DC-DC DCC1212-20 | 40 | 60 Version 1.
Important Safety Instructions Please save these instructions. This manual contains important safety, installation, and operating instructions for the charger. The following symbols are used throughout the manual to indicate potentially dangerous conditions or important notes. WARNING CAUTION NOTE Indicates a potentially dangerous condition. Use extreme caution when performing this task. Indicates a critical procedure for the safe and proper installation and operation of the controller.
Ensure secure location where it cannot tip or fall For installation on boats: if the electrical devices are incorrectly connected, this can lead to corrosion damage on the boat. Verify installation with a qualified electrician or installer. Lay cables so they cannot be damaged by doors or be a tripping hazard.
Table of Contents Safety Information 01 General Information 04 Product Overview 05 Identification of Parts 05 Dimensions 06 Optional Components 07 Installation Location Considerations Wiring and Fusing 07 09 Grounding 09 DC Output Wiring (House) 10 DC Input Wiring (Starter) 11 D+ Ignition Wiring 12 LC Current Limit Wiring 14 Operation 15 LED Indicators 15 Setting Battery Type 15 Setting Lead Acid 16 Setting Lithium 17 Battery Charging Logic 18 Lithium Activation 18 Trou
General Information The DC-DC Series battery chargers are the most effective way to charge your auxiliary or house batteries from the alternator/starter battery. Compatible with smart or traditional alternator types, the DC-DC offers correct charging for AGM, Flooded, Gel, and even Lithium deep cycle batteries! Featuring a 3-stage battery charger and multiple electronic protections, owners can feel confident that their batteries are being charged optimally and automatically.
Product Overview Identification of Parts 1 2 INPUT DC Input Side 3 INPUT Key Features 1. Negative DC Input Terminal 2. Positive DC Input Terminal 3. Ventilation Fans 1 2 3 4 5 6 sensor 7 OUTPUT 8 OUTPUT S1S2S3S4S5 DC Output Side Key Features 1.Power LED 2.Fault LED 3.Dip Switches 4.RJ11 Temperature Sensor Port (Model: RTSDCC, requires separate purchase) 05 5.D+ Ignition Terminal 6.LC Terminal – Current Limiting Terminal 7.Positive DC Output Terminal 8.
Dimensions 211.0mm 8.30in 175.0mm 6.90in 68.0mm 2.70in DCC1212-20 NOTE The dimensions have a ±0.5mm tolerance 261.0mm 10.30in 175.0mm 6.90in 68.0mm 2.70in DCC1212-40 NOTE 68.0mm 2.7in The dimensions have a ±0.5mm tolerance 175.0mm 6.90in 311.0mm 12.20in DCC1212-60 NOTE The dimensions have a ±0.
Optional Components DC-DC Temperature Sensor (Model: RTSDCC) CAUTION Do not use with Lithium batteries. CAUTION The RTSDCC comes in handy for reading incoming temperature values from the house battery bank while adjusting the charging voltage of your DC to DC On-Board Battery Charger.
Mounting Have at least 5cm of clearance from all areas and ensure some ventilation for best performance Trace the mounting holes with a pencil/pen when placing the DC-DC against the desired area Use 4 x screws to secure the dc-dc onto a surface 5 cm 5 cm A B 08
Wiring and Fusing Battery Ring terminals are recommended for 12V input and output connections. The following is a reference incorporating a critical 0-3% max voltage drop and may not cover all unique applications that may exist. When the battery charger is sending the rated amps, the input side may experience a draw higher current draw by a factor of up to 50%. Larger wire sizes generally improve performance, whereas smaller wire sizes may reduce performance, especially if undersized.
D+IGN Wiring to Ignition Circuit ALTERNATOR CK A LO RT TA ON S CC ANL FUSE ANL FUSE DC INPUT (STARTER) CHASSIS GROUND DC OUTPUT (HOUSE) CHASSIS GROUND DC Output Wiring (House) WARNING Only use 12V batteries. Damages due to connecting higher voltage batteries will not be covered in warranty. The DC-DC output will connect to the 12V auxiliary or house battery that you are intending to charge. These batteries may be a different chemistry from the starter battery.
1 counterclockwise 2 3 clockwise DC Input Wiring (Starter) NOTE The DC-DC will not power on or operate until the D+ ignition cable is connected. When connecting the DC input, note that the DC-DC will still be off until the D+ ignition cable voltage senses. The DC-DC input will connect to the 12V starter battery that will be used to charge your auxiliary or house battery. The starter battery may be a different chemistry from the house battery.
