ivt-hirschau 920033 Charging Booster Instruction Manual

ivt-hirschau 920033 Charging Booster

INTRODUCTION

Dear customer,
Thank you very much for the trust you have placed in us. You have acquired a reliable high-quality product which will deliver good services for a long time if used appropriately. Please read these instructions for use thoroughly and completely to familiarize yourself with the product prior to putting it into operation. This will give you important information for safe operation and maintenance of the device.

SCOPE OF SUPPLY

• 12 V, 30 A Charging Booster
• 1 m connection cable incl. plug for D+ signal
• Operating instructions in DE, EN, FR, NL

SAFETY INSTRUCTIONS

The following safety notes and hazard warnings serve not only for the protection of the device but also for the protection of your health. Please read the following points thoroughly. In case of property damage or personal injuries caused by improper handling or non-observance of these operating instructions or the safety notes stated herein, the warrant/guarantee shall lapse. We assume no liability for any consequential damages! The exemption from liability also extends to any services provided by third parties that have not been commissioned by us in writing.

• For safety and technical approval reasons (CE), any unauthorized conversion and/or modification of the product is inadmissible. Do not open the housing of the device. The device does not contain any user-replaceable parts and may contain voltages for a long time after it has been switched off (especially in the event of a fault).
• The device must only be used for the intended purpose.
• The use of the device under unfavourable conditions must be avoided. This includes ambient temperatures above 50 °C, moisture, environments containing flammable gases, solvent vapours, dust or humidity above 80 %. The device must not be operated outdoors.
• If there is reason to believe that safe operation of the device is no longer possible, it must be switched off immediately and secured against unintentional operation. A safe operation can no longer be assumed if the device shows visible signs of damage or after the device has been stored under adverse conditions.
• The cables must be laid in such a way that damage is excluded. Make sure that they are well fastened. 12 V cables must not be laid together with 230 V mains cables in the same cable duct (empty conduit).
• Regularly check live cables or lines for insulation defects, breakages or loose connections. Any defects that occur must be rectified immediately.
• During electrical welding work and work on the electrical system, the device must be disconnected from all connections.
• The user is responsible for complying with building and safety regulations of all kinds.
• Safety regulations of the battery manufacturer must be observed. If required, the battery compartment must be vented.
• Observe proper operation of the device. Please consult an expert immediately if you have doubts regarding the proper functioning, safety or connection of the device.
• If it is not clear to the non-professional user from the descriptions provided which characteristic values apply to a device or which regulations must be observed, the information of a specialist must be obtained.
• Keep children away from the device and batteries. Do not leave packing material unattended. It can become a hazardous toy for children.
• We cannot assume liability for damage or injuries caused by improper handling or non-observance of these instructions or safety notes. Any warranty claim shall be void under those circumstances. The warranty is 3 years from the date of purchase (on presentation of the receipt or invoice).

EXPLANATION OF THE SAFETY NOTES

DANGER!
Failure to observe this warning may result in danger to life and limb as well as damage to the device and to appliances and consumers connected to it.

  NOTE
Recommendations and instructions for connecting the device. Read them carefully and follow the instructions when putting the device into operation.

INTENDED USE

D The IVT Charging Booster has been built in accordance with the applicable safety regulations. It fulfil ls the legal requirements of the ECE regulation and therefore has the E-certification. It is suitable for permanent installation in all vehicles with road approval, whether passenger cars, commercial vehicles or other vehicles with 12 V on-board voltage.

The device may only be used:

1. or charging lead-gel, AGM, lead-acid and LiFePO4 batteries of the specified nominal voltages.
2. for the joint supply of consumers connected to these batteries in permanently installed systems.
3. taking into account the specified cable cross-sections for the connection to the device inputs and outputs (see table p. 22/23).
4. taking into account the specified battery capacities at the device inputs and outputs.
5. with fuses of the rating indicated in the connection diagrams (see from p. 18) to protect the wiring of the batteries.
6. in technically perfect condition.

