Projecta Intelli-Charge DC/Solar Battery Charger

Important Safety Information

Please read this manual thoroughly before use and store in a safe place for future reference.

Warnings

• Explosive gases may escape from the battery during charging. Prevent flames and sparks and provide adequate ventilation.
• Before charging, read the instructions.
• For charging 12 Volt automotive batteries only.
• Do not attempt to charge non-rechargeable batteries.
• Never charge a frozen battery.
• Corrosive substances may escape from the battery during charging and damage delicate surfaces. Store and charge in a suitable area.
• This appliance is not intended for use by young children or infirm persons unless they have been adequately supervised by a responsible person to ensure that they can use the appliance safely.
• Young children should be supervised to ensure that they do not play with the appliance.
• Fit fuses as close to the batteries as possible to protect the cable in case of short circuit P/n: FK25A

Features

The IDC25X charger is Intelli-Charge's next generation in DC-DC charging. It has been designed with next generation technology to ensure your DC-DC charging experience is unrivalled. The IDC25X features everything needed to maintain the auxiliary battery to its optimum condition and to prolong battery life.

Dual Input Operation

The IDC25X allows for simultaneous dual battery charging from both solar and alternator inputs with no manual switching required. The unit prioritises solar charging as its default and automatically adjusts to the alternator if sunlight is insufficient, reducing the power usage placed on the vehicle's electrical system.

Tough & Reliable

IDC25X is rated to IP68 & IP69K, ensuring it can withstand the toughest of conditions. All connections into the IDC25X are done via brass posts and crimped terminals. Ideal for mounting in the engine bay. IDC25X uses temperature compensation to ensure the battery receives the correct charge voltage regardless of ambient temperatures. It reduces the voltage in warmer climates to ensure the battery does not boil.

Smart DC-DC Charging

IDC25X paired with Intelli-IQ supports advanced control of the dual battery system including Bluetooth connectivity to an iOS or Android device. Note: Intelli-IQ is sold separately.

Charging Capabilities

Multi-Chemistry Charging

The IDC25X suits today's different battery technologies, including everyday automotive batteries and the newer lithium battery technology. For automotive batteries, multi-chemistry technology enables the user to tailor the charging profile to suit the battery type: AGM, GEL, WET, Calcium and LiFePO4 batteries. For other types of Lithium batteries, please check the battery's datasheet and see if IDC25X is suitable for the charging profile before connecting.

Parallel Charging

IDC25X can be wired in parallel to provide more charging current for larger systems. This flexibility gives users the option to add another IDC25X into their system should power requirements change. For example, two IDC25X would provide a total charging current of 50A.

Future Proof

IDC25X was designed to stand the test of time. When IDC25X is paired with an Intelli-IQ, the firmware can be updated via Bluetooth ensuring IDC25X software is always up to date with the latest features.

Solar MPPT

The IDC25X utilises sophisticated MPPT (Maximum Power Point Tracking) solar regular technology. MPPT maximises the power generated from the solar panels to the auxiliary battery.

Protective Features

• Output Capacitor Spark: The unit has an output capacitor inside; when a battery is connected to the AUX output, there will always be a small spark.
• Reverse Connection Protection: The unit has an output capacitor inside; when a battery is connected to the AUX output, there will always be a small spark.
• Over and Under Voltage Protection: The charger will automatically shut down if there is an over voltage or under voltage problem.
• Over Temperature Protection: The charger will lower its output current if the temperature of the unit begins to overheat.

Specifications

Product Overview

The IDC25X features a clear layout of input terminals, output posts, and status LEDs.

Key Indicators and Terminals:

• Power LED: Indicates IDC25X on/off charging status.
• Solar LED: Indicates solar input status.
• Alternator LED: Indicates alternator input status.
• Battery Chemistry Setting LED: Indicates the selected battery type (GEL, AGM, WET, CAL, LITH, USER).
• LIN BUS Input Terminal: For communication.
• Ignition Input Terminal: For ignition sensing.
• Temperature 1 & 2 Input Terminals: For temperature compensated charging.
• Auxiliary LED Input Terminal: Provision for an auxiliary LED to indicate IDC25X status.
• Alternator Input Post: Connection for alternator power.
• Ground Connection Input Post: Connection for ground.
• Auxiliary Battery Input Post: Output for the auxiliary battery.
• Solar Input Post: Connection for solar panel power.

The unit has dimensions of 137mm x 122mm x 50mm and weighs 1180g.

A QR code is present, which can be scanned to show the instruction manual URL and full series number.

Installation

Mounting

The IDC25X's IP68 & IP69K tough and rugged design allows for mounting where best suits the application. The entire PCB is potted using a high-quality thermal compound inside the aluminium extrusion, ensuring the unit is impervious to vibration, dust, moisture, and extreme temperatures. While robust, it is advisable to keep the charger as far away from exhaust, turbos, or other high-temperature components to ensure improved performance.

