Xantrex Truecharge TC10 Bedienungsanleitung

TC10

Owner’s Manual

Xantrex

Truecharge 10

Battery Charger

Table of Contents

Introduction 5

Truecharge 10 Features 5

Theory of Operation 7

Important Safety Instructions 10

Permanent Installation 13

Battery Charging Safety 15

Grounding and AC Power Cord Connection Instructions 16

Operating Instructions 17

Care and Maintenance 19

Troubleshooting 20

Warranty Terms 21

Specifications 25

Xantrex Truecharge 10 Battery Charger © November 2002

Truecharge is a registered trademark of Xantrex International.

Xantrex is a registered trademark of Xantrex International.

Disclaimer

UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECH-

NOLOGY 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: [email protected]

Phone: 1 800 670 0707 (toll free)

1 604 422 2777 (direct)

Fax: 1 604 420 2145

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

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.

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.

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

conditions are met:

•A battery is connected

•The battery is connected with proper polarity

•The battery voltage is between 5 volts and 13 volts

The Truecharge 10 will not act as a battery eliminator or power supply. It

must be connected to a battery to operate.

Once the Truecharge 10 detects proper connection to a battery, it begins

the three-step charging cycle. The Truecharge 10 will stop charging if it

detects the following conditions:

•Battery voltage less than 10 volts or greater than the gassing voltage

•Internal charger temperature greater than 70 °C

The Truecharge 10 will automatically start charging again if it detects

that the battery voltage or charger temperature have returned to safe levels.

The Truecharge 10 completes the absorption charge and goes to float

mode when one of the following two conditions are met:

•Charger output current has dropped below one ampere (flooded

type batteries remain at absorption voltage for an additional hour

after current has dropped to one ampere)

•The charger has been in absorption charge mode for more than

5 hours.

This “time out” feature protects against situations where a load

connected to the battery prevents the charger current from dropping

below one ampere.

The Truecharge 10 will leave float mode and start another three-step

charging cycle under any one of the following conditions:

•Battery voltage drops below 12.5 volts for more than 15 minutes

•21 days have passed since the last charging cycle occurred

•The battery has been disconnected for more than 30 seconds and is

then reconnected

•AC power has been disconnected for more than 30 seconds.

The first two conditions ensure that the Truecharge 10 keeps your battery

“topped up” if it is left permanently connected. The last two conditions

ensure that the Truecharge 10 starts in a predictable fashion after you

disconnect the battery or the AC power.

WARNING! To reduce the risk of sparking and damage to your

Truecharge 10, always disconnect AC power from your Truecharge 10

before connecting or disconnecting the battery or batteries.

Important Safety Instructions

SAVE THESE INSTRUCTIONS. This manual contains important safety

and operating instructions for the Truecharge 10 battery charger.

•Do not expose charger to rain, snow, or spray.

•Use of attachments not recommended or sold by the battery charger

manufacturer may result in a risk of fire, electric shock, or injury to

persons.

•To reduce risk of damage to electric plug and cord, pull by plug

rather than cord when disconnecting charger.

•An extension cord should not be used unless absolutely necessary.

Use of improper extension cord could result in a risk of fire and

electric shock. If an extension cord must be used, make sure:

a) That pins on plug of extension cord are the same number, size

and shape as those of plug on charger.

b) That extension cord is properly wired and in good electrical

condition, and

c) That wire size is 18 AWG (0.8 mm2) or larger and cord is less

than 100 feet (30 m) long.

•Do not operate charger with damaged cord or plug. Replace the cord

or plug immediately.

•Do not operate the charger if it has received a sharp blow, been

dropped, or otherwise damaged in any way. If the charger is dam-

aged, take it to a qualified service person.

•Do not disassemble the charger. Take it to a qualified service person

when service or repair is required. Incorrect reassembly may result in

a risk of electrical shock or fire.

•To reduce risk of electrical shock, disconnect power from the charger

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