WAGAN TECH 25A-7410 DC to DC Battery Charger User Guide
- June 3, 2024
- WAGAN TECH
Table of Contents
WAGAN TECH 25A-7410 DC to DC Battery Charger
WELCOME
Thank you for purchasing the DC to DC Battery Charger™ by Wagan Tech®. With
normal care and proper treatment, it will provide years of reliable service.
Please read all operating instructions carefully before use.
The 25A and 40A DC to DC Battery Chargers are designed to provide the optimal
charging characteristics for your auxiliary battery from either your
alternator or external solar source. The solar controller is designed with
Maximum Power Point Tracking (MPPT) to maximize the power coming from your
solar panels up to the maximum rated output. The DC to DC chargers also allow
you to select either vehicle power or solar power priority and is programmable
for all common types of automotive lead acid batteries and LiFePO4 type
starting batteries.
CAUTION
- Do not charge a LiFePO4 battery when temperature is below 32ºF (0ºC).
- Do not operate the battery charger unless you have read and understood this manual and the charger is installed as per these installation instructions. We recommend that the charger be installed by a qualified person.
- The battery charger should not be used by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they are supervised or have been instructed on how to use the appliance by a person responsible for their safety.
- Do not alter or disassemble the Battery Charger under any circumstances.
- Only use the battery charger for charging 12V standard automotive lead acid, Gel, AGM, Calcium or LiFePO4 type batteries.
- Check the manufacturer’s data for your battery to ensure that the maximum voltage of the profile you select as shown in the “Charge Control” section of this manual does not exceed the manufacturer’s recommended max charging voltage. If the max voltage is too high for your battery type, please select another charging profile.
- Check the mfg’s data for your battery to ensure that the “Continuous Current Rating” of the charger does not exceed the mfg’s recommended max charging current.
- When using the Battery charger to charge a Lithium Iron Phosphate battery, only batteries that feature a built-in battery management system featuring built-in under and over voltage protection and cell balancing are suitable. This charger is NOT compatible with other lithium ion or metal battery types.
- The battery charger is not intended to supply power to a low voltage electrical system other than to charge a battery
- Cable and fuse sizes are specified by various codes and standards which depend on the type of vehicle into which the Battery Charger is installed. Selecting the wrong cable or fuse size could result in harm to the installer or user and/or damage to the battery charger or other equipment installed in the system. The installer is responsible for ensuring that the correct cable and fuse sizes are used when installing this Battery Charger.
- Never smoke or allow a spark or flame in the vicinity of the battery or engine. this may cause the battery to explode.
- To assist with the safe operation and use of the Battery Charger when connected to the battery:
- wear complete eye and clothing protection. Avoid touching eyes while working near a battery.
- If battery acid contacts your skin or clothing, remove the affected clothing and wash the affected area of skin immediately with soap and water. If battery acid enters your eye, immediately flood the eye with running cold water for at least 10 min and seek medical assistance immediately.
WARNING:
Risk of explosive gases: Working in the vicinity of a lead-acid battery is dangerous. Batteries generate explosive gases during normal operation. For this reason, you must follow the instructions when installing and using the charger.
PRODUCT OVERVIEW
INSTALLATION
Mounting
The Battery Charger is designed for a variety of installation environments,
including chassis rail, engine cabin, and driver cabin. The Battery Charger
uses advanced technology so that the product can withstand extremely
turbulent, wet, dusty, and muddy environments.
Install the Battery Charger as close to the auxiliary battery as possible and
mount the unit securely with appropriate mounting screws.
Wiring
The Battery Charger wire may be not long enough for installation. If you need to extend the wire, please check the below table for suggested wire sizes. You can choose wires that are equal to or larger than this size.
| 25A DC to DC Battery Charger (7410)| 40A DC to DC Battery Charger
(7411)
---|---|---
<16 ft (5m) long| <32 ft (10m) long| <16 ft (5m) long| <32 ft (10m) long
Input + (Yellow) Output + (Red) Ground (Black)|
10AWG
|
8AWG
|
8AWG
|
6AWG
Ignition (Blue)| 20AWG| 20AWG| 20AWG| 20AWG
It is very important that all wire extensions are well connected, to ensure the stable and reliable operation of the product. For your convenience, butt splice connectors have been provided. After a secure connection is made, use the heat shrinkable tubing or electrical tape to completely cover any exposed wiring to prevent a short to surrounding metal.
Notes:
- Disconnect the negative battery cable (Earth) from the vehicle’s starting battery before installation.
