table of contents
Owner Manual
BATTERY CHARGER
Model: IBC80
FOR YOUR SAFETY
The use of the appropriate Tundra
CM Series installation kit is
highly recommended
www.tundrainternational.com
PN. IBC80-GD-1015-EN
Table of contents
1
FEATURES .................................................................................................................................... 3
1.1
Integrated charge controller ............................................................................................................... 3
1.2
GFCI Protection ................................................................................................................................. 3
1.3
Reverse battery protection ................................................................................................................. 3
1.4
Short circuit protection ....................................................................................................................... 3
1.5
Thermal protection ............................................................................................................................. 3
1.6
Ignition protection ................................................................................................................................ 3
1.7
Internal components cooling .............................................................................................................. 3
1.8
Overvoltage protection ....................................................................................................................... 3
2
GENERAL INFORMATION ........................................................................................................... 4
3
GENERAL OPERATION ............................................................................................................... 5
4
INSTALLATION ............................................................................................................................. 5
5
TROUBLESHOOTING GUIDE ...................................................................................................... 6
6
INPUT & OUTPUT SPECIFICATIONS .......................................................................................... 7
7
LIMITED ONE YEAR WARRANTY ............................................................................................... 8
2
IBC80-GD-1015-EN
1
1.1
FEATURES
Integrated charge controller
The IBC80 Chargers have been designed and tested to provide years of trouble-free and maintenance free operation.
The IBC80 is the intelligent way to recharge your truck batteries. The built-in microprocessor constantly monitors the
batteries state of charge then automatically adjusts the output voltage to provide the proper charging combination of
voltage & amperage for fast and safe recharges.
1.2
GFCI Protection
The IBC80 has one of the lowest ground fault leakage available. With this unit, the user can confidently utilize almost
any AC outlets without being concerned about a ground fault interruption of the facilities power source.
1.3
Reverse battery protection
If a battery is accidentally hooked up backwards, externally mounted ATO type fuses will blow and the charger will be
protected. In the case of reversed polarity, replace fuses with brand new ones that are the exact same type and rating.
CAUTION!
1.4
IF THE PROTECTION FUSES HAVE BURNED DURING THE INSTALLATION, MAKE SURE THE
INSTALLATION HAS BEEN REVIEWED BEFORE REPLACING THEM WITH NEW ONES. ONLY
REPLACE THE FUSES WITH THE SAME TYPE AND RATING THAN THE ORIGINAL FUSES.
USING DIFFERENT FUSES COULD RESULT IN CHARGER DAMAGES, VEHICLE DAMAGES,
INJURY OR OTHER SERIOUS CONSEQUENCES.
Short circuit protection
The IBC80 is designed to protect itself. It could sense within millionths of a second if the output terminals have been
shorted. If this condition occurs, the charger will limit its output current. Should this condition persists, the charger will
shut down. Once the "short circuit" is corrected, the charger will automatically resume its normal operation.
1.5
Thermal protection
If an over temperature condition should occur due to air flow obstruction or improper installation, the IBC80 will sense
the condition and will either decrease its power output or shut down until the unit returns to normal operating
temperature. The charger will return to full output capacity as soon as it cools down.
1.6
Ignition protection
All IBC80 chargers are ignition proof. Although sparks free, they must be kept away from all flammable liquids.
1.7
Internal components cooling
The IBC80 chargers are equipped with a variable speed cooling fan. The location of the fan allows the maximum cooling
of both the housing and the components. The fan will only run at the speed needed to prevent the charger from
overheating and shutting down. Running the fan at lower speeds when possible will reduce its consumption and reduce
the audible noise generated by the fan while protecting the charger from excess heat.
1.8
Overvoltage protection
If the input voltage exceeds the pre-set limit, the charger will shut down automatically to prevent damages. The unit will
return to normal operation when the voltage returns under the pre-set limit.
3
IBC80-GD-1015-EN
2
GENERAL INFORMATION
The IBC80’s are state-of-the-art electronic 120 VAC to 12 VDC Converter / Battery chargers that are UL and CUL
(Canadian) listed. Their compact size and quiet operation give greater flexibility in selecting the mounting location for
either OEM installation or aftermarket.
