45 Amp, 3 Stage Switchmode
INTELLI-CHARGE
DC/SOLAR BATTERY CHARGER
P/No. IDC45
WARNINGS
• Explosive gases may escape from the battery during charging.
Prevent flames and sparks and provide adequate ventilation.
• Before charging, read the instructions.
• FOR CHARGING 12 VOLT LEAD ACID BATTERIES ONLY.
• Do not attempt to charge non-rechargeable batteries.
• Never charge a frozen battery.
• Corrosive substances may escape from the battery during charging and damage
delicate surfaces. Store and charge in a suitable area.
• This appliance is not intended for use by young children or infirm persons unless they
have been adequately supervised by a responsible person to ensure that they can use
the appliance safely.
• Fit fuses as close to the batteries as possible to protect the cable in case of
short circuit.
FEATURES
The IDC45 DC-DC charger is purposely designed for charging auxiliary batteries.
It includes all the features needed to maintain the auxiliary battery to its optimum
condition and to prolong the battery life.
SWITCHMODE TECHNOLOGY
The IDC45 converts your vehicle’s 12VDC/24VDC alternator power to the voltage
level allowing your batteries to be fully charged, prolonging battery life and
reliability. With the latest synchronous switching technology, efficiency of IDC45
exceeds 94% at typical full load condition.
DUAL INPUT OPERATION
Allows two energy sources to power the IDC45 simultaneously. Solar input takes
precedence if solar and alternator inputs are present. When solar input cannot provide
enough energy to the load, the IDC45 will draw power from solar and alternator
simultaneously.
SOLAR MPPT
The IDC45 utilises sophisticated MPPT (Maximum Power Point Tracking) solar
regulator technology. MPPT maximises the power generated from the solar panels
to the auxiliary battery.
2
SUPERIOR 3 STAGE CHARGING
Using high speed microcontroller and proprietary charging algorithm, the IDC45
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 IDC45 supports GEL, AGM, WET and CALCIUM batteries. If the calcium battery
mode is selected, periodic equalisation will be provided to the calcium battery for
removing acid stratification.
IGNITION CONNECTION
The ignition connection activates the lower input voltage operation to suit vehicles
with smart (variable voltage) alternators.
TEMPERATURE COMPENSATION
The IDC45 is supplied with a 2 metre temperature sensor. The sensor monitors the
battery temperature and adjusts (compensates) the charger’s output to prevent
overcharging. This is ideal for batteries used in warmer climates or environments.
REMOTE CHARGER STATUS INDICATION
A pink wire is provided for driving an external panel mount LED indicator (Eg Narva
P/No. 62090BL) to show the status of the charger. It shows whether the auxiliary
battery is on charge (Solid Colour) or the charger is in a fault condition (Flashing).
PROTECTIVE FEATURES
Spark-Free Protection
The IDC45 will not start charging the battery (no output) unless the load is securely
connected. 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 IDC45 internal
circuit. The IDC45 detects reverse connection condition and indicates whether input
or output connection is 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.