- If your vehicle has a fixed voltage or temperature compensating alternator (standard alternators) installed, leave the Ignition Override cable (BLUE color) open. If your vehicle has a smart (variable voltage) alternator installed, the Ignition Override cable must be connected to the vehicle’s ignition. The Battery Charger will only operate when the vehicle’s ignition is turned on.
| 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
| <11.8V
<23.6V
- Do not re-connect the negative connection of the battery until all other connections are secure and insulated.
Fuse Specification
All recommended fuses should be connected in series in circuit. Bolt down fuses are preferred 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.
Input + (Yellow) Output + (Red)| 25A DC to DC Battery Charger (7410) — 40A
fuse 40A DC to DC Battery Charger (7411) — 60A fuse
---|---
Ignition (Blue)| 3A fuse
Solar Input (Green)| 25A DC to DC Battery Charger (7410) — 40A fuse 40A DC to
DC Battery Charger (7411) — 60A fuse
TYPICAL SETUP
OPERATION
Selecting Battery Type
Long Press the Mode button to select the battery type. There are 5 battery
chemistries available: Standard Lead Acid, Gel, AGM, Calcium and LiFePO4. Keep
pressing the button momentarily until the Battery Chemistry LED you want is
flashing. After you release the button, your selection is entered and saved.
Your selection will be restored automatically even after the Battery Charger
is fully
disconnected and reconnected. The default Battery Chemistry is STD.
Solar Priority Mode
Press the Solar Priority button to prioritize input from the solar panel over charging from the alternator. The solar priority LED will light up when selected.
LED Charge Indicator
You can tell which Charging Stage the battery is in by how fast the Alternator
and/or Solar charge LEDs are flashing.
Short flash = Bulk or Absorption charging stage
Long flash = Float charging stage
Fault Indicator LEDs
Problems with the operation of the Battery Charger are indicated by the Fault LED and/or a combination of solid or flashing Alternator, Solar, and Battery Type LEDs. Use this chart to troubleshoot the problem:
| Alternator LED | Solar LED | Battery Type LED | Fault LED | Trouble | Solution |
|---|
Flashing Green
|
Off
|
Flashing Green
|
Off
| Low voltage detected at Alternator input| Check battery voltage
Off
| Flashing Green| Flashing Green|
Off
| Low voltage detected at Solar input| Check solar voltage
Flashing Green
|
Flashing Green
|
Flashing Green
|
Off
|
Low voltage detected at Alternator or Solar input
| Check voltage of both alternator and solar panel
Flashing Green
|
Off
|
Off
|
Flashing Red
| High voltage detected at Alternator input| Check battery voltage
Alternator LED| Solar LED| Battery Type LED| Fault LED| Trouble| Solution
---|---|---|---|---|---
Off
| Flashing Green|
Off
| Flashing Red| High voltage detected at Solar input| Check solar voltage
Off
|
Off
|
Off
|
Flashing Red
|
Over temperature
| Let the unit cool down for some time or get better ventilation
Off
|
Off
|
Flashing Green
|
Flashing Red
| High voltage detected at output| Check the auxiliary battery voltage
*Indicator lights may go from solid to flashing in fault mode.
FEATURES
The Battery Charger is specifically designed for charging auxiliary batteries. It includes all the features needed to maintain an auxiliary battery at its optimum condition and to prolong battery life.
Superior 3-Stage Charging
Using a high speed microcontroller and proprietary charging algorithm, the
Battery Charger delivers a sophisticated 3-stage charging process resulting
in a faster and more powerful charge, ideal for deep cycle batteries. The
first stage, bulk (constant current), charges the battery faster while the
second stage, absorption (constant voltage), ensures the battery is thoroughly
charged. The final stage, float, maintains the battery at a safe voltage,
allowing it to be maintained and ready for use indefinitely.
Multi-Chemistry Support
The Battery Charger supports Standard Lead Acid, Gel, AGM, Calcium content or
LiFePO4 batteries. The LiFePO4 battery charging algorithm of this charger can
activate the lithium battery with BMS protection.
Switchmode Technology
The Battery Charger converts your vehicle’s 12V DC/24V DC alternator power to
a 12V system; allowing your batteries to be fully charged, prolonging battery
life and reliability. With the latest synchronous switching technology, the
efficiency of the Battery Charger is up to 95% at a typical full load
condition.
Dual Input Operation
The Battery Charger allows two energy sources to power your auxiliary battery.
Solar input takes precedence if solar input power is strong enough. When solar
input cannot provide enough energy to charge the battery, the Battery Charger
will draw power from the alternator. It supports both 12V and 24V alternator
input, and also supports the Smart Alternator system input.