1 counterclockwise 2 3 clockwise D+ Ignition Wiring The D+ terminal will be located on the output side but connects to the DC ignition circuit of the input starter battery. This may be in the engine bay fuse block for some vehicles. Refer to your own vehicle’s electrical diagram for D+ wiring placement. May require splicing or cable adjustments to connect correctly to your ignition circuit.
The DC-DC will not power on or operate until the D+ ignition cable is connected to the ignition circuit where it will detect a 12V source to operate ON. The purpose is to toggle the DC-DC switch on when the vehicle is running with the alternator to prevent the DC-DC from operating incorrectly with just the starter battery leaving you with a drained starter battery. Use 18-16AWG copper cable. You may need a multi-meter to test your connections to verify placement of the D+ wire.
Engine Bay Fuse Block Recommendation Review your vehicle’s fuse layout diagram to identify a fuse location that is live when the vehicle is running with the alternator. Key positions in the ignition are typically lock, accessory, on, and start. LOCK Off position where no accessories will work, and steering is also likely locked ACCESSORY Accessories are given power such as radio and some other small electronics. ON Turns on all your electronics.
sensor OUTPUT OUTPUT S1S2S3S4S5 LC+ 18-16AWG, copper cable recommended D+ Operation Assuming correct 12V battery connections and D+ ignition cable wiring, then the POWER LED will illuminate green.
DIP Switches The 5 x dip switches can be configured to charge lead acid or lithium batteries. Note that ON is position down and OFF is position up if facing the dip switches directly. Lead acid profiles have an absorption charge and a float charge whereas lithium batteries will only have an absorption charge and no float charge. OFF ON ON Setting Lead Acid Lead acid assumes deep cycle AGM, Gel, Flooded, and Sealed Lead Acid. To get started, make sure SW5 = ON to gear the charger for lead acid batteries.
Setting Lithium To get started, make sure SW5 = OFF to gear the charger for lithium batteries. There will not be a float voltage and instead users will select between Type 1 lithium voltages or switch into Type 2 lithium voltages depending on your lithium battery specifications. You must select a lithium Type to when selecting your charge voltage. Type 1 voltages range from 12.6V ~ 13.0V and Type 2 voltages range from 14.0V~14.6V.
Battery Charging Logic U/V I/A Bulk Absorption Float U I U0 U 100 % I 10 % t Bulk (Phase I) (Lead Acid + Lithium) In the beginning, a discharged battery will be charged with maximum current and voltage will be climbing steadily until reaching the absorption voltage setpoint. Absorption (Phase U0) (Lead Acid + Lithium) The battery reaches the absorption voltage setpoint and holds the voltage constant while the current gradually decreases until the battery is becoming full (within 10-20%).
Troubleshooting If the DC-DC is not functioning correctly, it may be undergoing an internal electronic protection and stop normal operation. This is not indicative of a defective unit but may require some troubleshooting to resume normal operation. Electronic Protection Behavior Troubleshoot Steps Protection 1.Use a multi-meter to measure the DC input and DC output batteries as well as the respective DC-DC input/output terminals. Battery over-voltage is 15.
Behavior Protection High Temperature Troubleshoot Steps 1.Double check that your wiring is correct with a multi-meter and that the battery levels are suitable within the operating voltage range 2. Observe the ambient temperature. Avoid installations in direct sun. Ambient temperatures above 122°F/50°C will cause the unit to stop functioning until conditions get cooler. Move the unit to a cooler location or introduce ventilation into the install location.
Behavior Cause Connection break Fix 1.Inspect your connections for tight, secure, and undamaged wiring to and from the DC-DC 2.Check fuses for any breaks and replace them to continue normal operation. 3.Use your multi-meter’s (check with manufacturer) continuity test to individually check each line (positive and negative) at the input and output to verify consistent connection. Audible multi-meter Beeps indicate continuity. No sound indicates connection break.
Technical Specifications Model DCC1212-20 DCC1212-40 Transformation DCC1212-60 12 V → 12 V Input Battery Voltage Range 8V ~ 16VDC Rated Charging Current 40 A 20 A 60 A Lead Acid: 13.2V ~ 14.7V Lithium: 12.6V ~ 14.6V Charging Voltage Range Rated Max Power 500W 250W Residual ripple of output voltage at rated current 750W < 50 mV 90 % Efficiency Idle power consumption 0.
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