KICKASS KADCDC40A-AND Charger With Solar MPPT Plus Pre Wired Anderson User Manual

KADCDC40A-AND Charger With Solar MPPT Plus Pre Wired Anderson

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SPECIFICATIONS

• Charger Model: KADCDC20A-AND, KADCDC40A-AND

• OPERATING CONDITIONS

• Input Voltage Range: 5-32V DC

• Alternator Input Voltage Range: 9-32V DC

• Solar Input Voltage Range: 10-32V DC

• Maximum Input Current: 27A (KADCDC20A-AND), 47A
  (KADCDC40A-AND)

• Maximum Continuous Charging Current: 20A (KADCDC20A-AND), 40A
  (KADCDC40A-AND)

• Maximum Output Power: 300W (KADCDC20A-AND), 500W
  (KADCDC40A-AND)

• Fuse Size: 40A (KADCDC20A-AND), 60A (KADCDC40A-AND)

• No Load Current Draw

• Efficiency

• Ambient Operating Temperature

• MECHANICAL

• Dimensions

• Weights

• IP Rating

• Certifications

• BATTERY CAPACITY GUIDE

• Lead Acid (WET, GEL, AGM, CAL)

• LiFePO4

PRODUCT INFORMATION

The KickAss 20/40A DCDC Charger with MPPT Solar Controller is
designed to charge multiple battery types including GEL, AGM, WET,
CALCIUM, or Lithium LiFePO4 batteries.

Key Features:

• Prevent auxiliary battery drainage from the start battery.

• Ensure full charging and maintenance of the auxiliary
  battery.

• Utilize the built-in MPPT solar controller for charging when
  the vehicle is not in use.

PRODUCT USAGE INSTRUCTIONS

1. Safety Warnings:

• Read and understand all instructions to avoid injury or
  damage.

• Ensure proper ventilation when charging batteries.

• Install circuit protection near the batteries as per wiring
  diagrams in the manual.

2. Charging Multiple Battery Types:

The charger is compatible with various battery types. Follow
these steps:

1. Connect the charger to the appropriate battery type.
2. Refer to the manual for specific settings for each battery
   type.

3. Preventing Auxiliary Battery Drainage:

To prevent drainage from the start battery:

• Ensure the voltage sensing feature is active.
• The charger will disconnect the start battery when the vehicle
  is not running.

4. Using the MPPT Solar Controller:

To charge from solar panels:

• Utilize the MPPT solar controller when the vehicle is not
  charging.

• This controller optimizes solar panel efficiency for
  charging.

FREQUENTLY ASKED QUESTIONS (FAQ)

Q: Can this charger be used with other battery types not listed

in the manual?

A: It is recommended to only use compatible battery types listed
in the manual to ensure safe and efficient charging.

Q: What should I do if the charger does not turn on?

A: Check battery connections and ensure correct polarity. The
charger has built-in protections that may prevent operation if not
correctly connected.

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® DCDC CHARGER WITH MPPT SOLAR CONTROLLER
USER MANUAL
KADCDC40A-AND KADCDC20A-AND
V1.7