3
SPECIFICATIONS
Operating Conditions
Input Voltage 9-32Vdc
Maximum Solar Input Voltage 28Vdc
Maximum Input Current 65A
Input Current (No Load) 20mA
Back Drain on Auxiliary Battery < 5mA
External LED Output – Constant Current 4mA
Output Current Input 9–11Vdc: 37A
Input 11V-32dc: 45A
Input Fuse Rating 80A (Not supplied)
Output Fuse Rating 80A (Not supplied)
Maximum Output Power 693W
Solar Input Turn On Voltage 9V
Size 255 x 122 x 40 mm
Solar MPPT Voltage 17.5V
Weight 1.54kg
Operating Temperature (Derated from 55
Charge Control
Charge Type 3 Stage
Bulk *37A at 9-11Vdc and 45A at 11-32Vdc *Constant Current up to:
GEL AGM WET CALCIUM
14.1V 14.4V 14.7V 15.4V
Absorption Constant Voltage until current drop to 7.5A
GEL AGM WET CALCIUM
14.1V 14.4V 14.7V 15.4V
Float Keep Constant Voltage at 13.7V
Equalisation 7.5A Constant Current Charge up to 16V
(Calcium mode only) then hold for 1 hour (5 hour timeout)
Battery Range
Battery Capacity 150-600Ah
Type of Batteries Supported GEL, AGM, WET & CALCIUM
Operating Mode
12V Vehicle 24V Vehicle
VSR Mode – Default (Ignition Override Turn on Turn off Turn on Turn off
Not Connected) 13.4-20V <12.8V 26.8-32V < 25.6V
Low Voltage Mode – Ignition Override cable Turn on Turn off Turn on Turn off
connected to ignition switch (ignition on) 12.2-20V <11.9V 24.4-32V <24V
Standards
EMC C-Tick, AS/NZS CISPR11:2011 Class B
IP Rating IP67
o
C) -10 to +80oC (Ambient Temperature)
4
PRODUCT OVERVIEW
Mounting
DC Leads
Slots
Charging
LED Indicates
charging status
Temperature
Sensing Cable
122
Solar LED
Indicates solar
input status
Alternator
LED Indicates
alternator input
status
255
63.5 63.5
Battery
Chemistry
Selection
(Mode) Button
40
LED Battery
Chemistry Display
Indicates selected
battery chemistry type
5
INSTALLATION
MOUNTING
The rugged design of the IDC45 affords it to be mounted wherever best suits the
application. By using advanced potting technology the unit is resistant to shock,
vibration, dust and water allows for under-bonnet or in-vehicle installation. Clever
`side extrusions’ incorporated within the enclosure allow the unit to be mounted to
flat surfaces as close to the auxiliary battery as possible. It is advisable however to
keep the charger as far away from exhausts, turbo’s or any other high temperate
components to ensure improved performance.
WIRING
To make sound electrical connections, battery cables will need to be made to the
correct length. Cable lugs should be crimped or soldered to the stripped battery
cable and then protected with the supplied heatshrink. Butt splices should be used
for cable extension.
Recommended cable size for wiring:
Cable Size
2
Alternator Input Cable (Red) 13mm
Solar Input Cable (Green) 13mm
Output Cable (Grey) 13mm
Common Ground (Black) 13mm
Ignition Override (Blue) 1-1.5mm
External LED (Pink) 1-1.5mm
(6 B&S)
2
(6 B&S)
2
(6 B&S)
2
(6 B&S)
2
2
Note the above recommendation is valid for cable length up to 5m.
1. Disconnect the negative battery cable (Earth) from the vehicle’s starting
battery or disconnect power to the trailer. Note: To prevent the loss of
vehicle electronic memories, radio presets & security codes, it is recommended
that an “Electrical System Memory Protector” be used.
2. Connect the Auxiliary Battery positive (+) terminal to the Output Cable
(grey colour) from IDC45. Fit a 80A fuse to the cable as close as possible
to the Auxiliary Battery positive (+) terminal.
3. Connect the Auxiliary Battery negative (-) terminal to the IDC45 Common
Ground cable (black colour). Alternatively connect both Auxiliary Battery
negative (-) terminals and IDC45 Common Ground cable to vehicle
chassis ground.
6
4. Connect the Starter Battery positive (+) terminal to the IDC45 Alternator Input
cable (red colour). Fit a 80A fuse to the cable as close as possible to the Starter
Battery positive (+) terminal.
5. If your vehicle has fixed voltage or temperature compensating alternator
installed, leave the Ignition Override cable (blue colour) open.
If your vehicle has smart (variable voltage) alternator installed, the Ignition
Override cable must be connected to the vehicle’s ignition. The IDC45 will only
operate when the vehicle’s ignition is turned on.
However, if solar panels are connected to IDC45, the IDC45 will operate and
only draw power from solar panels (assuming vehicle’s ignition is turned off).
