PerfectPower DCC 121240 - Battery charger DOMETIC - Free user manual and instructions

USER MANUAL PerfectPower DCC 121240 DOMETIC

1 Description of symbols

2 General safety instructions The manufacturer accepts no liability for damage in the following cases:

• Faulty assembly or connection

• Damage to the product resulting from mechanical influences and excess voltage

• Alterations to the product without express permission from the manufacturer

• Use for purposes other than those described in the operating manual For protection, pay close attention to the following basic safety information when using electrical devices:

• Injury DANGER! Safety instruction: Failure to observe this instruction will cause fatal or serious injury. WARNING! Safety instruction: Failure to observe this instruction can cause fatal or serious injury. CAUTION! Safety instruction: Failure to observe this instruction can lead to injury. NOTICE! Failure to observe this instruction can cause material damage and impair the function of the product. NOTE Supplementary information for operating the product. DCC1224-2424--IO-16s.book Seite 8 Donnerstag, 8. März 2018 3:06 15EN PerfectCharge General safety instructions

• In the event of fire, use a fire extinguisher which is suitable for electrical devices.

• Only use the product as intended.

• Ensure that the red and black terminals never come into contact with each other.

• Disconnect the product from the battery – each time before cleaning and maintenance – before a fuse change (only by specialists)

• if you disassemble the product: – Detach all connections. – Make sure that no voltage is present on any of the inputs and outputs.

• The product may not be used if the product itself or the connection cable are visibly damaged.

• If the power cable for this product is damaged, it must be replaced by the manufacturer, customer service or a similarly qualified person in order to prevent safety hazards.

• This product may only be repaired by qualified personnel. Inadequate repairs may cause serious hazards.

• This product can be used by children aged 8 years or over, as well as by persons with diminished physical, sensory or mental capacities or a lack of experience and knowledge, providing they are supervised or have been taught how to use the product safely and are aware of the resulting risks.

• Electrical devices are not toys. Always keep and use the product out of the reach of children.

• Children must be supervised to ensure that they do not play with the product.

• Before start-up, check that the voltage specification on the type plate is the same as that of the power supply.

• Ensure that other objects cannot cause a short circuit to the contacts of the product.

2.2 Safety when installing the product

• Never mount the product in areas where there is a risk of gas or dust explosion.

• Ensure a secure stand! The product must be set up and fastened in such a way that it cannot tip over or fall down.

• Do not expose the product to any heat source (such as direct sunlight or heating). Avoid additional heating of the product.

• Set up the product in a dry location where it is protected against splashing water.

2.3 Safety when connecting the product electronically

• For installation on boats: If electrical devices are incorrectly installed on boats, this can lead to corrosion damage on the boat. Have the product installed by a quali- fied (boat) electrician.

• If you are working on electrical systems, ensure that there is somebody close at hand who can help you in emergencies.

• Make sure that the lead has a sufficient cross-section.

• Lay the cables so that they cannot be damaged by the doors or the bonnet. Crushed cables can lead to serious injury.

• Lay the cables so that they cannot be tripped over or damaged.

• Use ductwork or cable ducts if it is necessary to lay cables through metal panels or other panels with sharp edges.

• Do not lay the cables so that they are loose or heavily kinked.

• Firmly secure the cables.

• Do not pull on the cables.

2.4 Safety when operating the product

• If the product is used in facilities with open lead acid batteries, the room must be well ventilated. These batteries give off explosive hydrogen gas that can be ignited by sparks on electrical connections.

• Do not operate the product – In salty, wet or damp environments – In the vicinity of corrosive fumes – In the vicinity of combustible materials – In areas where there is a danger of explosions

• Before activating, ensure that the power supply line and plug are dry.

• Always disconnect the power supply when working on the product.

• Please be aware that parts of the product may still produce voltage even after activation of the safety guard (fuse).

• Do not disconnect any cables when the product is still in use.

• Make sure the air inlets and outlets of the product are not covered.

• Ensure good ventilation.

