Xantrex Technology Tc10tb User Manual

TC10TB  
Owner's Manual  
Xantrex  
TM  
Truecharge 10TB  
Multistage Battery Charger  
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  
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 Truecharge10TB 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 (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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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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Truecharge 10TB Owner’s Manual  
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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Truecharge 10TB Owner’s Manual  
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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Truecharge 10TB Owner’s Manual  
Figure 1. AC and DC Connections  
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Truecharge 10TB Owner’s Manual  
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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Truecharge 10TB Owner’s Manual  
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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Truecharge 10TB Owner’s Manual  
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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Truecharge 10TB Owner’s Manual  
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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Truecharge 10TB Owner’s Manual  
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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Truecharge 10TB Owner’s Manual  
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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Truecharge 10TB Owner’s Manual  
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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Truecharge 10TB Owner’s Manual  
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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Truecharge 10TB Owner’s Manual  
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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Truecharge 10TB Owner’s Manual  
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.  
18  
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.  
19  
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  
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.  
20  
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.  
21  
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  
22  
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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