The IBC80 battery chargers have a built-in charge controller module which constantly monitors the batteries, in order to
adjust its output voltage based on their state of charge. The charge controller has four (4) operating modes (BOOST,
NORMAL, STORAGE and EQUALIZE). Each mode is automatically selected by the charge controller to ensure a fast
and safe recharge for the batteries. See the chart below for details.
14.4 Volts (Boost Mode)
Rapidly brings the batteries up to 90% of full charge / LED is steady ON
13.6 Volts (Normal Mode)
Safely completes the charge / LED blinks rapidly (2 sec).
13.2 Volts (Storage Mode)
Maintains charge with minimal gassing or water loss / LED blinks slowly (5 sec).
14.4 Volts (Equalizing Mode) Every 21 hours of constant use, the output voltage will raise to 14.4 for a
15-minute period to prevent sulphating
THE ABILITY OF THE INTEGRATED CHARGE CONTROLLER TO CHANGE THE OUTPUT VOLTAGE OF THE
CHARGER WILL SIGNIFICANTLY REDUCE THE AMOUNT OF TIME IT TAKES TO RECHARGE YOUR BATTERY.
THE LOWER VOLTAGE OF THE STORAGE MODE PREVENTS GASSING AND REDUCES WATER LOSS DURING
LONG-TERM STORAGE.
4
IBC80-GD-1015-EN
3
GENERAL OPERATION
The IBC80 charger will supply an output voltage between 13.2 to 14.4 VDC from an input voltage ranging from 90 to130
VAC.
The IBC80 charger is primarily designed for use with batteries; however, the output of the IBC80 is a regulated, filtered
DC voltage that can power sensitive electronics without the need for batteries or other filtering. The full rated capacity
is available for loads, battery charging or both. When functioning as a converter, the IBC80 has a nominal output
voltage of 13.6 VDC. When connected to batteries, the system was designed to sense battery resistance and
automatically selects one of 4 operating modes (Boost, Normal, Storage or Equalization) in order to provide the best
charge possible.
NOTE!
IF THE INPUT VOLTAGE IS LESS THAN 105 VAC, THE CHARGER MAY NOT FUNCTION
PROPERLY.
CAUTION!
FLUID LEVEL OF ANY CONNECTED BATTERIES MUST BE CHECKED ON A REGULAR BASIS
(when possible). BATTERIES MAY “GAS” AND LOOSE SOME FLUIDS WHEN CONTINUOUSLY
CONNECTED TO A CHARGING SOURCE.
4
INSTALLATION
Horizontal installation of the ICB80 is recommended. However, it can be mounted in any position as long as the fan and
air vents are never obstructed. Firmly mount the charger to the mounting surface using standard bolts and nuts.
If the charger is installed in a place where ventilation is not adequate, it will stop and restart abruptly until the
environmental conditions are adequate.
The charger can be safely installed up to 12 ft. from the batteries using AWG 4 cables and a 100A CNL type fuse. Using
undersized cables may overheat the charger and cause a premature shutdown. Make sure to use PVC strain reliefs
when routing the cables thought sheet metal to prevent short circuit.
CAUTION!
THE IBC80 CHARGERS ARE NOT DESIGNED FOR ZERO CLEARANCE COMPARTMENTS.
CAUTION!
DO NOT EXCEED 50 IN / LB TORQUE ON THE OUTPUT TERMINALS.
CAUTION!
THE OUTPUT TERMINALS ARE RATED FOR AWG 2 COPPER WIRE MAX.
CAUTION!
THE IBC80 CHARGERS ARE NOT WATERTIGHT. THEY MUST BE INSTALLED AWAY FROM
WATER AND HIGH HUMIDITY.
5
IBC80-GD-1015-EN
5
TROUBLESHOOTING GUIDE
IF THE CHARGER/CONVERTER DOES NOT SEEM TO WORK PROPERLY;
1. MAKE SURE THE CHARGER/CONVERTER IS CONNECTED TO AN AC POWER SOURCE OF 20A @ 105130 VOLTS AC. YOU MAY USE AN AC VOLTMETER TO CHECK FOR PROPER VOLTAGE AT THE OUTLET
WHERE THE CHARGER IS PLUGGED IN.
