Tundra IBC45 User manual

TUNDRA INTERNATIONAL INC.
2041-A, Leonard-de Vinci, Sainte-Julie (Quebec) Canada J3E 1Z2
Tel : [phone] Fax : [phone]
Owner’s Guide
IBC45
February 2010
OMIBC450210E
www.tundrainternational.com

TUNDRA INTERNATIONAL INC.
2041-A, Leonard-de Vinci, Sainte-Julie (Quebec) Canada J3E 1Z2
Tel : [phone] Fax : [phone]
Owner’s Guide IBC45
February 2010 / P.N. OMIBC450210E
Table of contents
1Features.....................................................................................................................................................................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 Component Cooling..........................................................................................................................3
1.8. Overvoltage Protection ...................................................................................................................................3
2General Information
3General Operation ...................................................................................................................................................5
4Installation Instructions...........................................................................................................................................5
5Trouble shooting guide............................................................................................................................................6
6Input / Output Specifications..................................................................................................................................7
7Limited One year warranty....................................................................................................................................8

TUNDRA INTERNATIONAL INC.
2041-A, Leonard-de Vinci, Sainte-Julie (Quebec) Canada J3E 1Z2
Tel : [phone] Fax : [phone]
1 Features
1.1. Integrated Charge Controller
The IBC45 Chargers have undergone tens of thousands of hours of strenuous engineering testing to insure years of
trouble-free operation. They have been designed and tested to provide maintenance free operation. The IBC45 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 IBC45 has one of the LOWEST ground fault leakage. 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, the charger will be protected. Externally mounted ATC type fuses
will blow when a battery is connected in reverse. Replace with same type and rating.
CAUTION: IF THE REVERSE BATTERY PROTECTION FUSES ARE BLOWN DURING
INSTALLATION, CHECK TO SEE THAT THE BATTERIES HAVE BEEN CONNECTED
PROPERLY BEFORE REPLACING THE FUSES. REPLACE THE FUSES ONLY WITH THE
SAME TYPE AND RATING AS THE ORIGINAL FUSES. USING OTHER FUSES COULD
RESULT IN THE CHARGER BEING DAMAGED, VEHICLE DAMAGE, INJURY OR
OTHER CONSEQUENCES.
1.4. Short Circuit Protection
The IBC45 senses, within millionths of a second, if the output terminals have been shorted. If this condition should
occur the charger first limits the current available. Should the condition continue to exist, the charger then shut down.
The IBC45 was designed to protect itself. Once the "short circuit" has been corrected, it will automatically return to
normal operating conditions.
1.5. Thermal Protection
If an over temperature condition should occur due to air flow obstruction or improper installation, the IBC45 senses the
condition and decreases power output or shut down, until the unit returns to normal operating temperature. The charger
will return to full output capacity as it cools down.
1.6. Ignition Protection
All IBC45 Chargers are ignition protected, but must be kept away from flammable liquids.
1.7. Internal Component Cooling
The IBC45 Chargers are equipped with a variable speed cooling fan. The fan will only run at the speed needed to
prevent the charger from overheating and shutting down. Running the fan at lower speeds where possible will reduce
the audible noise generated by the fan while protecting the charger from excess heat. The location of the fan allows for
the maximum cooling of both the case and components.
1.8. Overvoltage Protection
If the Input Voltage exceeds a preset limit the charger will shutdown to prevent damages. The unit will return to normal
operation when the voltage returns to normal.

TUNDRA INTERNATIONAL INC.
2041-A, Leonard-de Vinci, Sainte-Julie (Quebec) Canada J3E 1Z2
Tel : [phone] Fax : [phone]
2General Information’s
The IBC45’s are state-of-the-art electronic 120 VAC to 12 VDC Converter / Battery chargers and are UL and CUL
(Canadian) listed. Their compact size and quiet operation gives greater flexibility in selecting the mounting location for
either OEM aftermarket or installation.
The IBC45 battery chargers have a built-in Charge Controller module. The Charge Controller is a microprocessor
controlled device incorporated in the IBC45 Charger which constantly monitors the batteries, and then automatically
adjusts the charger’s output voltage based on its charge status. The Charge Controller has four (4) operating Modes
(BOOST, NORMAL, STORAGE and EQUALIZE). Each Mode is automatically selected by the Charge Controller and
ensures a fast yet safe recharge for the batteries. See 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 INTEGRATED CHARGE CONTROLLER’S ABILITY TO CHANGE THE OUTPUT VOLTAGE OF THE
CHARGER WILL SIGNIFICANTLY REDUCE THE AMOUNT OF TIME IT TAKES TO RECHARGE YOUR
BATTERY. THE LOWER VOLTAGE FOR STORAGE MODE PREVENTS GASSING AND REDUCES WATER
LOSS DURING LONG-TERM STORAGE.