OPERATION AND DISPLAY ELEMENTS

1. Temperature and power controlled fan

2. Connection for temperature sensor

3. Connection for starter battery

4. Connection for second battery

5. Connection for D+ signal

6. Status LED: charging status

7. Status LED: battery status
   

8. DIP switch for mode & battery selection

9. 3-pole plug (not assigned)
   

FEATURES

• For charging 12 V car batteries while driving (lead-acid, lead-gel, AGM and LiFePO4)
• Mandatory for Euro 6 vehicles
• Can also be used for 12 V solar applications
• Adjustable charging modes: 30 A mode and 10 A caravan mode
• Current-dependent switchover to charge retention
• Fast charging through constant current charging (IUoU)
• Deep discharge protection for starter battery
• Temperature management and overtemperature protection
• Output short-circuit protection
• Overvoltage protection for input and output
• Mounting rail

FUNCTIONAL DESCRIPTION

The intelligent charging booster is used to charge lead-acid, lead-gel, AGM and lithium batteries in vehicles with 12 V systems while driving.
It is a clocked up/down converter that compensates for the fluctuating alternator voltage. As soon as an alternator signal (D+) is applied to the charging booster, it automatically goes into operation. The connected second battery is charged independently of the alternator voltage. Switching to charge retention is current-dependent and automatic.
The charging current is limited by the charging booster to max. 30 A (constant current charging). This prevents overloading of the cut-off relay and the cable harness due to high equalizing currents.
The IVT Charging Booster has two charging stages – the 30 A mode and the 10 A caravan mode – which are simply selected via DIP switch 3 on the device. Before installation, it must be clarified which connection will be used and which charging level is to be selected on the device.
By using a charging booster, powerful consumers can be operated even when the engine is running.
Additional consumers should only be connected to the second battery. Safe starting remains guaranteed, even after long periods of standing without charging. A longer battery life is achieved through an optimally charged and maintained second battery. In addition, the charging booster can optionally be used in solar systems.

Charging booster in EURO 6 vehicles
Alternators with energy-saving charging strategies are often installed in EURO 6 vehicles.
These alternators are subject to very strong fluctuations of the charging voltage depending on the driving condition (e.g. in the Mercedes Benz Sprinter between 12.6 V and 15.0
V). Without a charging booster, this prevents optimum charging of the living area/second battery. With a fully charged battery (e.g. via the 230 V mains) there is even a risk of discharge.
Due to these circumstances, the use of a charging booster is absolutely necessary in EURO 6 vehicles.

MOUNTING THE DEVICE

The device is suitable for both wall and floor mounting. Choose a dry installation location for the charging booster. For optimum charging with low charging losses, it should be mounted close to the battery to be charged.

The charging booster is attached to a stable and level surface using four suitable screws (drill diameter 4.6 mm, screw diameter 4 mm) at the mounting holes provided. Minimum distances to surrounding equipment must be ensured:

• Keep a clearance of at least 50 mm to all sides (except mounting side).
• Maintain at least 80 mm clearance to the bottom for the connections.

Dimension sketch IVT Charging Booster 12 V, 30 A

ELECTRICAL CONNECTION OF THE DEVICE

Before installing the IVT Charging Booster, make yourself familiar with the installation situation. Here, a basic distinction is made between four installation situations in vehicles and operation in stand-alone solar systems:

1. Standard connection with separate ground connections.
2. Standard connection with on-board ground connection of both batteries (direct connection or connection via body).
3. Special case with customer-installed cut-off relay in the vehicle.
4. Connection in caravan/trailer with second battery.
5. Operation in a stand-alone solar system.

General hazard warnings for all types of connection:

• When disconnecting a battery, always disconnect all cables from the negative terminal first, then the cables from the positive terminal.
• When connecting cables to a battery, always connect all cables to the positive terminal first.