WARNINGS
Y To avoid injury or damage to your vehicle ensure the instructions are read carefully and understood.
Y Batteries can produce harmful vapour and explosive gases when being charged.
Y Ensure batteries are mounted and stored in an area with good ventilation. Y As this Charger has powerful output current, circuit protection such as fuses or
circuit breakers must be installed as near as possible to the batteries – refer to wiring diagrams in this manual for correct fitting. This manual will give you all of the essential information you need to own and operate your new KickAss 20/40A DCDC Charger with MPPT Solar Controller.
The purpose & features of the KickAss 20/40A DCDC Charger with MPPT Solar Controller:
u Can charge multiple battery types: Compatible with GEL, AGM, WET, CALCIUM or Lithium LiFePO4.
u Prevent your auxiliary battery from draining your start battery: Built-in voltage sensing will ensure your start battery charges your auxiliary battery when the vehicle is running. It will then disconnect the start battery from the auxiliary battery when the vehicle is not running.
u Ensure your auxiliary battery is being fully charged and maintained: Most modern vehicles (especially those manufactured after 2010) do not provide the correct voltages and charge control to safely and completely charge your auxiliary battery. The Charger overcomes this issue by boosting the charge voltage to an optimal output level while ensuring your auxiliary battery is safely charged via its multi-stage charge algorithm.
u When your vehicle is not charging, charge from the built-in MPPT solar controller: Maximum power point tracking is the most efficient type of solar controller and allows you obtain the maximum amount of charge from your solar panels. When your vehicle is not doing the charging, the built-in MPPT solar controller will let your solar panels do the work.
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Stay safe and protect your assets with these protective features: ,, Short circuit protection
The Charger will not turn on unless the batteries are connected correctly. ,, Reverse polarity protection
If you connect positive and negative the wrong way around the Charger will show a fault. ,, Over voltage protection If the Charger detects voltages connected to its inputs or outputs that are too high it will shut down. ,, Over temperature protection The Charger will lower its output current if it senses that the unit will overheat. ,, Temperature compensation: The included temperature sensor will measure the battery temperature and adjust current accordingly to prevent overcharging. For more technical details, specifications & videos please visit kickassproducts.com.au
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SPECIFICATIONS

Charger Model OPERATING CONDITIONS
Input Voltage Range Alternator Input Voltage Range
Solar Input Voltage Range Maximum Input Current
Maximum Continuous Charging Current Maximum Output Power Fuse Size No Load Current Draw Efficiency
Ambient Operating Temperature MECHANICAL
Dimensions Weights IP Rating
Certifications
BATTERY CAPACITY GUIDE Lead Acid ( WET,GEL,AGM,CAL) LiFePO4

KADCDC20A-AND

KADCDC40A-AND

5-32V DC

9-32V DC

10-32V DC

27A

47A

20A

40A

300W

500W

40A

60A

<15 mA

Approx. 93% when full load

20 °C to +80 °C

15412044mm

19212044mm

870g

950g

IP66

PROP65

80 ­ 200Ah 50 ­ 120Ah

200 ­ 500Ah 120 ­ 500Ah

BATTERY Compatible Battery Type Absorption Voltage Float Voltage
Minimum Auxiliary Battery Voltage

GEL 14.1V 13.5V

WET

AGM

14.4V 14.7V

13.4V

9V

CAL LiFePO4 15.3V 14.5V
13.6V 0V

INTERGRATED ISOLATOR CONTROL *30 SEC DELAY BEFORE THE CHARGER WILL CUT IN OR OUT

Input voltage
Cut in / Cut out Voltage (Ignition override OFF)
Cut in / Cut out Voltage (Ignition override ON)