Solar Priority
The Solar Priority function allows for you to prioritize solar charging over
charging from your alternator. As long as the solar panels produce more than
25W (for 7410) or 50W (for 7411) of power, the unit will select charging by
solar. If the auxiliary battery decreases below a certain level, the unit will
charge by alternator regardless of solar input.
Solar MPPT Optimized Charging
The Battery Charger utilizes sophisticated MPPT (Maximum Power Point Tracking)
solar regulator technology. MPPT maximizes the power generated from the solar
panels to the auxiliary battery. The maximum power point tracking efficiency
is up to 95%, creating a maximum charging current of 25A/40A.
Remote Monitor (Optional)
An external remote monitor (Part. No. 7400) is available to show the status of
the charger. It shows how the auxiliary battery is charged by the alternator
or the solar panel, and other useful information.
SAFETY PROTECTIONS
Spark-Free Protection
The Battery Charger will not start charging the battery (no output) unless the
load is securely connected (except the LiFePO4 mode which allows 0 volt
start). It prevents the output leads from sparking due to accidental short
circuit making the charger safer to use around batteries.
Reverse Connection Protection
Reverse connection on input and output terminals does not damage Battery
Charger internal circuit. The Battery Charger will not charge if output
connections are reversed.
Over and Under Voltage Protection
The charger will automatically shut down if there is an over voltage or under
voltage problem.
Over Temperature Protection
The charger will lower its output current if the temperature of the unit
begins to overheat.
SPECIFICATIONS
Operating Conditions
Model| 25A DC to DC Battery Charger (7410)| 40A DC to DC Battery
Charger (7411)
---|---|---
Input Voltage| 9−32V DC
Maximum Input Current| 25A| 45A
Back Drain on Auxiliary Battery| < 15mA
Output Current:| 25A| 40A
Input Fuse Rating| 40A (Not included)| 60A (Not included)
Output Fuse Rating| 40A (Not included)| 60A (Not included)
Maximum Output Power| 300W| 500W
IP Rating| IP66
Size| 1.7 × 5.1 × 5.7 in.
(4.3 × 12.9 ×
14.5 cm)
| 1.7 × 5.1 × 7.3 in.
(4.3 × 12.9 ×
18.5 cm)
Weight| 1.4 lbs (0.63 kg)| 2.0 lbs (0.89 kg)
Model| 25A DC to DC Battery Charger (7410)| 40A DC to DC Battery
Charger (7411)
---|---|---
Operating Temperature| -4˚F to 176˚F ( -20˚C to +80˚C)
Charge Control
| Charge Type | 3-Stage |
|---|---|
| Charging Profile | STD |
| Maximum Voltage | 14.4V |
| Float Voltage | 13.4V |
Battery Range
| Battery Capacity | 50–500Ah, | 80–800Ah |
|---|---|---|
| Type of Batteries Supported | STD, GEL, AGM, Calcium, LiFePO4 |
Limited Warranty
The WAGAN Corporation warranty is limited to products sold only in the United States.
Warranty Duration:
Product is warranted to the original purchaser for a period of one (1) year
from the original purchase date, to be free of defects in material and
workmanship. WAGAN Corporation disclaims any liability for consequential
damages. In no event will WAGAN Corporation be responsible for any amount of
damages beyond the amount paid for the product at retail.
Warranty Performance:
During the warranty period, a product with a defect will be replaced with a
comparable model when the product is returned to WAGAN Corporation with an
original store receipt. WAGAN Corporation will, at its discretion, replace or
repair the defective part. The replacement product will be warranted for the
balance of the original warranty period. This warranty does not extend to any
units which have been used in violation of written instructions furnished.
Warranty Disclaimers:
This warranty is in lieu of all warranties expressed or implied and no
representative or person is authorized to assume any other liability in
connection with the sale of our products. There shall be no claims for defects
or failure of performance or product failure under any theory of tort,
contract or commercial law including,but not limited to negligence, gross
negligence, strict liability, breach of warranty, and breach of contract.
Returns:
WAGAN Corporation is not responsible for any item(s) returned without an
official Return Authorization number (RA#). Please contact our customer
service team by phone or email to obtain an RA#. You can also visit our
website and chat with our team during our normal business hours. For more
details and instructions on how to process a warranty claim, please read the
“Returns” section under the “Contact” page on our website. WAGAN Corporation
is not responsible for any shipping charges incurred in returning the item(s)
back to the company for repair or replacement.
31088 San Clemente Street
Hayward, CA 94544, U.S.A.
Tel: +1.510.471.9221
U.S. & Canada Toll Free: +1.800.231.5806
[email protected]
www.wagan.com
©2022 Wagan Corporation. All Rights Reserved Wagan Tech and wagan.com are trademarks of Wagan Corporation