General safety instructions for all types of connection:

• Observe the cable cross-sections and lengths (see table p. 22/23)!
• To protect the devices and batteries, insert fuses according to the respective connection diagram. Note that the fuses and suitable fuse holders are not included in the scope of delivery and must be ordered separately (see “Optional accessories”).
• Avoid reverse polarity at the connection terminals of the IVT Charging Booster! It has no reverse polarity protection either at the input or at the output. If the polarity is incorrectly connected, there is a risk that the device will be damaged.
• When disconnecting the cables from the battery, we recommend labelling them immediately. This will prevent errors when reconnecting them later. It is sufficient if the cables are labelled with a (+) plus or (-) minus.

STANDARD CONNECTION WITH SEPARATE GROUND CONNECTIONS

Procedure for connection:

Always follow the general hazard warnings and safety notes above when connecting the charging booster.

1. Disconnect all cables from the starter and second battery before connecting/wiring the devices.
2. Mount the charging booster in a suitable place.
3. Lay the cable from the “starter battery (-)” connection to the negative terminal of the starter battery. Do not connect the cable to the battery yet! Label the cable with (-) minus.
4. Lay the cable from the “second battery (-)” connection to the negative terminal of the second battery. Do not connect the cable to the battery yet! Label the cable with (-) minus.
5. Lay the cable from the “starter battery (+)” connection of the IVT Charging Booster to the positive terminal of the starter battery. Integrate a 40 A fuse with suitable fuse holder in the line. Do not connect the cable to the battery yet! Label the cable with (+) plus.
6. Lay a cable from the “second battery (+)” connection of the IVT Charging Booster to the positive terminal of the second battery. Integrate a 40 A fuse with suitable fuse holder in the line. Do not connect the cable to the battery yet! Label the cable with (+) plus.
7. Connect the D+ signal to the charging booster. Integrate a 2 A fuse in the line at a suitable point. The following pickup options are available:
   • D+ signal from the generator/alternator
   • 12 V signal from terminal 15 (switched plus)
   • 12 V signal from switched socket
   • Switched signal from radio
8. Finally, reconnect all cables with the correct polarity to the two batteries that were previously disconnected. Observe the general hazard warnings and safety notes above.

STANDARD CONNECTION WITH VEHICLE-SIDE GROUND CONNECTION OF BOTH BATTERIES

Procedure for connection:

Always follow the general hazard warnings and safety notes on page 17 when connecting the charging booster.

1. Disconnect all cables from the starter and second battery before connecting/wiring the devices.
2. Mount the charging booster in a suitable place.
3. Check whether there is a connection from the body to the negative terminal of the second battery and establish it if necessary. Alternatively, check whether there is a direct connection between the negative terminal of the starter battery and the negative terminal of the second battery. Do not connect the cable to the battery yet! Label the cable with (-) minus.
4. Make a connection from the body or the negative terminal to one of the two negative terminals on the charging booster.
5. Lay the cable from the “starter battery (+)” of the IVT Charging Booster to the positive terminal of the starter battery. Integrate a 40 A fuse with suitable fuse holder in the line. Do not connect the cable to the battery yet! Label the cable with (+) plus.
6. Lay a cable from the “second battery (+)” connection of the IVT Charging Booster to the positive terminal of the second battery. Integrate a 40 A fuse with suitable fuse holder in the line. Do not connect the cable to the battery yet! Label the cable with (+) plus.
7. Connect the D+ signal to the charging booster. Integrate a 2 A fuse in the line at a suitable point. The following pickup options are available:
   • D+ signal from the generator/alternator
   • 12 V signal from terminal 15 (switched plus)
   • 12 V signal from switched socket
   • Switched signal from radio
8. Finally, reconnect all cables with the correct polarity to the two batteries that were previously disconnected. Observe the general hazard warnings and safety notes.