12V

CUT IN 13.2V

CUT OUT 12.6V

CUT IN 12.2V

CUT OUT 10.5V

24V

CUT IN 26.4V

CUT OUT 25.2V

CUT IN 24.4V

CUT OUT 21.0V

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DIMENSIONS
KADCDC20A-AND
4

KADCDC40A-AND
5

PRODUCT OVERVIEW
Fault LED Solar LED Alternator LED

Solar Priority LED

Charging Stage LEDs

Solar Priority Button

Mounting Slots 4.5mm
Battery Mode Button Battery Type LEDs

6

INSTALLATION GUIDE
SAFETY FIRST!
,, The KickAss Charger has been engineered to charge 12 Volt GEL, AGM, WET, CALCIUM or Lithium LiFePO4 only. Do not use this charger for any other purpose or with any other battery types.
,, Do not attempt to charge known faulty, damaged, frozen or broken batteries. ,, Ensure charger is close to battery, however never mount the charger directly on the
battery. ,, Ventilation is very important in battery charging, always ensure battery positioning is
in a well ventilated area to allow charging gases to dissipate. ,, Keep sparks or flames away from batteries being charged as they could emit
explosive gases. ,, Always check the batteries and charging system periodically to ensure no faults
occur. ,, Ensure all cabling is secure and cannot be cut, broken or short circuited. ,, Battery acid is corrosive. If acid comes into contact with skin or eyes, please seek
medical advice. ,, Never connect this charger to mains supply. ,, We recommend fitting a 50-75 amp fuse on both the input and output sides of the
charger such as the SKU: KAMAXIFHAND or SKU: KAFUSECOVER-KIT to protect cables from short circuits etc.
MOUNTING
It is most important to mount your KickAss Charger as close as possible to your auxiliary battery and be sure to keep your charger away from sources of heat. eg. Turbos and exhaust pipes. This will ensure maximum performance out of your charger.
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WIRING SIZE
To make sound electrical connections, the battery cable should be the correct size and the correct terminals should be crimped or soldered.
CABLE SIZING The table below outlining the required cable size for a given install length.
Please refer to this table for Vehicle Input, Solar Input, Ground and Battery Output cable thickness requirements. Always choose a wire cross sectional area equal to or greater than what is specified below.

Part Number KADCDC20A-AND KADCDC40A-AND

Cable Install Length meter(m) feet(ft)

1 – 6.5

3 – 21

6.5 – 8

12 – 26

1 – 6.5

3 – 21

6.5 – 8

21 – 26

Recommended Wire Cross
Section (mm²) 7.71 13.56 13.56 13.56

Closest (BAE, B&S, AWG)
8 6 6 6

Recommend KickAss Wiring Kit
KAPRDBWK8MMPP KAHDDBWKPP80 KAHDDBWKPP65 KAHDDBWKPP80

Note:
· Always use a fuse in-line for all connections to the starter and aux battery!
· The input and output negative cables labeled Ground 3 and Ground 2 should be connected at the battery negative poles for improved performance.

For more information or assistance, see installation videos at kickassproducts.com.au

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80A 5A
i
i
80A
BLACK – TEMPERATURE SENSOR
9

WIRING DIAGRAM
BLUE – IGNITION OVERRIDE 1.5mm2 FUSE BOX
FUSE TAPPER SKU: KAFTMINI KAFTMINLP MAFTMICRO2 KAFTREG

ALT. IN

KICKASS HEAVY DUTY PLUG & PLAY WIRING KIT
SKU:KAHDDBWKPP65: 6.5M KIT SKU: KAHDDBWKPP80: 8M KIT

SOLAR PANEL

SOLAR

KICKASS 5M EXTENSION LEAD KAPVVAND05

FUSE/BREAKER (OPTIONAL)

KICKASS INLINE MAXIFUSE
– KAMAXIFHAND
ABUAXTITLEIARRYY

MOUNT DC-DC CHARGER AS CLOSE AS POSSIBLE TO THE AUXILIARY BATTERY
NOTE: Ignition override used only if required CAUTION: Check model specification for solar input CAUTION: Always ensure fuses are installed

WIRING DIAGRAM – SOLAR PANEL ONLY

SOLAR PANEL

SOLAR

KICKASS 5M EXTENSION LEAD KAPVVAND05

FUSE/BREAKER (OPTIONAL)

I BLACK – TEMPERATURE SENSOR
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OUTPUT

KICKASS INLINE MAXIFUSE
– KAMAXIFHAND
ABUAXTITLEIARRYY

MOUNT DC-DC CHARGER AS CLOSE AS POSSIBLE TO THE AUXILIARY BATTERY

CAUTION: Check model specification for solar input CAUTION: Always ensure fuses are installed

CHOOSING THE BATTERY TYPE
The battery type setting must be confirmed during device installation. When the auxiliary battery is connected, press and hold the Mode button for 2 ~ 4 seconds, upon releasing the button, the battery type LED will move to the next position. Repeat the steps until required battery type LED is selected. Battery type setting is now programed The selected battery type will be saved as the new default.