Wiring

To make reliable and durable electrical connections, battery cables must be made to the correct length. Properly reducing wire or cable lengths helps avoid unexpected voltage drops and noise. Cable lugs should be crimped and insulated to the cable before connection to the brass posts and spade terminals.

Minimal Cable Size for Wiring (up to 12m):

Please increase the cable size for cables beyond 12m length as required. Contact Technical Support for assistance on 1800 422 422.

Installation Steps:

1. Disconnect the negative battery cable (Earth) from the vehicle's starting battery or disconnect power to the trailer. Note: To prevent the loss of vehicle's electronic memories, radio pre-sets & security codes, it is recommended that an "Electrical System Memory Protector" be used.
2. Connect the Auxiliary Battery positive (+) terminal to the IDC25X auxiliary battery output post. Fit a fuse (50A for IDC25X) to the cable as close as possible to the Auxiliary Battery positive (+) terminal.
3. Connect the Auxiliary Battery (-) terminal to the IDC25X common ground output post. Alternatively, connect both Auxiliary battery negative (-) terminals and IDC25X common ground output post to the vehicle's chassis ground. After the Auxiliary battery has been connected, check LED indicators. Do not proceed if there is an Output Overvoltage alarm (red LED) or if the LEDs do not turn ON.
4. Connect the Starter Battery positive (+) terminal to the IDC25X Alternator Input Post. Fit a fuse (50A for IDC25X) to the cable as close as possible to the Starter Battery positive (+) terminal.
5. If your vehicle has a fixed voltage or temperature compensating alternator installed, do not make connection to the Ignition Input Blade Terminal. If your vehicle has a smart (variable voltage) alternator installed, the Ignition Input Blade Terminal must be connected to the vehicle's ignition. At 12.2V ALT voltage, the IDC25X will only operate when the vehicle's ignition is turned on (may take up to 2 minutes to start charging). Fit a 1-2A fuse to the cable as close as possible to the vehicle's ignition. Consult the vehicle manufacturer for the type of alternator installed in your vehicle.
6. To add 12Vdc solar panels to the system, connect the solar panel positive terminal (+) to the IDC25X solar input post. Fit a fuse to the cable as close as possible to the Solar Panel positive (+) terminal (refer to the table below for fuse size). Note: No solar controller is required with the IDC25X. If using portable solar panels that include a solar controller, the controller will need to be bypassed. After the positive has been connected, connect the solar panel negative (-) terminal to the vehicle chassis ground.
7. The LED output terminal provides about 5mA constant current output. It can power an LED panel mount indicator without an external resistor. This terminal is not required to be wired if an external LED indicator is not needed. If an external LED indicator is required, connect the positive (+) terminal of a LED Indicator to the LED input terminal. Connect the negative terminal of the LED indicator to the vehicle chassis ground.
8. The TEMP1 & TEMP2 input terminals are used to provide temperature compensated battery charging. Attach the provided temperature sensing loom blade terminals to TEMP1 & TEMP2 inputs on IDC25X; the ports are dual polarity, allowing the negative and positive to be plugged into either port. The temperature sensing loom is provided with 5m wire; please cut the excess length to minimize voltage drops and noise.

Wiring Instruction Guides

1. Full System with Intelli-IQ Configuration

This diagram shows a complete system setup including the IDC25X charger, an Intelli-IQ display, and smart relays. Connections include:

• Alternator/Starter Battery: Red 8mm² cable from the starter battery positive terminal to the IDC25X Alternator Input Post (fused).
• Ground: Black 8mm² cable from vehicle chassis ground to the IDC25X Ground Connection Input Post.
• Auxiliary Battery: Grey 8mm² cable from the auxiliary battery positive terminal to the IDC25X Output/Auxiliary Battery Post (fused).
• Auxiliary Battery Ground: Black 8mm² cable from the auxiliary battery negative terminal to the IDC25X Ground Connection Input Post or vehicle chassis ground.
• Solar Panel: Green 8mm² cable from the 12V Solar Panel positive terminal to the IDC25X Solar Input Post (fused). Solar panel negative connects to vehicle chassis ground.
• Ignition Override: Blue 1.5mm² cable from the vehicle's ignition feed (for smart alternators) to the IDC25X Ignition Input Terminal.
• LIN BUS: Purple 1.5mm² cable from a junction box to the IDC25X LIN BUS Input Terminal.
• External LED: Pink 1.5mm² cable from an LED Panel Mount Indicator to the IDC25X L.E.D. Input Terminal.
• Temperature Sensor: Black-Red wire from the temperature sensor (mounted to battery casing) to the IDC25X TEMP1/TEMP2 Input Terminals.