SPECIAL CASE WITH CUSTOMER-INSTALLED CUT-OFF RELAY IN THE VEHICLE

Procedure for connection:

When connecting the charging booster, always follow the general hazard warnings and safety notes.

1. Disconnect all cables from the starter and second battery before connecting/wiring the devices.

2. Mount the charging booster in a suitable place.

3. Check whether there is a connection from the body to the negative terminal of the second battery and establish it if necessary. Do not connect the cable to the battery yet! Label the cable with (-) minus.

4. Make a ground connection to the charging booster. You have the following connection options:
   • Direct connection from the negative terminal of the second battery
   • Connection from the body to one of the two negative terminals on the charging booster.

5. Disconnect the connection between the cut-off relay and the second battery at a suitable point. Attach a fuse holder to each of the two open cable ends and integrate a 40 A fuse.

6. Connect the end of the cable with the fuse holder coming from the cut-off relay to the “starter battery +” connection.

7. Connect the end of the fuse holder wire that leads to the secondary battery to the “Second battery +” connection.

8. Connect the D+ signal to the charging booster. Integrate a 2 A fuse in the line at a suitable point. The following pickup options are available:

   • D+ signal from the generator/alternator
   • 12 V signal from terminal 15 (switched plus)
   • 12 V signal from switched socket
   • Switched signal from radio

9. Finally, reconnect all cables to the two batteries that were previously disconnected.

CONNECTION IN THE CARAVAN / TRAILER WITH SECOND BATTERY

Procedure for connection:

Always follow the general hazard warnings and safety notes on page 17 when connecting the charging booster.

For the connection illustrated above, the 13-pin plug coupling must be assigned according to EN 1648-1. Set the charging booster to 10 A caravan mode. For this purpose, set DIP switch 3 to ON position.

1. Mount the charging booster in a suitable place.
2. Check whether there is a connection from the body in the towing vehicle to the negative terminal of the second battery and establish it if necessary. Then check the ground connection to contacts 11 and 13 in the plug coupling.
3. Check whether there is a connection between the positive terminal of the starter battery and contact 9 of the plug coupling and establish it if necessary. Integrate a suitable 20 A fuse in this line.
4. Check whether there is a connection between contact 10 of the plug coupling and the D+ signal of the towing vehicle and establish it if necessary. Check whether a 15 A fuse is integrated in this line. If not, integrate it in a suitable place.
5. Now connect the charging booster to the second battery according to the above wiring diagram.

The reduction of the charging current to 33 % of the specified values is mandatory for this connection variant! Therefore, set the 10 A caravan mode on the charging booster via DIP switch 3.

OPERATION IN STAND-ALONE SOLAR SYSTEM

The IVT Charging Booster can also be used in stand-alone solar systems with separate 12 V systems. For this purpose, the D+ signal must be routed to the device via a switch (S1).
In systems in which, for example, consumers with high priority are operated, the use of two 12 V systems is recommended. All important consumers (e.g. alarm system or surveillance cameras) should be connected to the primary battery. The primary battery is charged via the solar panels. Consumers with lower priority can be connected to the second battery system (e.g. lighting, electrical appliances, etc.).
In addition, thanks to the IVT Charging Booster, you can charge batteries with different final charge voltages in a stand alone power system (e.g. primary battery = lead-acid; second battery = LiFePO4).
The charging booster can be put into operation via the switch (S1) and the second battery can be charged additionally. If the voltage at the primary battery drops below 11.8 V, the charging current is automatically reduced. If the voltage reaches 11.0 V, the charge to the second battery is completely interrupted to prevent a deep discharge of the primary battery.
Connect the charging booster with the correct polarity according to the wiring diagram above.