12V 20A

CHARGING STAGE PROFILE

STAGE

DESCRIPTION

BULK

GEL 100% Current Until 14.1 V

AGM 100% Current Until 14.7 V

WET 100% Current Until 14.4 V

CALCIUM 100% Current Until 15.3 V

LifePO4 100% Current Until 14.5 V

ABSORPTION

Constant 14.1 V
Until 2.6A

Constant 14.7 V
Until 2.6A

Constant 14.4 V
Until 2.6A

Constant 15.3 V
Until 2.6A

Constant 14.5 V
Until 2.6A

FLOAT

13.5V at 100% Current
Max

13.4V at 100% Current
Max

13.4V at 100% Current
Max

13.6V at 100% Current
Max

13.6V at 100% Current
Max

NOTE: When in FLOAT stage, the battery is fully charged. At float stage, when the battery voltage drops to 0.3V below the specified float voltage for the battery type connected, the charger will restart charging form the BULK stage.

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UNDERSTANDING SOLAR, ALTERNATOR & CHARGING LIGHTS

Standby Mode No inputs detected. Once the Aux battery has been connected and is within the detectable voltage range, the battery type LED will short flash to indicate the device is in standby mode and no input sources are detected

12V 20A

Battery type selection mode Press and hold the Mode button for 2 ~ 4 seconds, upon releasing the button, the battery type LED will move to the next position. Repeat the steps until required battery type LED is selected. Battery type setting is now programed and charger will return to Standby mode after a short time.

12V 20A

Standby Mode Alternator input detected With no Solar connected or detected and the Alternator is the only available input source, the input LED will short flash to indicate input voltage is below the set cut-in voltage. Charger is still in Standby mode and has not begun to charge the battery.
Standby Mode Alternator and Solar inputs detected Both input sources are detected but neither has reached the set cut in voltage range. By default Alternator input has priority and will provide power to charge the battery. Solar priority has not been selected and indicator LED is on.

12V 20A 12V 20A

Charging with Alternator or Solar only Once the input source reaches the set cut-in voltage, charging will begin. The battery type LED will turn solid and the active charge stage LED will come on and remain solid, while the input source LED will continue to flash.

ALTERNATOR ONLY

SOLAR ONLY

12V 20A
12

12V 20A

Absorption Charge Stage ALTERNATOR ONLY

SOLAR ONLY

12V 20A

12V 20A

Float stage Input source LED will change to a long flash sequence when charging stage transfers to float. Battery is now fully charged.

ALTERNATOR ONLY

SOLAR ONLY

12V 20A

12V 20A

Charging with Alternator as priority (default) Once the Alternator input voltage reaches the set cut-in voltage, charging can begin. The battery type LED will turn solid and the active charge stage LED will come on and remain solid, while the input source LED will continue to flash. Solar input LED will remain solid while source is available. The charger will transition through the different charging stages as previously shown, until the battery is full.

12V 20A

Charging with Solar as priority – Setting Solar Priority mode The function of Solar Priority mode is to allow the charger to check for available solar input before choosing the alternator as the input source. To do this, the charger will assess the state of charge of the battery and decide if the available solar can effectively supply enough charge or choose the alternator as the best input source. The Solar Priority function can be set at any time, once the Aux battery has been connected. To set Solar Priority, press and hold Solar Priority button for 2 ~ 4 seconds, then realse the button, to change the priority . The Solar Priority indicator LED will start to flash.