2. Full System Configuration

This diagram illustrates a full system setup without the Intelli-IQ display and smart relays. Connections are similar to the Intelli-IQ configuration:

• Alternator/Starter Battery: Red 8mm² cable from the starter battery positive terminal to the IDC25X Alternator Input Post (fused).
• Ground: Black 8mm² cable from vehicle chassis ground to the IDC25X Ground Connection Input Post.
• Auxiliary Battery: Grey 8mm² cable from the auxiliary battery positive terminal to the IDC25X Output/Auxiliary Battery Post (fused).
• Auxiliary Battery Ground: Black 8mm² cable from the auxiliary battery negative terminal to the IDC25X Ground Connection Input Post or vehicle chassis ground.
• Solar Panel: Green 8mm² cable from the 12V Solar Panel positive terminal to the IDC25X Solar Input Post (fused). Solar panel negative connects to vehicle chassis ground.
• Ignition Override: Blue 1.5mm² cable from the vehicle's ignition feed (for smart alternators) to the IDC25X Ignition Input Terminal.
• External LED: Pink 1.5mm² cable from an LED Panel Mount Indicator to the IDC25X L.E.D. Input Terminal.
• Temperature Sensor: Black-Red wire from the temperature sensor (mounted to battery casing) to the IDC25X TEMP1/TEMP2 Input Terminals.

3. Alternator/Starter Input Only Configuration

This configuration focuses on using the alternator/starter battery input and connecting to the auxiliary battery, without solar input.

• Alternator/Starter Battery: Red 8mm² cable from the starter battery positive terminal to the IDC25X Alternator Input Post (fused).
• Ground: Black 8mm² cable from vehicle chassis ground to the IDC25X Ground Connection Input Post.
• Auxiliary Battery: Grey 8mm² cable from the auxiliary battery positive terminal to the IDC25X Output/Auxiliary Battery Post (fused).
• Auxiliary Battery Ground: Black 8mm² cable from the auxiliary battery negative terminal to the IDC25X Ground Connection Input Post or vehicle chassis ground.
• Ignition Override: Blue 1.5mm² cable from the vehicle's ignition feed (for smart alternators) to the IDC25X Ignition Input Terminal.
• External LED: Pink 1.5mm² cable from an LED Panel Mount Indicator to the IDC25X L.E.D. Input Terminal.
• Temperature Sensor: Black-Red wire from the temperature sensor (mounted to battery casing) to the IDC25X TEMP1/TEMP2 Input Terminals.

4. Solar & Auxiliary Battery Input Configuration

This setup utilizes the solar panel input and connects to the auxiliary battery, excluding the alternator input.

• Solar Panel: Green 8mm² cable from the 12V Solar Panel positive terminal to the IDC25X Solar Input Post (fused). Solar panel negative connects to vehicle chassis ground.
• Ground: Black 8mm² cable from vehicle chassis ground to the IDC25X Ground Connection Input Post.
• Auxiliary Battery: Grey 8mm² cable from the auxiliary battery positive terminal to the IDC25X Output/Auxiliary Battery Post (fused).
• Auxiliary Battery Ground: Black 8mm² cable from the auxiliary battery negative terminal to the IDC25X Ground Connection Input Post or vehicle chassis ground.
• Ignition Override: Blue 1.5mm² cable from the vehicle's ignition feed (for smart alternators) to the IDC25X Ignition Input Terminal.
• External LED: Pink 1.5mm² cable from an LED Panel Mount Indicator to the IDC25X L.E.D. Input Terminal.
• Temperature Sensor: Black-Red wire from the temperature sensor (mounted to battery casing) to the IDC25X TEMP1/TEMP2 Input Terminals.

LED Indicators

LED Charge Indicators

LED Battery Charge Status Indicators

How to Select Battery Chemistry

The IDC25X allows you to select the appropriate charge setting for your auxiliary battery.

To change the battery type, hold and press the Mode Button [○] for about 3 seconds. When the Charge LED turns OFF and the Battery Type LED will begin to flash, then release the Mode button. After which, the Mode Button [○] can be short pressed to select the Battery Type. When the Battery Type LED is in the correct Battery Chemistry for about 3 seconds, then that Battery Type chemistry is deemed selected.

To confirm you have selected the correct battery chemistry, press the Mode button [○].

Output Override

If the auxiliary battery has been heavily discharged, hold and press the Mode button [○] for about 10 seconds. When all Battery Type LEDs light up simultaneously, let go of the Mode Button. This will cause IDC25X to commence charging.

Frequently Asked Questions

Q: Is the IDC25X waterproof?