2. DISCONNECT THE BATTERY CABLES AND USE A DC VOLTMETER IN ORDER TO VERIFY THE OUTPUT
VOLTAGE OF THE CHARGER/CONVERTER. IF YOUR READING IS AT LEAST 13 VOLTS, THE
CHARGER/CONVERTER IS WORKING PROPERLY.
3. CHECK THE FUSES LOCATED ON THE FRONT PANEL OF THE CHARGER/CONVERTER. THESE FUSES
CAN BLOW FOR MANY REASONS. DISCONNECT THE CHARGER/CONVERTER FROM ITS POWER SOURCE
AND REPLACE THE BURNED FUSES WITH IDENTICAL FUSES, THEN REPEAT STEP 1 AND 2.
4. IF THE PROBLEM PERSISTS, USE THE CHART BELOW.
PROBLEMS
POSSIBLE CAUSES
ACTIONS
1. No Output
Not connected to a 120 VAC source
Connect the charger to an AC source
Check AC distribution panel source for a tripped
breaker
External Fuses Blown
Check cables for reversed polarity
Replace fuses with same type and rating
Short Circuit
Trace AC Circuits for possible fault
Unit has shut down due to overheating
Check air flow
Allow unit to cool down
Unit has shut down due to over voltage
Check AC input voltage
Charger will shut down if the AC input voltage
exceeds 132 Volts
2. External Fuses
Blown
Reversed polarity at the battery
Properly connect DC cables
Replace damaged DC cables
Damaged DC cables
Replace fuses with same type and rating
3. Charger does On – Off
cycles
Compartment gets too hot
Check air flow around the charger/converter
4. Low output
Excessive load for the charger
Reduce load or install a more powerful charger
Improper input voltage
Supply the correct voltage (105-130 VAC)
Bad batteries
Replace batteries
Improve ventilation in the compartment
6
IBC80-GD-1015-EN
6
INPUT & OUTPUT SPECIFICATIONS
Input
Output
Dimensions
Weight
105-130 VAC
60 Hz
13.2 to 14.4 VDC
80 Amps
11.5 x 9.0 x 3.6 (in.) / 29.2 x 22.9 x 9.1 (cm)
7.5lbs / 3.4kg
14.9A
* SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
7
IBC80-GD-1015-EN
7
LIMITED ONE YEAR WARRANTY
TUNDRA INTERNATIONAL INC. warrants its products against defects in material or workmanship for a period of one
(1) year from the date of first end-user purchase. This warranty applies to the original purchaser (end-user) of the
product only. This limited warranty is voided if the unit is abused, modified, installed improperly, if the housing has been
removed, if the serial number is missing, or if the original identification markings have been defaced, altered, or
removed or if there is a lack of maintenance. Tundra International Inc. is not liable for any incidental, consequential or
other damages arising from the use, misuse, or operation of this product; including, without limitation, damages resulting
from loss of use, cost of removal, installation, or troubleshooting of the customer's electrical systems.
IMPORTANT NOTES
1.
2.
3.
Before returning a defective product, the end-user must certify that he has read and understood the
TROUBLESHOOTING section of this manual.
The product should have never been abused or modified.
The product should have never been exposed to liquids, heavy dust or corrosive material.
FOR TECHNICAL SUPPORT, CONTACT US AT 450-649-2470 or 1-877-964-2582
STEPS TO GET WARRANTY & SUPPORT:
1.
2.
3.
4.
5.
6.
A Warranty Form must be filled by the merchant and/or the end customer
The merchant and/or the end customer MUST contact us to get an RMA number.
A proof of purchase MUST BE INCLUDED with ALL returned products.
The returned product MUST BE PROPERLY PACKAGED to prevent shipping related damages.
Shipping related damages are not covered by the warranty.
All defective products MUST be sent with all shipping charges PREPAID.
Returned products will be evaluated by our technical department where a decision will be made as to whether the
product is covered by the warranty will be repaired, replaced or credited.
ALL DEFECTIVE PRODUCTS COVERED BY THE WARRANTY WILL BE RETURNED FREE OF CHARGE.
8
IBC80-GD-1015-EN
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