RECOMMENDED CABLE CROSS-SECTIONS FOR CONNECTION TO THE CHARGING

| Cable| Length| Wire cross-section| Fuse protection
---|---|---|---|---
30 A mode| Connection cable for starter battery ”+”| up to 6 m| 10 mm²| 40 A
from 6 m| 16 mm²| 40 A
Connection cable for starter battery “-”| up to 6 m| 10 mm²| –
from 6 m| 16 mm²| –
Connection cable for second battery “+”| up to 6 m| 10 mm²| 40 A
from 6 m| 16 mm²| 40 A
Connection cable for second battery “-”| up to 6 m| 10 mm²| –
from 6 m| 16 mm²| –
Connection line for “D+” signal| up to 10 m| 1.5 mm²| 2 A
| Cable| Length| Wire cross-section| Fuse protection
---|---|---|---|---
10 A mode| Connection cable for starter battery ”+”| up to 10 m| ≥2.5mm²| 15 A
Connection cable for starter battery “-”| up to 10 m| ≥2.5mm²| –
Connection cable for second battery “+”| up to 10 m| ≥2.5mm²| 20 A
Connection cable for second battery “-”| up to 10 m| ≥2.5mm²| –
Connection for “D+” signal| up to 10 m| ≥2.5mm²| 2 A

LED STATUS DISPLAY

switched off)
LED 1 flashes quickly red (≈0.5 s)| Deep discharge protection has responded (output switched off)
LED 1 flashes green| Constant current charging
LED 1 permanently green| Trickle charging
LED 1 is off| There is no D+ signal
LED 2: Battery status| Function
---|---
LED 2 flashes quickly red (~0.5s)| Output voltage <11 V
LED 2 is permanently red| Output voltage is between 11 and 12 V
LED 2 is permanently orange| Output voltage is between 12 and 13 V
LED 2 is permanently green| Output voltage is above 13 V
LED 2 is off| There is no D+ signal

SELECTION OF BATTERY TYPE

You can select the battery type with DIP switches 1 and 2:

Battery type| DIP switch 1| DIP switch 2| DIP switch 3| DIP switch 4| Switch position
---|---|---|---|---|---
Lead-acid| OFF| OFF| ON/OFF| –|
AGM/Gel| OFF| ON| ON/OFF| –|
LiFePO4| ON| OFF/ON| ON/OFF| –|

DIP switch 4 is not assigned and currently has no function.

SELECTION OF CHARGING MODE

DIP switch 3 can be used to set the maximum charging current of the device:

Charging mode| DIP switch 3| Switch position| Charging current| Description
---|---|---|---|---
30 A mode| OFF| | 100 % max. 30 A| This setting is used to recharge the second battery with a maximum charging current of 30 A.
10 A caravan mode| ON| | 33 % max. 10 A| In this setting, the charging booster charges the living area/second battery in the caravan via the 13-pin socket with a maximum of 10
A. This prevents the plug coupling and the cable harness from being overloaded.

A reduction of the charging current to 33 % of the specified values or the selection of charging level 2 is mandatory for connection variant 4!

TEMPERATURE COMPENSATION

With the optionally available temperature sensor, the charging of the second battery can be adjusted according to temperature. This function is not activated if the temperature sensor is not connected. The temperature sensor should be attached to the negative terminal of the second battery to be charged and then connected to the “temperature sensor” connection (2) on the charging booster. The compensation is -25 mV/°C. The compensation is additionally limited between 12.6 V and 15.7 V.

PROTECTION FUNCTIONS

Deep discharge protection for starter battery

• The charging current is reduced linearly – between 11.8 V (100 %) and 11.0 V (0 %) input voltage.
• The output is switched off when the input voltage drops below 11.0 V.
• The output is switched on again when the input voltage exceeds 11.5 V.

Temperature management/overtemperature protection

The charging booster has a temperature- and power-controlled fan. This fan switches on when required.

• The fan is switched on when the internal temperature exceeds 60 °C.
• The fan is switched off when the internal temperature falls below 50 °C.
• The charging current is reduced to 70 % when the internal temperature is between 85 °C and 90 °C.
• The charging current is reduced to 35 % when the internal temperature is between 90 °C and 95 °C.
• The output is switched off when the internal temperature exceeds 95 °C..
• The output is switched on again when the temperature falls below 75 °C.