A: The IDC25X was designed and engineered to the stringent ingress protection rating of IP68 & IP69K. This allows the IDC25X to meet the toughest of challenges whether that be river crossings, engine bay washing or direct high pressure washing of the unit.

Q: Why do the positive cables from the batteries need to be fused?

A: High-Capacity batteries can produce large amounts of power and are capable of melting cable insulation and catching fire in the case of a short circuit. Each positive (+) cable connected to the battery must be protected by a fuse located in close proximity to the battery.

Q: Is the IDC25X safe to use with modern ‘electronic’ vehicles?

A: The IDC25X has been designed to work with all vehicles, including new vehicles with EFI and computer management systems. The charger utilises sophisticated electronics that ensures complete safety for you and your vehicle.

Q: How do I know if the battery is charged?

A: Refer to the diagram "LED BATTERY CHARGE STATUS INDICATORS" on page 13 to identify when the IDC25X is indicating battery charging is complete.

Q: I have connected the IDC25X properly but the power LED [⚡] does not come on?

A: Check the cable size. The IDC25X is designed to power on and charge from an input source as little as 9V. If small size cables are used for wiring, the voltage might drop below 9V when IDC25X is attempting to start up. Please refer to the Installation wiring section for recommended cable size.

Q: I have connected the IDC25X to solar [☀️] and alternator [?] inputs, but the LEDs do not come on?

A: In some cases, batteries can be discharged to the point where they have very little or no voltage. This can occur if a small amount of power is used for a long time, for example, a map reading light is left on for a week or more. The IDC25X is designed to charge an auxiliary battery from as little as 2 Volts. Refer to Page 13 Output Override for detailed instruction.

Q: Why does the IDC25X indicate the battery is fully charged straight away?

A: There are three possible reasons why the IDC25X indicated the battery is fully charged:
1. The battery is fully charged.
2. The battery has taken a surface charge.
3. The battery has a faulty cell.

Q: What is a "Surface Charge"?

A: Batteries unused or left discharged for some time build up a resistance to being recharged. When the charger is first connected, these batteries will take a surface charge, and the IDC25X LEDs will indicate the auxiliary battery is fully charged within a short period of time. The battery, however, is not fully charged. The charger is voltage sensitive and cannot differentiate between a surface charge and a fully charged battery. After a few hours, the battery may start to accept some charge, but most batteries with this condition may not recover.

Q: What is a "Faulty Cell"?

A: 12 Volt batteries contain 6 cells, and one faulty cell is enough to ruin your battery. If after twelve hours of charging your battery is still accepting charge, you should test the cells using a hydrometer. If one reading is lower than the rest, it indicates a faulty cell. It is pointless to continue charging; the battery needs replacing.

Q: Why is there no output at the IDC25X's auxiliary battery output?

A: The IDC25X incorporates short circuit protection that makes it much safer to use. For this reason, the IDC25X will only output power when properly connected to a battery. To check if the IDC25X is functioning, follow the instructions to connect and operate the charger as normal on a flat battery. While the battery is charging, measure the battery voltage with a volt or multi-meter. Charging can be confirmed if the voltage is increasing (within the voltage parameters set out in the specifications).

Warranty Statement

Brown & Watson International Pty. Ltd. ("BWI") of 1500 Ferntree Gully Road, Knoxfield, Vic., telephone (03) 9730 6000, fax (03) 9730 6050, warrants that all products described in its current catalogue will under normal use and service be free of failures in material and workmanship for a period of five (5) year from the date of the original purchase by the customer as marked on the invoice (see elsewhere for specific warranty period). This warranty does not cover ordinary wear and tear, abuse, alteration of products, or damage caused by the purchaser.

To make a warranty claim, the consumer must deliver the product at their cost to the original place of purchase or to any other place which may be nominated by either BWI or the retailer from where the product was bought, in order that a warranty assessment may be performed. The consumer must also deliver the original invoice evidencing the date and place of purchase together with an explanation in writing as to the nature of the claim.

In the event that the claim is determined to be for a minor failure of the product, then BWI reserves the right to repair or replace it at its discretion. In the event that a major failure is determined, the consumer will be entitled to a replacement or a refund, as well as compensation for any other reasonably foreseeable loss or damage.

This warranty is in addition to any other rights or remedies that the consumer may have under State or Federal legislation.

Important Note

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

Distributed by:

AUSTRALIA

Brown & Watson International Pty. Ltd.
Knoxfield Victoria 3180
Phone: (03) 9730 6000
Fax: (03) 9730 6050
National Toll Free: 1800 113 443

NEW ZEALAND OFFICE

Griffiths Equipment Ltd.
19 Bell Avenue,
Mount Wellington,
Auckland 1060, New Zealand
Phone: (09) 525 4575

Intelli-start.com

IS555 Issue 22.05.2023