• Batteries may contain aggressive and corrosive acids. Avoid battery fluid coming into contact with your body. If your skin does come into contact with battery fluid, thoroughly wash the part of your body in question with water. If you sustain any injuries from acids, contact a doctor immediately. DCC1224-2424--IO-16s.book Seite 11 Donnerstag, 8. März 2018 3:06 15EN Scope of delivery PerfectCharge

• When working on batteries, do not wear any metal objects such as watches or rings. Lead acid batteries can cause short circuits which can cause serious injuries.

• Danger of explosions! Never attempt to charge a frozen or defective battery. In this case place the battery in a frost-free area and wait until the battery has adjusted to the ambient temperature. Then start the charging process.

• Wear goggles and protective clothing when you work on batteries. Do not touch your eyes when you working on batteries.

• Do not smoke and ensure that no sparks can arise in the vicinity of the engine or battery.

• Only use rechargeable batteries.

• Use sufficient cable cross sections.

• Protect the positive conduit with a fuse.

• Prevent any metal parts from falling on the battery. This can cause sparks or short circuit the battery and other electrical parts.

• Make sure the polarity is correct when connecting.

• Follow the instructions of the battery manufacturer and those of the manufacturer of the system or vehicle in which the battery is used.

• If you need to remove the battery, disconnect it first from the ground connection. Disconnect all connections and all consumers from the battery before removing it. 3Scope of delivery Description1 Battery charger– Installation and operating manual DCC1224-2424--IO-16s.book Seite 12 Donnerstag, 8. März 2018 3:06 15EN PerfectCharge Accessories

4Accessories Available as accessories (not included in the scope of delivery): 5 Target group for this manual The chapter “Connect charging converter” on page 18 chapter is solely intended for qualified professionals who are familiar with the relevant VDE regulations. All other chapters are intended for the users. 6 Intended use The PerfectCharge DCC battery chargers can charge batteries used on board vehicles or boats while driving, or supply them with a maintenance voltage for power generation. Additionally, the devices can be used as a stable power supply. The DCC battery chargers are used for continuous charging of supply or on-board batteries (body batteries):

• 24V g Voltage converter: DCC1224-10, DCC1224-20 The DCC battery chargers are used to charge the following battery types:

• Fleece batteries (AGM batteries)

7 Technical description Because of its low weight and compact design, the charging converter can easily be installed in RVs, commercial vehicles or motor and sailing yachts. While driving it charges batteries that are used on board vehicles or boats to generate power or supplies them with a retention voltage so that they do not unload. The 12 Vg or 24 Vg voltage from a vehicle or boat battery is transformed into a stable 12 Vg or 24 Vg DC voltage. The isolation of the input and output voltages means the output voltage can be kept stable without interference from the input circuit. The charging converter is switched on via a 12/24 V signal:

• a switched input signal

The battery charger has various protective mechanisms:

• High voltage shutdown: The battery charger shuts itself off when the voltage exceeds the cut-off value. It restarts when the voltage returns to the restart value.

• Low voltage shutdown: The battery charger shuts itself off when the voltage sinks below the cut-off value. It restarts when the voltage rises to the restart value.

• High temperature shutdown: The battery charger switches off when the temperature inside the device exceeds a cut-off value. It restarts when the voltage rises to the restart value.

• Protection against short circuit: The LED on the battery charger signals a mal- function if a short circuit has been generated. The device fuse must be replaced by a professional after it has been triggered by excess current. WARNING! Danger of explosions!

• Do not charge batteries with a cell conclusion. The oxyhydrogen they produce can cause explosions.

• Do not charge lead acid batteries in unventilated rooms. The oxyhydrogen they produce can cause explosions.

• Do not charge NiCd batteries or non-rechargeable batteries with this device. The sleeves of these batteries can explode. NOTICE! When terminal 15 is used, the starter battery may discharge even when the engine is off, if the ignition is set to “ON”. DCC1224-2424--IO-16s.book Seite 14 Donnerstag, 8. März 2018 3:06 15EN PerfectCharge Technical description

The battery charger can be adapted to different battery types via DIP switches. When a TS-1 temperature sensor is connected, the charging converter adjusts the charging voltage according to the measured temperature, see chapter “Technical data” on page 24.