12V 20A

12V 20A

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Lithium BMS Sleep Mode & Recovery Feature: Most lithium batteries are built with a Battery Management System (BMS) inside to protect the battery from over charging, over discharging and extreme temperature changes. One of the key functions of the BMS is to protect your battery by internally disconnecting the load¹ when voltage drops below specific parameters, this will then result in the battery entering into a “sleep” mode. ¹ (Load includes any accessories and/or device/s drawing charge from the battery. Eg: fridges, pumps, food sealers, etc) The KickAss DCDC MPPT Solar Battery Controller has a lithium battery recovery function. This function has been designed to recover lithium batteries from a sleep mode. Lithium Battery Recovery Mode Procedure First disconnect any load connected to the lithium battery. Secondly connect Alternator Input or Solar Input to the KickAss DCDC Charger with MPPT Solar Controller. Thirdly connect the output from the DCDC charger to the lithium battery. When the DCDC Charger with MPPT Solar Controller input charging voltage reaches the relevant cut in voltage, the DCDC Charger with MPPT Solar Controller will automatically try to activate the battery every minute. When DCDC Charger with MPPT Solar Controller attempts to activate the battery, if a open-circuit or short-circuit error is detected, the DCDC Charger with MPPT Solar Controller will enter standby mode until the next activation attempt. If the activation attempt is successful, DCDC Charger with MPPT Solar Controller will initiate the regular three stage charging sequence. Once the DCDC Charger with MPPT Solar Controller indicates the battery has reach the FLOAT charge state, the battery has been fully recovered and loads reconnected.
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FAULT CODES
If the fault light is flashing, please refer to the fault codes below for diagnostics. Note: Only the selected battery type LED will flash when the device detects a fault condition.

12V 20A

Alternator Solar (green) (green)

Battery Type (green)

Solar Priority (Green)

Fault (red)

Fault

Solution

Over voltage detected at alternator input
Over voltage detected at solar input
Over voltage detected at
output
Over temperature

Check alternator battery voltage
Check solar panel open circuit
voltage
Check auxiliary battery voltage
Let the unit cool down for some time or
improve ventilation

15

TROUBLESHOOTING

The following table provides some additional fault finding advice should any potential issues arise with the system installation, or unexpected system behavior is identified afer normal operation.

Alternator Solar (green) (green)

Battery Type (green)

Solar Priority (Green)

Fault (red)

System Behavior

Recommended Troubleshooting Procedure

No voltage detected at alternator and solar input

§ Check alternator and solar panel voltages.
§ Check system wiring for potential connection issues.

Low voltage detected at alternator input (Voltage is below cut-in range)

§ Check alternator battery voltage.
§ Check system wiring for potential connection issues.
§ Check alternator operation.

Low voltage detected at solar
input (Voltage is below
cut-in range)

§ Check solar panel voltage. § Check system wiring for
potential issues.

Low voltage detected at alternator or solar
input (Voltage is below
cut-in range)

§ Check alternator battery voltage.
§ Check system wiring for potential connection issues.
§ Check alternator operation. § Check solar panel voltage. § Check system wiring for
potential issues.

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FCC COMPLIANCE STATEMENT
This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
Note: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation.
If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
Y Reorient or relocate the receiving antenna. Y Increase the separation between the equipment and receiver. Y Connect the equipment to an outlet on a circuit different from that to which the
receiver is connected. Y Consult the dealer or an experienced radio/TV technician for help.
Changes or modifications to this product not authorized by KickAss could void the electromagnetic compatibility (EMC) and wireless compliance and negate your authority to operate the product.
This product has demonstrated EMC compliance under conditions that included the use of compliant peripheral devices and shielded cables between system components. It is important that you use compliant peripheral devices and shielded cables between system components to reduce the possibility of causing interference to radios, television sets, and other electronic devices.
Exposure to radio frequency energy. The radiated output power of this device meets the limits of FCC/IC radio frequency exposure limits. This device should be operated with a minimum separation distance of 20 cm (8 inches) between the equipment and a person’s body.
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NEED HELP?
KickAss constantly updates frequently asked questions, troubleshooting, videos and specifications, please visit:
kickassproducts.com.au
for the most up to date information.
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THANK YOU FOR CHOOSING
DC-DC CHARGERS
For more informa on please visit us at:
kickassproducts.com.au
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References

• KickAss Products – 12V, 4WD, Caravan, Camping and Outdoor Specialist

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