Fit a 1-2A fuse to the cable as close as possible to the vehicle’s ignition.
Consult the vehicle manufacturer for type of alternator installed in your vehicle.
6. When 12V solar panels are present, connect the solar panel positive terminal (+)
to the IDC45 Solar Input cable (green colour). Fit a 80A fuse to the cable as
close as possible to the Solar Panel positive (+) terminal.
Then, connect the Solar Panel negative (-) terminal to the IDC45 Common
Ground cable (black colour). Alternatively connect both Solar Panel negative (-)
terminals and IDC45 Common Ground cable to vehicle chassis ground.
7. The external LED wire provides 4mA constant current output. It can power an
LED panel mount indicator with or without an internal resistor.
Leave External LED cable open if you do not need the external LED indication.
If external LED indication is required, connect the positive (+) terminal of a LED
Indicator to the External LED cable.
Then, connect the negative terminal of LED Indicator to the vehicle
chassis ground.
8. Cut/remove Temperature Sensing cable if temperature compensated battery
charging is not needed. Use supplied heatshrink to insulate the open end of
Temperature Sensing cable.
If temperature compensated charging is required, attach the ring terminal
of the Temperature Sensing cable to the auxiliary battery negative terminal.
For best results, attach the ring terminal to the auxiliary battery plastic surface
with thermal conductive adhesive such as 3M TC-2810 or equivalent.
Heatshrink
Temperature
Sensing Cable
7
SELECTION OF AUXILIARY BATTERY TYPE
Press the Mode button on the front panel until all Battery Chemistry LEDs are
flashing. There are 4 battery chemistries available: Gel, AGM, Wet and Calcium.
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 IDC45 is fully
disconnected and reconnected. The default Battery Chemistry is AGM.
Charging profile for each selection:
Bulk *Constant Current up to:
*37A at 9-11Vdc, GEL AGM WET CALCIUM
45A at 11-32Vdc 14.1V 14.4V 14.7V 15.4V
Absorption Constant Voltage until current drop to 7.5A
GEL AGM WET CALCIUM
14.1V 14.4V 14.7V 15.4V
Float Keep Constant Voltage at 13.7V
Equalisation 7.5A Constant Current Charge up to 16V
(Calcium mode Only) then hold for 1 hour (5 hour timeout)
Calcium Chemistry mode is good for charging Optima batteries or deeply discharged
calcium-calcium lead acid batteries (e.g Delkor DC31).
Please consult the battery manufacturer if you are unsure of your battery’s
chemistry.
8
TYPICAL WIRING INSTALLATION
1. Full System
)
2
)
2
)
2
)
2
)
2
)
2
Ground/Chassis – Black (8mm
Alternator/Starter Battery – Red (8mm
connects to ignition feed if smart alt.
Ignition override – Blue (1.5mm
*
For vehicles fitted with
a Smart Alternator only
Solar – Green (8mm
Output/Auxiliary Battery – Grey (8mm
Temperature Sensing – Black (twin core)
External LED – Pink (1.5mm
LED Panel
Mount Indicator
*
Earth/Chassis
Lithium Iron Phosphate
charging mode
Fuse
Battery 1
(Starter Battery)
Temp Sensor mount
to battery casing
Fuse
*
Earth/ChassisGround/Chassis
Battery 2
(Aux Battery)
12V Solar Panel
Earth/Chassis
* Optional
Important: For 24V vehicles, a battery master switch is required to connect a 12V solar
panel to the IDC45 solar input. This switch is used to turn the solar panel on and off.
When solar power is too low to provide fast charge to the auxiliary battery, by turning
off the 12V solar panel, IDC45 can provide fast charge through alternator input.
9
2. Alternator/Starter Battery Input Only
)
2
)
2
)
2
)
2
)
2
Ground/Chassis – Black (8mm
Alternator/Starter Battery – Red (8mm
For vehicles fitted with
a Smart Alternator only
connects to ignition feed if smart alt.
