iTECHWORLD The Power Expert

Safety Precautions

For safe operation and ideal performance, the iTECHDCDC40 Intelligent Battery Charger must be installed and operated correctly. Please carefully read, understand, and follow all instructions and guidelines in this User Guide.

iTechworld recommends that the iTECHDCDC40 charger be installed by a certified technician. Failure to follow these instructions may result in damage to the unit, property, death, or serious injury.

Disclaimer: While iTechworld has taken every precaution to ensure the accuracy of the contents of this user guide, iTechworld assumes no responsibility for any errors or omissions. Furthermore, all specifications and functionality may change at any time without notice.

• WARNING: People with physical disabilities, visual, sensory, or mental impairments (including children) should not use this device. Children should be supervised to ensure they do not play with battery chargers.
• DANGER: Do not disassemble or modify the charger, doing so may result in a risk of electrical shock, fire, death, or serious injury.
• DANGER EXPLOSION HAZARD: Do not use the charger in an environment where flammable fumes or gases are present (such as gas bottles, petrol engines or lead acid battery compartments).
• DANGER: This charger is only suitable for battery types listed in the manual. Do not use it for other purposes.
• WARNING: Please select the correct battery charging profile applicable to the auxiliary battery. If the incorrect battery charging profile is selected, it may cause damage to your auxiliary battery or result in fire. If you are unsure of the correct battery charging profile to use, please consult your battery's manufacturer.
• WARNING: Please use the fuses and wires recommended in this user guide, otherwise, it may result in damage to the charger, risk of electrical shock, fire, death, or serious injury.
• WARNING: Ensure that the selected battery charging profile's charge voltage does not exceed the battery's recommended maximum charging voltage. If you are unsure of the maximum charging voltage of your battery, please consult your battery's manufacturer.
• WARNING: Ensure that the continuous output current of the charger does not exceed the battery's recommended maximum charging current. If you are unsure of the maximum charging current of your battery, please consult your battery's manufacturer.
• Warning: When using the charger to charge a lithium battery, ensure that it contains an inbuilt battery management system (BMS) that features under and over voltage protection with cell balancing. Failure to do so may result in fire, death, or serious injury.
• DANGER: Never smoke or allow a spark or flame in vicinity of battery or engine. This may cause the battery to explode.
• LIMITATIONS OF USE: Do not use in connection with life support systems or other medical equipment or devices.

Product Function

Introduction

The iTECHDCDC40 charger is suitable for charging all common types of automotive or recreational lead acid and LiFePO4 Lithium 12-volt batteries. The iTECHDCDC40 can operate on 12- or 24-volt alternators and unregulated 12-volt nominal solar input. The iTECHDCDC40 features a Maximum Power Point Tracking (MPPT) solar regulator. This allows for the maximum power to be harvested from the connected solar panels, which increases charging efficiency. The iTECHDCDC40 has been designed with high efficiency in mind, this allows the charger to be compact and suitable for limited space installations. Furthermore, the iTECHDCDC40 is also designed to isolate the auxiliary battery from the cranking battery, this is to avoid over-discharging the cranking battery.

Key Features

• Suitable for charging all common types of automotive or recreational 12-Volt lead acid batteries, such as Standard Lead Acid, Gel, AGM, and Calcium, or LiFEPO4 (Lithium Iron/Ferro Phosphate) Chemistry 12-Volt Lithium batteries.
• 40A MPPT Solar Regulator
• Dual input from both solar and alternator
• Charging efficiency of up to 95%
• Excellent performance in harsh environments
• IP67 rated, for resistance to dust, water, and shock damage.
• Smart alternator compatible
• In-built Low-Voltage, Over-Voltage, Over-Temperature and Reverse Polarity Protection

Display and Operation

2.1 Display Panel

The front panel of the iTECHDCDC40 features several LED indicators. These include:

• MODE: Indicates the selected battery charging profile.
• Alternator/Solar LED: Indicates the input source (Alternator or Solar).
• Battery Type LEDs: Indicate the selected battery type (STD, GEL, AGM, CAL, LiFePO4).
• Solar Priority LED: Indicates if the Solar Priority function is active.
• Fault LED: Indicates if a fault condition is present.

A diagram of the display panel shows these indicators.

2.2 Battery Charging Profile

To change the battery charging profile, press and hold the “Mode” button for at least 3 seconds then release. The battery type indicator will advance one LED to the right. Note that the next battery type indicator will not illuminate until the “Mode” button is released. It may take up to 2 minutes after any changes for the charger to start charging.

2.3 Solar Priority

The iTECHDCDC40 is set up with alternator priority by default, as power from solar can be unstable and affect charging efficiency. However, if solar charging is preferred regardless of efficiency, or if the auxiliary battery has a very small load and solar charging is desired, the “Solar Priority” function can be enabled. When enabled, the iTECHDCDC40 will always select input power from the Solar connector if the solar input power is above the minimum required power. It may take up to 2 minutes after any changes for the charger to start charging.