Output short-circuit protection

• If the output voltage is < 6 V, the output current is reduced to 5 A.

Overvoltage protection for input and output

• If the input or output voltage exceeds 16 V, the output is switched off.
• If the input or output voltage drops below 15.5 V, the output is switched on again.

Please note that the IVT Charging Booster has no reverse polarity protection – neither at the input nor at the output. If the polarity is incorrectly connected, there is a risk that the device will be damaged.

TECHNICAL DATA

| 30 A mode| 10 A caravan mode
---|---|---
Input voltage| 9 V DC – 16 V DC
Output voltage| 9 V DC – 15 V DC
Power consumption, max..| 420 W| 140 W
Charge current, max.| 30 A| 10 A
Supported types of battery| Lead-acid, lead-gel, AGM, lithium
Battery capacity| from 35 Ah
End-of-charging voltage| 14.4 V lead-acid batteries
14.7 V lead-gel, AGM batteries
14.4 V lithium batteries
Trickle charging| 13.8 V lead-acid batteries
13.7 V lead-gel, AGM batteries
14.4 V lithium batteries
Temperature range| -10 °C to + 70 °C
Charging characteristic| IUoU (current-dependent switchover to charge retention)
Temperature compensation| -25 mV/°C (only with connected temperature sensor) Temperature compensation limitation between 12.6 V and 15.7 V
Trickle charging switchover| I < 2.0 A
Switchover to charging| I > 3.0 A
Charge current, max.

“Boost mode”: Vin = 12.5 V; V out = 14.4 V
“Buck-Boost mode”: Vin = 12.5 V; V out = 13.0 V
“Buck-Boost mode”: Vin = 14.6 V; V out = 14.4 V
“Buck mode”: Vin = 14.6 V; V out = 12.6 V

| 22 A
24.5 A
26 A
30 A| 10 A
10 A
10 A
10 A
Charge current limit| 100 % charge current at Uin > 11.7 V 0 % charge current at Uin < 11.0 V
Own power consumption| < 1 mA (if no D+ signal is applied)
< 80 mA (Normal operation)
< 20 mA (when output switched off)
Control signal (D+)| 2 V DC – 16 V DC
Control current (D+)| < 1 mA
Efficiency factor| > 90 % (with max. charge current)
Material| Metal
Dimensions (W x H x D)| 133 x 90 x 49 mm
Weight| 550 g

ENVIRONMENTAL PROTECTION NOTE

At the end of its useful life, this product may not be disposed of together with normal household waste, but has to be dropped off at a collection centre for the recycling of electrical and electronic devices. The symbol on the product, the instructions for use or the packaging indicates this. The materials of which this product is made are recyclable pursuant to their labelling. With the reuse, the recycling of the materials or other forms of scrap usage, you are making an important contribution to the protection of the environment. Please ask your local authorities for the appropriate disposal centre.

ACCESSORIES AND COMPLEMENTARY PRODUCTS

• Art.-Nr.: 920061
  Temperature sensor

• Art.-Nr.: 911010
  Fuse holder extension
  

• Art.-Nr.: 911011
  Mini-ANL fuse holder
  

• Art.-Nr.: 911013
  MINI-ANL fuse 40 A
  

• Art.-Nr.: 911015
  MINI-ANL fuse 20 A
  

• Art.-Nr.: 911012
  Standard flat fuse 2 A

• Art.-Nr.: 911016
  Single core cable 16 mm²
  

Customer Support

More information at www.ivt-hirschau.de

IVT Innovative Supply Technology GmbH
Dienhof 14
D-92242 Hirschau
fon +49 (0) 9622 71991-0
fax +49 (0) 9622 71991-20
info@ivt-hirschau.de
www.ivt-hirschau.de
© IVT Innovative Versorungstechnik GmbH

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