BAINTECH DC-DC 40A Intelligent Battery Charger User Manual

: June 14, 2024
: BAINTECH

Table of Contents

DC-DC 40A Intelligent
- Model:BTDC-DCS40A
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DC-DC 40A Intelligent

Battery Charger

BAINTECH DC-DC 40A Intelligent Battery Charger

www.baintech.com.au

Model:BTDC-DCS40A

1 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.

2 PRODUCT FUNCTIONS

BAINTECH DC-DC 40A Intelligent Battery Charger - a1

Battery Selection Button
Mounting Slots
Input/Output Leads

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 polarity

2.1 Display Panel

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2.2 LED Charge Indicator

Alternator/Solar LED

| Battery Type LED| Charging Stage
---|---|---
Short flash GREEN| Solid GREEN|

Bulk or Absorption

Long flash GREEN

| Solid GREEN|

Float

2.3 Fault LED Indicators

Alternator (Green)

| Solar (Green)| Battery Type (Green)| Fault (Red)| Trouble| Solution
---|---|---|---|---|---
Quick flash| Off| Quick flash| Off| Low voltage detected at alternator input|

Check alternator input voltage

Off

Check alternator input and solar input voltage

Quick flash

Check alternator input voltage

Off

Check auxiliary battery voltage

Off

| Off| Off| Quick flash| Over temperature|

Let the unit cool down for some time or get better ventilation

3 THE INSTALLATION

3.1 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 the 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 80°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.

3.2 Selectioin of Cable Size

The DC40A charger wire may be 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)
ALTERNATOR (Yellow)
OUTPUT (Red)
GND (Black)| <5m| <10m
---|---|---
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.

Butt Splice Connector| BN8 for 10-8AWG|
---|---|---

3.3 Wiring Steps

In order to prevent accidental short circuit during installation, 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.

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To Auxiliary Battery Positive
To Auxiliary Battery Negative
To Start Battery Positive
To Ignition
To Solar Panel Positive

1. The OUTPUT (Red) is connected to the positive pole of the auxiliary battery.

2. 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.

3. The Alternator (Yellow) is connected to the positive (+) pole of start battery.

4. The IGNITION (Blue) is connected or not depends on the type of vehicle alternator. For standard alternators, just leave it alone. Pay attention to insulation protection. 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.

5. 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 protection. Connect the negative pole of solar panel to common Ground cable or to vehicle chassis ground.

6. Restore the negative connection of the battery. If all are ready, the charger will start to work.

3.4 Typical Setup

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Solar Panel
Fuse
Vehicle Ignition
12V or 24V Start Battery
DC-DC Battery Charge
Auxiliary Battery
GND

3.5 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