To turn "Solar Priority” ON, press and hold the “Solar Priority” button for at least 3 seconds then release; the “Solar Priority” indicator will illuminate.

To turn "Solar Priority” OFF, press and hold the "Solar Priority" button for at least 3 seconds then release; the “Solar Priority” indicator will turn off.

2.4 LED Charge Indicator

The following table describes the LED indicators for charging status:

2.5 Unit Operation

When the iTECHDCDC40 is connected, all LED indicators may light up, which is normal operation during initialization. This process may take up to 2 minutes to start charging.

The iTECHDCDC40 will enter standby mode if input voltages are below the cut-off voltage. The charger will continue to charge the auxiliary battery for up to 2 minutes before entering standby. This is indicated by the charge input and battery type indicator LEDs blinking momentarily. Once charging voltages rise above the cut-in voltage, it will take up to 2 minutes for the charger to “wake” and begin charging.

The iTECHDCDC40 will start charging from solar input if the panel supply voltage is above 16 Volts and outputting at least 25 Watts (1.5-2 Amps).

iTECHDCDC40 Operation Table

The following table details the voltage thresholds for turning the charger on and off based on the input source:

2.6 Fault LED Indicators

The following table outlines fault conditions indicated by the LEDs:

Installation

3.1 Install Location

The iTECHDCDC40 charger has been designed for installation in a variety of locations on a vehicle, such as the chassis rail, engine bay, and in the vehicle cabin. If the charger is mounted externally, please ensure that it does not become covered by a build-up of mud. If the charger is to be installed in the engine bay, try to locate it away from components that generate high heat (such as Turbochargers and exhaust manifolds), as this will greatly impact the performance of the charger and may cause it to overheat and shut down.

If the charger is to be installed in the vehicle cabin, please ensure there is adequate ventilation around the charger and that it is not installed in an enclosed space where airflow is restricted.

The temperature of the charger case can typically be 20-30 degrees Celsius above ambient temperature. It is normal for the charger to feel hot, and for you to not be able to keep a finger on the surface for more than a couple of seconds, as the case can exceed 60 degrees Celsius.

The iTECHDCDC40 charger should be installed as close as possible to the battery being charged (auxiliary battery) to allow for more efficient charging. The iTECHDCDC40 can be mounted with 4 screws (Not included); there are cut-outs on the heatsink of the charger where the screws can be affixed.

3.2 Selection of Cable Size

The iTECHDCDC40 charger cables may not be long enough for your application. If the Anderson connectors need extending, please refer to the table below for recommended wire sizes. You can select wires that are equal to or larger than the recommended sizes.

iTechworld recommends a suitably trained/qualified person to perform the work, as failure to make a good connection may cause a short circuit, which may lead to fire and/or damage to property.

When extending the wires, it is recommended to use a soldered butt splice connector to ensure low resistance connections. It is best to crimp both sides of the connector, then solder both sides. Once the connection is made, ensure to use heat shrink to cover the connections to prevent short circuits. A diagram illustrates this connection method.

Butt splice connector: BN8 for 10-8AWG.

3.3 Wiring

Before any connections are made during installation, please disconnect the main cranking battery to prevent short circuits. Note down any radio anti-theft codes before the battery is disconnected.

A wiring diagram shows the connections:

• 1. Output Anderson connector (Red and Black wires): Goes to the battery being charged (the auxiliary battery).
• 2. Alternator Input Anderson connector (Yellow and Black wires): Goes to the main cranking battery.
• 3. Solar Input Anderson connector (Green and Black wires): Connects to an unregulated solar panel.
• 4. Ignition wire (Blue): This wire is optional and depends on the vehicle alternator type.

For standard alternators, leave this wire disconnected and ensure it is well insulated to prevent shorting.

For vehicles with a smart alternator, connect this wire to a switched ignition source (i.e., a point that supplies 12V only when the key is in the 'ON' position and disconnects when the key is in the 'OFF' position). This is usually found in the vehicle's fuse box, and a fuse tap can be used.

3.4 Typical Setup

A typical setup diagram shows the components and their connections: A 12V or 24V Start Battery, Vehicle Ignition, Solar Panel, DCDC Battery Charger, and Auxiliary Battery. These are connected via fuses and ground (GND) to the charger.

3.5 Fuse Specifications

All recommended fuses should be connected in series in the circuit and as close as possible to power sources. Bolt-down fuses are preferred as they ensure a low-resistance connection. Blade type fuses are not recommended as they can result in high resistance connections, causing excess heat generation and potential damage to the fuse holder and/or wiring. Self-resetting circuit breakers are not recommended as they may prematurely trip due to heat generated by large current flowing through the wires.

Please refer to the table below for recommended fuses. (NOTE: FUSES ARE NOT SUPPLIED)

Contact Information

iTechworld

281 Great Eastern Hwy

Burswood WA 6100

Phone: 1300 483 249

Website: www.itechworld.com.au

Email: service@itechworld.com.au