BAINTECH BTDC-DCS40A Battery Charger Instruction Manual
- June 13, 2024
- BAINTECH
Table of Contents
BAINTECH BTDC-DCS40A Battery Charger
SAFETY PRECAUTIONS
WARNING
To avoid any personal injury, please read the safety instructions below.
- It is best to have professional guidance when installing and using the charger. People with physical disabilities, visual impairments and olfactory impairments (including children) should not use this device. Children should be supervised to ensure they do not play with battery chargers.
- Do not disassemble or modify the charger, otherwise it will cause a safety accident.
- This charger is only suitable for battery types listed in the manual. Do not use it for other purposes.
- When charging, please select the charging procedure applicable to the auxiliary battery. If you choose the wrong charging procedure, it may cause certain damage to your auxiliary battery, and even cause safety accidents in serious cases. If you are not sure what kind of charging procedure you should choose, please consult relevant professionals.
- Please use the fuses and wires recommended in the instruction manual, otherwise it may damage the product and cause serious safety accidents.
- NEVER smoke or allow a spark or flame in vicinity of battery or engine. This may cause the battery to explode
PRODUCT FUNCTIONS
The DC40A charger suits for 12V lead acid batteries and 12V LiFePO4 batteries. It is workable for both 12V alternators and 24V alternators. The unit also supports solar panel input and has MPPT strategy. The MPPT strategy allows solar panels to work at the maximum power point. The high power density design concept ensures the charger has excellent efficiency, and the ultra-thin size is suitable for limited installation space. It’s built to work in some harsh environments, which is very common for refitted off-road vehicles and touring cars.
- Compatible for multi-battery types such as Standard Lead Acid, Gel, AGM, Calcium content or LiFePO4
- 40A Solar MPPT
- Dual input from both solar and alternator
- Efficiency up to 95%
- Excellent performance in harsh environments
- IP66, resistant to dust, water, and shock damage
- Smart alternator compatible
- Smart protections including Low-voltage, Over-voltage, Over Temperature and reverse polar
Display Panel
LED Charge Indicator
| Alternator /Solar LED | Battery Type LED | Charging Stage |
|---|---|---|
| Short flash GREEN | Solid GREEN | Bulk |
| Long flash GREEN | Solid GREEN | Float |
Fault LED Indicators
Alternator (Green)| Solar
(Green)
| Battery Type Fault
(Green) (Red)
| Trouble| Solution
---|---|---|---|---
Quick flash
|
Off
|
Quick flash
|
Off
| Low voltage detected at alternator input|
Check alternator input voltage
Off
|
Quick flash
|
Quick flash
|
Off
| Low voltage detected at solar input|
Check solar input voltage
Off
|
Off
|
Quick flash
|
Off
| Low voltage detected at alternator input and solar input| Check alternator input and solar input
voltage
Quick flash
|
Quick flash
|
Quick flash
|
Off
| Low voltage detect at alternator and solar input| Check voltage of both alternator and solar input
Quick flash
|
Off
|
Off
|
Quick flash
|
High voltage detected at alternator input
|
Check alternator input voltage
Off
|
Quick flash
|
Off
|
Quick flash
| High voltage detected at solar input|
Check solar input voltage
Off
|
Off
|
Quick flash
|
Quick flash
|
High voltage detected at output
|
Check auxiliary battery voltage
Off
|
Off
|
Off
|
Quick flash
|
Over temperature
| Let the unit cool down for some time or get better ventilation
INSTALLATION
Selection of Installation Location
The DC40A charger is designed for a variety of installation environments,
including chassis rail, engine cabin, driver cabin and etc. DC40A charger uses
advanced technology so that the product can work stabely in the shaking, wet,
dusty and muddy environment. The DC40A charger is as thin as 45mm and it can
work up to ao·c, so it can be installed in the engine cabin. But please note
that if you want to get a higher charging efficiency, you should try to get it
stay away from the high-temperature parts of the engine cabin. When
installing, the charger should be put closely to the auxiliary battery and
please select the proper charging mode. After selecting the installation
position, please fix the charger with screws.
Selection of Cable Size
The DC40A charger wire maybe not long enough for installation. So if you need
to extend the wire, please check the below table with suggested wire sizes.
You can choose wires that are equal to or larger than this size.
SOLAR (Green)|
<5m
|
<10m
---|---|---
ALTERNATOR (Yellow)| |
OUTPUT (Red)
GND (Black)
|
8AWG
|
6AWG
IGNITION (Blue)| 20AWG| 20AWG
It is very important that the extension wire and the reserved wire are well connected, and the low conduction impedance can ensure the stable and reliable operation of the product. It is recommended to use Butt Splice Connectors. After completion, heat shrinkable tubing must be used for insulation to prevent short circuits.
Wiring Steps
In order to prevent accidental short circuit during install ation , it is
recommended to turn off the car during the installation and the negative pole
of the starter battery should be disconnected. Please note that vehicle power
down may result in loss of memory data . If the installation is powered on,
please proceed with caution.
- The OUTPUT (Red) is connected to the positive pole of the auxiliary
- The GND (Black) is connected to the negative pole(-) of the auxiliary battery, or connect both Auxiliary Battery negative (-) terminals and DC-DC charger common Ground cable to vehicle chassis ground.
- The Alternator (Yellow) is connected to the positive(+) pole of start battery
- The IGNITION (Blue) is connected or not depends on the type of vehicle alte rnator. For standard alternators, just leave it alone. Pay attention to insulation For smart alternators, please connect to the ignition terminal of the vehicle. You can usually find such a connection point in the car fuse box. When the car is started, the terminal is power on. When the car is turned off, the terminal is power off.
- The Solar (Green) is connected to the positive pole (+)of the solar panel if necessary. If the solar panel is not needed, just leave it unconnected. Pay attention to insulation Connect the negative pole of solar panel to common Ground cable or to vehicle chassis ground.
- Restore the negative connection of the If all are ready, the charger will start to work.
Typical Setup
Fuse Specification
All recommended fuses should be connected in series in circuit. Bolt down
fuses are prefered because they ensure a low resistance connection. Blade type
fuses are not recommended as they can result in a high resistance connection
which causes excess heat and may damage the fuse holder and/or the wiring.
Self-resetting circuit breakers are not recommended as they may trip
prematurely due to the heat generated by the current flowing through the
wires.
SOLAR (Green)| 60A 500W
30A 200W
---|---
ALTERNATOR (Yellow) OUTPUT (Red)| 60A
IGNITION (Blue)| 3A
Specification
Operating Conditions
Vehicle Input Voltage| 9-32V
Solar Input Voltage| 9-32V
Max Input Current| 45A
Input Fuse Rating| 60A
Continuous Output Current| 40A
Output Fuse Rating| 60A
Minimum Start Voltage| 4.0VDC or 0.0V for LiFePo4
Standby Current| <15mA
Battery Type| STD, GEL, AGM, CALCIUM & LiFePO4
Operating Temperature| -20’C to +B0′ C
IP Rating| IP66
Dimensions| 194x130x45 mm
Charge Control
Charge Type| 3 Stage
Charging Profile| STD| GEL| AGM| Calcium Li| FeP04
Maximum Voltage| 14.4V| 14.1V| 14_7V| 15.3V| 14.5V
Float Voltage| 13.4V| 13.5V| 13.4V| 13.6V
Operating Mode
Input| Turn On| Turn Off
12V Standard Alternator 24V Standard Alternator| >13.1V
26.2V
| <12_8V
<25.6V
12V Smart Alternator 24V Smart Alternator| >12.0V
24.0V
| <11.BV
<23.6V