7.1 Connections and controls

NOTE The individual values are found in chapter “Protective devices” on page 27. Item in fig. 1, page 3 Description 1 Input terminals (+) of starter battery 2 Input terminals (–) of starter battery 3 Control cable (I1) for turning on the vehicle with on-board voltage (D+ or terminal 15 (ignition)) 4 LED display 5 Power regulation (I2) to limit the charging current to 5 A 6 RJ11 terminal: Connection of a temperature sensor (accessory)

The charging characteristics are referred to as IU0U characteristics. 1: I phase (bulk) At the beginning of the charging process, the flat battery is charged with a constant current (100 % charge current) until the battery voltage reaches the charging end voltage. The charging current decreases when the battery has reached this charging level. 2: U0 phase (absorption) Now the absorption charging process (U0 phase) begins, where the duration depends on the battery. The voltage remains constant (U0). This phase is limited to maximal 3 hours to prevent overcharging the battery while driving. 3: U phase (float) After the U0 phase, the battery charger switches to conservation charging function (U phase). U0 U

8Mount charging converter

For the electrical connection you will need the following tools:

• 4 flexible connection cables: + and – for the starter battery, + and – for the body battery. 1 flexible signal cable for connection to D+ or the ignition. The required cross-section can be found in the table chapter “Connect charging converter” on page 19.

• Cable lugs and conductor sleeves For fastening the battery charger you will need the following tools:

• Machine bolts (M4) with washers and self-locking nuts or

• self-tapping screws or wood screws.

8.2 Installation instructions

When selecting the installation location, pay attention to the following instructions:

• The battery charger can be installed horizontally as well as vertically.

• The battery charger must be installed in a place that is protected from moisture.

• The battery charger may not be installed in the presence of flammable materials.

• The battery charger may not be installed in a dusty environment.

• The place of installation must be well ventilated. A ventilation system must be available for installations in small, enclosed spaces. The minimum clearance around the battery charger must be at least 5 cm (fig. 2, page 4).

• The battery charger air inlet and air outlet must remain free.

• At ambient temperatures higher than 40 °C (ex. in engine or boiler rooms, direct sunlight), the battery charger may switch off, although the power of the con- nected loads is below the rated load (derating).

➤ Pay attention to the distance specifications (fig. 2, page 4). ➤ Mount the charging converter as shown (fig. 3, page 4). 9 Connect charging converter

Observe the following instructions when connecting the battery:

• Make sure the battery poles are clean when connecting the terminals.

• Make sure the plug connector is fitted securely.

• Select a sufficient cross-section for the connection cable.

• Lay the cables in accordance with VDE 100 (Germany).

• Connect the negative cable directly to the negative terminal of the battery, and not to the chassis of a vehicle or boat.

• Use the following cable colors: – Red: positive connection – Black: negative connection NOTICE! Before drilling any holes, make sure that no electrical cables or other parts of the vehicle can be damaged by drilling, sawing and filing. WARNING! Do not reverse the polarity. Reverse polarity of the battery connections can cause injury and damage the device. CAUTION!

• Avoid coming into contact with the battery fluid under any circumstances.

• Batteries with a cell short circuit may not be charged as explosive gases may form due to overheating of the battery. NOTICE! Tighten the nuts and bolts with a maximum torque of 12 – 13 Nm. Loose connections may cause overheating. DCC1224-2424--IO-16s.book Seite 18 Donnerstag, 8. März 2018 3:06 15EN PerfectCharge Connect charging converter

The minimum cable cross-section depends on the maximum cable length:

9.1 Connect charging converter

➤ Connect the charging converter as shown: – Correct connection diagram: fig. 4, page 5 – Connecting the batteries: fig. 5, page 6 – Connect control line (I1): fig. 6, page 6

9.2 Connect accessories

➤ Connect the accessory to the following contacts: – Performance regulation (I2): fig. 1 5, page 3 – Temperature sensor: fig. 1 6, page 3 NOTE Keep the distance to the body battery as short as possible. Cable length Minimum cable cross-section/Fuse