TUNDRA INTERNATIONAL INC.
2041-A, Leonard-de Vinci, Sainte-Julie (Quebec) Canada J3E 1Z2
Tel : [phone] Fax : [phone]
3General Operation
The IBC45 Charger will supply "clean" nominal 13.6 VDC (Normal Mode) power from input voltages that range from
90-130 VAC.
The IBC45 chargers are primarily designed for use with batteries; however, the output of the IBC45 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 regulated battery charger the IBC45
has a nominal voltage output of 13.6 VDC. The system was designed to sense voltage on the battery and automatically
selects one of 4 operating modes (Boost, Normal, Storage and Equalization) to provide the correct charge level to the
batteries.
NOTE: AT A NORMAL INPUT VOLTAGE THE FULL LOAD RATED CAPACITY IS AVAILABLE.
- AT AN INPUT VOLTAGE LESS THAN 105 VAC THE CHARGER MAY NOT SUPPLY IT’S
FULL RATED OUTPUT CAPACITY.
CAUTION: IT IS IMPORTANT THAT THE FLUID LEVEL OF ANY CONNECTED BATTERIES BE
CHECKED ON A REGULAR BASIS (When possible). BATTERIES MAY “GAS” AND LOSE
SOME FLUIDS WHEN CONTINUOUSLY CONNECTED TO ANY CHARGING SOURCE.
4Installation Instructions
Horizontal mounting of the ICB45 is recommended although it can be mounted in any position that provides
unobstructed ventilation to the fan and vent holes. Secure the charger firmly to the mounting surface using standard
fasteners.
Failure to provide adequate ventilation to the charger will cause it to cycle on and off as it responds to ambient
conditions.
The charger can be mounted safely up to 15 ft from the batteries using AWG 6 cables and a 60A CNL fuse. Using
undersized cables may overheat the charger and cause a premature shutdown. Make sure to use every possible
precaution when routing the cables thought sheet metal to prevent short circuit.
CAUTION: THE IBC45 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 IBC45 CHARGERS ARE NOT WEATHER TIGHT NOR DESIGNED FOR WET
LOCATION MOUNTING. THEY MUST BE PROTECTED FROM DIRECT CONTACT
WITH WATER OR HIGH HUMIDITY.

TUNDRA INTERNATIONAL INC.
2041-A, Leonard-de Vinci, Sainte-Julie (Quebec) Canada J3E 1Z2
Tel : [phone] Fax : [phone]
5Trouble shooting guide
1. LOOSEN THE SCREW ON THE POSITIVE TERMINAL AND DISCONNECT THE POSITIVE WIRE. READ
THE CONVERTER OUTPUT VOLTAGE USING A DC VOLTMETER. IF THE VOLTAGE IS ABOVE
13 VOLTS, THE CONVERTER IS WORKING PROPERLY.
2. IF THE CONVERTER OUTPUT IS ZERO VOLTS, USE AN AC VOLTMETER TO CHECK FOR PROPER
VOLTAGE AT THE 120 VAC INLET, WHERE THE CHARGER IS PLUGGED IN. THIS VOLTAGE
SHOULD BE BETWEEN 105 AND 130 VOLTS.
3. CHECK THE FUSES LOCATED AT THE FRONT OF THE CONVERTER. THESE FUSES CAN BLOW IF
THE BATTERY OR DC OUTPUT LEADS HAVE BEEN CONNECTED IN REVERSE, EVEN FOR A
MOMENT, OR IF THE CHARGER DC CABLES OVERHEAT BECAUSE THEY ARE UNDERSIZED OR
IMPROPERLY CONNECTED. REPLACE THE FUSES AND REPEAT STEP 1.
4. IF THE PROBLEM PERSISTS, USE THE CHART BELOW.
PROBLEM
POSSIBLE CAUSES
ACTION
1. No Output Not connected to 120 VAC source
Connect to an AC source
Check AC distribution panel source for a tripped
breaker
External Fuses Blown
Check cable for Reverse Polarity
Replace Fuses with same type and rating
Short Circuit Trace AC Circuits for possible fault
Unit has shutdown due to overheating Check air flow
Allow unit to cool
Unit has shutdown due to over voltage
(Also see Item 5 below)
Check input voltage
Charger will shut down if the input voltage exceeds
132 Volts AC
Correct Input Voltage
2. External Fuses
blown
Reverse Battery Hook-Up Correct Hook-up and replace Fuses with same type
and rating
3. Charger cycles
on & off Compartment gets too hot
Check air flow to the charger
Improve Ventilation to the compartment
4. Low Output
Excessive Load for Charger
Reduce load requirements or Install Larger Charger
Input Voltage not between 105-130 VAC Correct input supply voltage
Bad Battery Cell(s)
Replace Battery
5. Intermittent or no
Output on
Generator, but
works on Shore Power
Unit has shutdown due to over voltage. Add another load to the generator, this may reduce
the “spikes” to an acceptable level
Some generators provides excessive
voltage spikes on the AC power output,
this may cause the over voltage protection
to shut the unit down
Contact generator manufacturer for possible defect
in the generator

TUNDRA INTERNATIONAL INC.
2041-A, Leonard-de Vinci, Sainte-Julie (Quebec) Canada J3E 1Z2
Tel : [phone] Fax : [phone]
6Input / Output Specifications
Input
105-130 VAC
60 Hz
725 Watts
Output
13.6 VDC
45 Amps
Dimensions
4.5H x 8.25L x 7.25W (in.)
Weight
4.5lbs

TUNDRA INTERNATIONAL INC.
2041-A, Leonard-de Vinci, Sainte-Julie (Quebec) Canada J3E 1Z2
Tel : [phone] Fax : [phone]
7Limited One year warranty
Tundra International Inc. warrants its battery chargers against defects in workmanship and materials for a period of one
(1) year from the date of first consumer purchase. This warranty is given only to the first end-use purchaser of the
product.
This limited warranty is void 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. 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.
Tundra International Inc. will, without charge, repair or replace, at its option, a defective product upon delivery, with
all shipping and handling costs, and full insurance, paid for by the purchaser, to the Tundra Service Department: 2041-
A Leonard-de Vinci, Sainte-Julie Quebec, Canada, J3E 1Z2. The following information, clearly printed, must be
included with the defective unit: Your name and street address, a daytime telephone number and/or email address, a
detailed description of the problem and the proof of the date of first consumer purchase, such as duplicated sale receipt.
2041-A, LEONARD-DE VINCI,
SAINTE-JULIE (QUEBEC) CANADA, J3E 1Z2
TEL: [phone]
FAX : [phone]