KICKASS DCDC MPPT 12V-24V Solar Charge Controller User Manual

1. Introduction and Overview

The KICKASS DCDC MPPT Solar Charge Controller is an advanced power management solution designed to efficiently charge your auxiliary battery from both solar panels and your vehicle's alternator. This versatile unit supports a wide range of battery chemistries, including Gel, AGM, Wet, Calcium, and Lithium, ensuring optimal charging performance with its true 4-stage charging algorithm. Its robust design, featuring an IP67 dust and waterproof rating, makes it suitable for various outdoor and mobile applications.

Figure 1.1: KICKASS DCDC MPPT Solar Charge Controller with integrated wiring.

Product Features:

• Dual Input Charging: Charges from solar panels and vehicle alternator simultaneously.
• IP67 Rated: Dust and waterproof for reliable outdoor use.
• Wide Input Voltage Range: Handles 9 to 32 VDC.
• Lithium BMS Sleep Mode Recovery: Trickle charges lithium batteries until cut-in voltage is reached, then resumes normal charging.
• True 4-Stage Charging: Utilizes BULK, ABSORPTION, FLOAT, and PULSE modes for optimal battery health.
• Universal Battery Compatibility: Supports AGM, GEL, Calcium, Wet, and Lithium batteries (7Ah to 300A).
• Anderson Style Connectors: Features a Three Pin Anderson Style Connector for easy and secure wiring, compatible with common two-pin connectors.
• Built-in MPPT Solar Controller: Automatically switches to solar charging when the vehicle is not running.

Product Overview Video:

2. Safety Information

Please read and understand all safety instructions before installing or operating the KICKASS DCDC MPPT Solar Charge Controller. Failure to follow these instructions may result in electric shock, fire, or serious injury.

• Electrical Safety: Always disconnect power sources before making or breaking electrical connections. Ensure all wiring is correctly sized and fused according to local regulations and the product's specifications.
• Battery Safety: Batteries can produce explosive gases. Ensure adequate ventilation when working with batteries. Avoid sparks, flames, and smoking near batteries. Wear appropriate personal protective equipment (PPE), including eye protection and gloves.
• Installation: Installation should be performed by a qualified professional if you are unsure about any steps. Securely mount the unit to prevent movement or damage.
• Water and Dust: While the unit is IP67 rated, ensure all connections are properly sealed and protected from direct water ingress, especially during installation.
• Temperature: Do not operate the unit outside its specified operating temperature range. Ensure adequate airflow around the unit to prevent overheating.

3. Package Contents

Verify that all items are present in the package:

• 1 x KADCDC25A DCDC MPPT Solar Charge Controller
• 1 x Three Pin Anderson Style Connector (pre-attached to wiring harness)

4. Setup and Installation

Proper installation is crucial for the optimal performance and longevity of your KICKASS DCDC MPPT Solar Charge Controller. The unit is designed for wall mounting.

4.1 Mounting the Unit

Select a secure, well-ventilated location for mounting the charger. Ensure the mounting surface is stable and can support the unit's weight. Use appropriate fasteners for your chosen surface. The unit's dimensions are 0.83 x 0.98 x 0.26 inches and it weighs 3 pounds.

Figure 4.1: Example of the KICKASS DCDC MPPT Solar Charge Controller in an outdoor installation.

4.2 Wiring Connections

The KADCDC25A features a pre-attached wiring harness with a Three Pin Anderson Style Connector for simplified installation. This connector is also compatible with common two-pin Anderson style connectors.

Figure 4.2: Detailed view of the labeled wiring harness for connection.

Identify the following wires on the harness:

• Positive Alternator Input: Connect to your vehicle's alternator output.
• Negative Ground: Connect to a suitable chassis ground point.
• Ignition Wire: Connect to a switched ignition source (e.g., accessory circuit) to enable alternator charging when the vehicle is running.
• Solar Input: Connect to your solar panel array.
• Battery Output: Connect to your auxiliary 12V battery.

Figure 4.3: Anderson style connectors facilitate easy and secure connections.

4.3 Connection Diagrams:

Figure 4.4: Alternator Charging Setup.

Figure 4.5: Solar Charging Setup.

5. Operating Instructions

The KICKASS DCDC MPPT Solar Charge Controller is designed for intuitive operation, automatically managing charging processes once correctly installed.

5.1 Battery Type Selection

The charger features a 'MODE' button on its front panel to select the appropriate battery type for your auxiliary battery. It is crucial to select the correct battery chemistry for optimal charging and battery longevity.

Figure 5.1: Control panel with 'MODE' button and battery type indicators.

Press the 'MODE' button repeatedly to cycle through the available battery types:

• GEL
• AGM
• WET
• CALCIUM
• LITHIUM

An indicator light will illuminate next to the selected battery type.

5.2 4-Stage Charging Process

The charger employs a true 4-stage charging process to ensure efficient and safe charging:

• BULK: Charges the battery at its maximum current until it reaches approximately 80% capacity.
• ABSORPTION: Charges at a constant voltage, gradually reducing current as the battery approaches full charge.
• FLOAT: Maintains the battery at a safe voltage to prevent self-discharge, keeping it fully charged.
• PULSE: Applies short bursts of charge to maintain optimal battery health and desulfation (for lead-acid batteries).

5.3 Charging Modes

• Alternator Charging: When the vehicle's ignition is on, the charger will draw power from the alternator to charge the auxiliary battery.
• Solar Charging: The built-in MPPT solar controller automatically detects solar input and prioritizes charging from solar panels when the vehicle is not running or charging from the alternator.
• Lithium BMS Sleep Mode Recovery: For lithium batteries in sleep mode, the charger will provide a trickle charge until the battery reaches its cut-in voltage, then initiate normal charging cycles. This protects the lithium battery from overcharging, over-discharging, and extreme temperature changes.

Figure 5.2: Automatic disconnection feature for battery protection.

6. Maintenance

The KICKASS DCDC MPPT Solar Charge Controller is designed for durability and requires minimal maintenance. Regular checks will ensure its continued optimal performance.

• Cleanliness: Periodically wipe down the unit with a dry or slightly damp cloth to remove dust and dirt. Do not use harsh chemicals or abrasive cleaners.
• Connections: Regularly inspect all electrical connections (Anderson connectors, wiring terminals) to ensure they are clean, tight, and free from corrosion. Loose connections can lead to poor performance or overheating.
• Ventilation: Ensure that the area around the charger remains clear and unobstructed to allow for proper airflow and heat dissipation.
• Environmental Exposure: While IP67 rated, prolonged exposure to extreme conditions (e.g., direct submersion, extreme temperatures) should be avoided where possible to maximize lifespan.

7. Troubleshooting

If you encounter issues with your KICKASS DCDC MPPT Solar Charge Controller, refer to the following common troubleshooting steps:

If the problem persists after attempting these solutions, please contact KICKASS customer support for further assistance.

8. Specifications

9. Warranty and Support

For warranty information and customer support regarding your KICKASS DCDC MPPT Solar Charge Controller, please refer to the official KICKASS website or contact their customer service directly.

You can visit the KICKASS store for more information and contact details: KICKASS Store on Amazon