30 A 4 mm² / 40 A 6 mm² / 60 A 10 mm² / 80 A DCCxxxx-10 to the starter battery 7m 11 m 16 m – to battery structure 2m 3.5 m 5m – DCC xxxx–20 to the starter battery – 5.5 m 8m 14 m to battery structure – 1.5 m 2.5 m 4m DCCxxxx-40 to the starter battery – – – 7m to battery structure – – – 2m NOTICE! The charging converter must not be connected directly to the alternator. NOTE - Performance regulation To limit the output current of the charging converter to 5 A, a positive control signal must be present at contact “I2” (fig. 1 5, page 3). DCC1224-2424--IO-16s.book Seite 19 Donnerstag, 8. März 2018 3:06 15EN Use charging converter PerfectCharge

10.1 Switch charging converter on/off

The charging converter turns on automatically as soon as it receives a positive control signal. The status LED glows blue. The charging converter switches off automatically when the control signal is no longer present.

10.2 Adjust charging converter

You can adjust the device using the DIP switch (fig. 1 7, page 3). Set switchover voltage/constant voltage You can use the DIP switches S1 and S2 to set the value of the end-of-charge voltage. NOTE If the control signal of the charging converter is switched via the ignition, the starter battery can discharge if the engine is not started in a timely manner. NOTE Take the values for the charging end voltage and maintenance charge voltage of your battery from the battery manufacturer's specifications. S1 S2Switchover voltage/constant voltage12 V 24 VON ON 14.4 V 28.8 VOFF ON 14.1 V 28.2 VON OFF14.7 V 29.4 VOFF OFF DCC1224-2424--IO-16s.book Seite 20 Donnerstag, 8. März 2018 3:06 15EN PerfectCharge Use charging converter

Set float voltage You can use the DIP switches S3 and S4 to set the float voltage in the U phase (float). Set charging mode

OFF OFF WARNING! Danger of explosions! Use only the charging mode appropriate for your battery type. If neces- sary inquire at a specialist workshop. S5 S6 Charger Mode ON ON IU0U- charging Refer to chapter “Battery charging function” on page 16. OFF ON Constant voltage 1 The battery charger works as a constant voltage source, where the value of the voltage corresponds to the set charging end voltage. ON OFF Constant voltage 2 The battery charger works as a constant voltage source, with the value of the voltage corresponding to the set floating voltage. OFF OFF DCC1224-2424--IO-16s.book Seite 21 Donnerstag, 8. März 2018 3:06 15EN Maintaining and cleaning the charging converter PerfectCharge

Set eStore mode (DCC1212-40 only and DCC2412-40 with optional eStore battery) You can set the eStore charging mode using the S7 DIP switch. For the eStore charging characteristic, a temperature sensor must be connected.

The eStore charging mode has the following charging characteristics: 11 Maintaining and cleaning the charging converter

➤ Occasionally clean the device with a damp cloth. S7 eStore charging characteristicON OFF OFF ON NOTE When used without a temperature sensor, the eStore charging mode is constant at 13.8 V with a maximum of 35 A. Output voltage(Charging end voltage): 13.8 VgOutput current(Charging current):< –10 °C 0 A< –10 °C bis 0 °C 5 A> 0 °C 35 A NOTICE! Risk of damage to the device! Never clean the device under running water or in dish water. Do not use abrasive cleaning agents or hard objects during cleaning as these can damage the appliance. DCC1224-2424--IO-16s.book Seite 22 Donnerstag, 8. März 2018 3:06 15EN PerfectCharge Troubleshooting

LED does not glow ➤ Check the electric connections. If you cannot find an error, contact customer service. 13 Warranty The statutory warranty period applies. If the product is defective, please contact the manufacturer's branch in your country (see the back of the instruction manual for the addresses) or your retailer. For repair and guarantee processing, please include the following documents when you send in the device:

• A copy of the receipt with purchasing date

• A reason for the claim or description of the fault 14 Disposal ➤ Place the packaging material in the appropriate recycling waste bins wherever possible.

