or to attempt repair.
There are no user-serviceable parts inside.
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8.0 Output Protection Fuse Replacement
The Truecharge has two built-in 15 amp, 32 volt rated, automotive blade-type output
protection fuses. Their function is to protect the unit against reverse battery polarity
caused by incorrect installation. Should one or both fuses be blown, replace as
follows.
1. Disconnect AC power to the Truecharge and disconnect the DC cables
at the battery(s).
2. Remove the wiring compartment cover by removing the 4 screws that
attach it to the Truecharge.
3. Locate the fuses just inside the upper left corner of the wiring
compartment.
4. Pull each fuse directly toward the Truecharge’s mounting surface to
remove them from their fuseholders. Never pull towards the lower end
of the unit, or wiggle the fuses back and forth to remove them.
5. Replace any blown fuse with an identical 15 amp, 32 volt rated,
automotive blade-type fuse. Never substitute with any other type or
rating, or damage to the Truecharge may result.
6. Find and correct the problem that caused the fuse(s) to blow. Generally
this will be reversed battery polarity.
7. Replace the wiring compartment cover and reconnect AC and DC
power.
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9.0 Troubleshooting
Problem: Indicator lights do not turn on.
Possible Cause
Suggested Remedy
Check to ensure AC connections are
correct, and breaker is switched on.
No AC Power.
Have AC fuse replaced by qualified
service person.
Blown internal AC fuse in
charger.
Verify battery connections. Replace
output protection fuse if unit was
subjected to reverse battery polarity
(see Section 8.0).
Battery not properly
connected.
Problem: Sequential flashing of all three lights occurs for 2 to 3
seconds, then repeats every 10 seconds.
Suggested Remedy
Possible Cause
Leave battery connected for several
hours. If continuous flashing still
continues, the battery is most likely
damaged and cannot accept a charge.
Replace battery.
Battery is not responding to
initial charging current.
The Truecharge can only charge 12 Volt
lead acid batteries.
A 6 Volt battery is installed.
Problem: "Ready/Float" light and "Bulk" light flash simultaneously (the
Truecharge is detecting excessive battery voltage).
Possible Cause
Suggested Remedy
Remove the higher voltage battery and
charge only 12 Volt batteries.
A battery greater than 12 Volts
(such as a 24 Volt battery) is
connected.
Disconnect the other charging source or
switch off the motor or generator. The
battery voltage will drop to more normal
values and the Truecharge will begin
normal operation.
The battery is connected to
another charging source such
as a generator or alternator
with poor voltage regulation.
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Truecharge 10TB Owner’s Manual
Problem: "Bulk" light (only) flashes (the Truecharge is detecting
excessive internal temperature).
Possible Cause
Suggested Remedy
Eliminate ventilation blockage or reduce
ambient temperature to less than 105°F
(40°C). The Truecharge will resume
normal operation once it has cooled
sufficiently.
The Truecharge has shut
down due to internal
overheating.
Problem: Long charging times. "Ready/Float" light does not switch
on even after 24 hours of charging.
Suggested Remedy
Possible Cause
Total battery capacity (the sum of both
Ampere-Hour ratings if two batteries
are installed) must be 200 Ampere-
hours or less, or excessive charging
times will result.
Total battery capacity is
higher than the recommended
200 Ampere-Hours.
This is a normal situation if a load is
drawing current from the battery. Once
the load is switched off, normal charging
will resume.
Load connected to battery is
continuously operating, thus
diverting the charge current
directly to the load.
Replace battery.
Battery has damaged cell.
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Truecharge 10TB Owner’s Manual
10.0 Limited Warranty
What does this warranty cover?
This Limited Warranty is provided by Xantrex Technology, Inc. (“Xantrex”) and covers defects in workmanship and materials in your
Xantrex Truecharge 10TB Battery Charger. This warranty lasts for a Warranty Period of 12 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.
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 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 merchant. If you are unable to contact your merchant, or the
merchant is unable to provide service, contact Xantrex directly at:
Phone: 1-800-670-0707 (toll free in North America) 1-604-422-2777 (outside of North America)
Fax: 1-604-420-2145
Email: [email protected]
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
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)
b)
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;
the product if it has been subjected to fire, water, generalized 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)
d)
e)
the product if repairs have been done to it other than by Xantrex or its authorized service centers (hereafter “ASCs”);
the product if it is used as a component part of a product expressly warranted by another manufacturer;
the product if its original identification (trade-mark, serial number) markings have been defaced, altered, or removed.
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Truecharge 10TB Owner’s Manual
Disclaimer
Product
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, DIRECT, 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, 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 and provinces 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 from state to state or province to province.
Warning: Limitations On Use
Please refer to your product user manual for limitations on uses of the product. Specifically, please note that the Xantrex Truecharge
10TB 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.
Return Material Authorization Policy
Before returning a product directly to Xantrex you must obtain a Return Material Authorization (RMA) number and the correct factory
“Ship To” address. Products must also be shipped prepaid. 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
Return Procedure
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.
2.
Include the following:
•
•
•
•
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
3.
Ship the unit prepaid to the address provided by your Xantrex customer service representative.
If you are returning a product 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.
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Truecharge 10TB Owner’s Manual
11.0 Specifications
Output current1
10 amps
Output voltage2
Bulk Charge mode:
Float Charge mode:
Input voltage
14.2–14.4 volts
13.5–13.8 volts
120 VAC nominal
(90–135 VAC) 50/60 Hz
Efficiency (nominal)
Weight
85%
3 lbs (1.4 kg)
Dimensions (L x W x H)
10-5/8" x 6-1/2" x 2-3/4"
(270 mm x 165 mm x 70 mm)
Output fuses
15 amp, 32 volt automotive blade type
Safety approvals
CSA/NRTL approved to CSA C22.2
No. 107.2, and UL 1236, including
Ignition Protection and Marine
requirements.
1 maximum continuous duty
2 exact value dependent on battery selector switch setting
Specifications subject to change without notice
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Xantrex Technology Inc.
Toll free 1 800 670 0707
Direct 1 604 422 2777
Fax 1 604 420 2145
445-0091-01-01 Rev. 2
Printed in China
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