Ignition override – Blue (1.5mm
*
External LED – Pink (1.5mm
Output/Auxiliary Battery – Grey (8mm
Temperature Sensing – Black (twin core)
LED Panel
Mount Indicator
*
Earth/Chassis
Lithium Iron Phosphate
charging mode
10
Fuse
Battery 1
(Starter Battery)
Temp Sensor mount
to battery casing
Fuse
*
Earth/ChassisGround/Chassis
Battery 2
(Aux Battery)
* Optional
3. Solar Battery Input Only
)
2
)
2
)
2
)
2
Ground/Chassis – Black (8mm
12V Solar Panel
Solar – Green (8mm
Output/Auxiliary Battery – Grey (8mm
Temperature Sensing – Black (twin core)
Earth/Chassis
External LED – Pink (1.5mm
Temp Sensor mount
to battery casing
LED Panel
Mount Indicator
*
Earth/Chassis
Fuse
Battery 2
*
(Aux Battery)
* Optional
Lithium Iron Phosphate
charging mode
Earth/Chassis
11
HOW TO READ LED DISPLAY
CHARGING
SOLAR
ALTERNATOR
MODE
GEL AGM WET CALCIUM
12V 45A DC 3-Stage
LED Charge Indicators
Charging LED Battery Type LED Charging Stage
GREEN Flashing Solid BLUE Bulk Charge
GREEN Flashing BLUE Flashing Adsorption Charge
Solid GREEN BLUE Flashing Equalization Charge
Solid GREEN Solid BLUE Float Charge
Fault LED Indicators
Charging Solar Alterator Battery Fault Remedy
LED LED LED Type LED
Solid RED The unit is faulty Check if there is any output
current from the unit
Amber Bulking charging time out Auxiliary battery may be
Flashing faulty or heavy load is
connected to the battery
for long time
Solid RED BLUE Output battery is reversely Check output cable
Flashing Connected connection
RED BLUE Overvoltage is detected Check auxiliary battery
Flashing Flashing at output voltage
Solid AMBER BLUE Output open circuit or Check auxiliary battery
Flashing dead Battery voltage & cable connections
Solid RED Solar Input is reversly Check Solar input
connected connection
RED Overvoltage is detected at Check solar panel open
Flashing Solar Input circuit voltage
Solid RED Alternator Input is Check Alternator input
reversly connected connection
RED Overvoltage is detected at Check vehicle battery
Flashing Alterantor voltage
12
FREQUENTLY ASKED QUESTIONS
Q. Is the IDC45 waterproof?
A. The Projecta IDC45 is designed to be dust and weather proof. Normal use
including river crossings and light engine washing will not pose any problem.
Direct high pressure washing of the IDC45 unit or submersion for a period of
time may cause some water damage and will not be covered under warranty.
Q. Why do the positive cables from the batteries need to be fused?
A. High Capacity batteries can produce large amounts of power and are capable of
melting cable insulation and catching fire in the case of a short circuit. Each
positive (+) cable connected to the battery must be protected by a fuse.
Q. Is the charger safe to use with modern ‘electronic’ vehicles?
A. The Projecta IDC45 has been designed to work with all vehicles, especially
new vehicles with EFI and computer management systems. The charger utilises
sophisticated electronics that ensures complete safety for you and your vehicle.
Q. How do I know if the battery is charged?
A. When Charging LED is in Solid Green and one of the Battery types LED is in
Solid Blue, it indicates the auxiliary battery is in full charged.
Q. I have connected the charger properly but the ‘INPUT LED’ does not
come on?
A. Check the cable size. The IDC45 is designed to power on and charge from an
input source as little as 9V. If small size cables are used for wiring, the voltage
might drop below 9V when IDC45 is attempting to start up. Please refer to
Installation – wiring section for recommended cable size.
Q. I have connected the charger properly but the ‘OUTPUT LED’ does not
come on?