If you wish to finally dispose of the product, ask your local recycling centre or specialist dealer for details about how to do this in accordance with the applicable disposal regulations. WARNING! Do not open the device. You risk exposing yourself to an electric shock by doing this. NOTE If you have detailed questions about the battery charger data, please contact the manufacturer (addresses on the back of the instruction manual). DCC1224-2424--IO-16s.book Seite 23 Donnerstag, 8. März 2018 3:06 15EN Technical data PerfectCharge

15 Technical data DCC1224-10 DCC1224-20Ref. no.: 9600003748 9600003749 Transformation: 12 V 24 V Nominal input voltage: 12 VgInput voltage range: 8 V – 16 VCharging current: 10 A 20 ACharging voltage: 26.4 V – 29.4 VOutput: 250 W 500 WResidual ripple of output voltage at rated current:< 50 mV rmsEfficiency: up to 90 %Idle power consumption: < 0.4 AAmbient temperature for operation: –20°C to +50°C Ambient humidity: 95 % Non-condensing Dimensions (W x D x H): 153 x 73 x 220 mm 153 x 73 x 260 mm Weight: 1.55kg 1.85kg Inspection/certification:

Ref. no.: 9600003750 9600003751 Transformation: 24 V 12 V Nominal input voltage: 24 Vg Input voltage range: 16 V – 32 V Charging current: 20 A 40 A Charging voltage: 13.2 V – 14.7 V Output: 250 W 500 W Residual ripple of output voltage at rated current: < 100 mV eff Efficiency up to: 90 % Idle power consumption: < 0.4 A Ambient temperature for operation: –20°C to +50°C Ambient humidity: 95 % Non-condensing Dimensions (W x D x H): 153 x 73 x 220 mm 153 x 73 x 260 mm Weight: 1.55kg 1.85kg Inspection/certification:

Ref. no.: 9600003752 9600003753 Transformation: 24 V 24 V 12 V 12 V Nominal input voltage: 24 Vg 12 Vg Input voltage range: 16 V – 32 V 8 V – 16 V Charging current: 10 A Charging voltage: 26.4 V – 29.4 V 13.2 V – 14.7 V Output: 250 W 120 W Residual ripple of output voltage at rated current: < 100mV eff < 50 mV eff Efficiency up to: 90 % Idle power consumption: < 0.4 A Ambient temperature for operation: –20°C to +50°C Ambient humidity: 95 % Non-condensing Dimensions (W x D x H): 153 x 73 x 220 mm 153 x 73 x 180 mm Weight: 1.55kg 1.25kg Inspection/certification:

Ref. no.: 9600003754 9600003755 Transformation: 12 V 12 V Nominal input voltage: 12 Vg Input voltage range: 8 V – 16 V Charging current: 20 A 40 A Charging voltage: 13.2 V – 14.7 V Output: 250 W 500 W Residual ripple of output voltage at rated current: < 50 mV eff Efficiency up to: 90 % Idle power consumption: < 0.4 A Ambient temperature for operation: –20°C to +50°C Ambient humidity: 95 % Non-condensing Dimensions (W x D x H): 153 x 73 x 220 mm 153 x 73 x 260 mm Weight: 1.55kg 1.85kg Inspection/certification: 12 V 24 V Input: High voltage, low voltage, reverse polarity protection (internal fuse) Low-voltage cut-out: 8 V 16 V Low voltage restart: 10 V 20 V High voltage shutdown: 16 V 32 V High voltage restart: 15.5 V 31 V Temperature: Shutdown Short circuit protection: yes, I

Temperature compensation

NOTE The temperature compensation is only effective if a TS-1 temperature sensor is connected and the IU0U charging mode is selected.

• Signal de l'alternateur (borne 15)

• Sinal do alternador (borne 15)

UIT AAN 13,5 V 27,0 V

FRA TIL 13,5 V 27,0 V

complete list of Dometic companies, which comprise the Dometic Group, can be found in the public filings of: DOMETIC GROUP AB Hemvärnsgatan 15 SE-17154 Solna Sweden 4445102493 07/2019