A. In some cases batteries can be discharged to the point where they have very
little or no voltage. This can occur if a small amount of power is used for a long
time, for example a map reading light is left on for a week or more. The IDC45
is designed to charge an auxiliary battery from as little as 5 Volts. If the voltage
is lower than 5 Volts use a pair of booster cables to connect between two
batteries to provide more than 5 Volts to the battery being charged. The IDC45
can then start to charge the battery and the booster cables can be removed.
Q. Why does the ‘FULLY CHARGED’ LED come on straight away?
A. There are three possible reasons why the ‘FULLY CHARGED’ LED may come
on straight away.
1. The battery is fully charged.
2. The battery has taken a surface charge.
3. The battery has a faulty cell.
13
Q. What is Surface Charge?
A. Batteries unused or left discharged for some time build up a resistance to being
recharged. When the charger is first connected, these batteries will take a
surface charge, and the ‘FULLY CHARGED’ LED will illuminate within a short
period of time. The battery however is not fully charged. The charger is voltage
sensitive and cannot differentiate between a surface charge and a fully charged
battery. After a few hours the battery may start to accept some charge but most
batteries with this condition may not recover.
Q. What is a Faulty Cell?
A. 12 Volt batteries contain 6 cells and one faulty cell is enough to ruin your
battery. If after twelve hours of charging your battery is still accepting charge,
you should test the cells using a hydrometer. If one reading is lower than the
rest it indicates a faulty cell. It is pointless to continue charging; the battery
needs replacing.
Q. Why is there no output at the charger’s terminals?
A. The charger incorporates short circuit protection that makes it much safer to
use. For this reason the charger will only output power when properly connected
to a battery. To check if the charger is functioning, follow the instructions to
connect and operate the charger as normal on a flat battery. While the battery
is charging measure the battery voltage with a volt or multi-meter. Charging can
be confirmed if the voltage is increasing (within the voltage parameters set out
in the specifications).
14
NOTES
15
WARRANTY STATEMENT
Applicable only to product sold in Australia
Brown & Watson International Pty Ltd of 1500 Ferntree Gully Road, Knoxfield, Vic.,
telephone (03) 9730 6000, fax (03) 9730 6050, warrants that all products described in
its current catalogue (save and except for all bulbs and lenses whether made of glass or
some other substance) will under normal use and service be free of failures in material
and workmanship for a period of one (1) year (unless this period has been extended as
indicated elsewhere) from the date of the original purchase by the consumer as marked
on the invoice. This warranty does not cover ordinary wear and tear, abuse, alteration of
products or damage caused by the consumer.
To make a warranty claim the consumer must deliver the product at their cost to the
original place of purchase or to any other place which may be nominated by either BWI or
the retailer from where the product was bought in order that a warranty assessment may
be performed. The consumer must also deliver the original invoice evidencing the date and
place of purchase together with an explanation in writing as to the nature of the claim.
In the event that the claim is determined to be for a minor failure of the product then
BWI reserves the right to repair or replace it at its discretion. In the event that a major
failure is determined the consumer will be entitled to a replacement or a refund as well as
compensation for any other reasonably foreseeable loss or damage.
This warranty is in addition to any other rights or remedies that the consumer may have
under State or Federal legislation.
IMPORTANT NOTE
Our goods come with guarantees that cannot be excluded under the Australian Consumer
Law. You are entitled to a replacement or refund for a major failure and compensation for
any other reasonably foreseeable loss or damage. You are also entitled to have the goods
repaired or replaced if the goods fail to be of acceptable quality and the failure does not
amount to a major failure.
Distributed by
AUSTRALIA
Brown & Watson International Pty Ltd
Knoxfield, Victoria 3180
Telephone (03) 9730 6000
Facsimile (03) 9730 6050
National Toll Free 1800 113 443
NEW ZEALAND
Narva New Zealand Ltd
22–24 Olive Road
PO Box 12556 Penrose
Auckland, New Zealand
Telephone (09) 525 4575
Facsimile (09) 579 1192
IS386
Issue 1 19.01.18
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