Voltronic VCC 1212-25 IUoU-Li, 3306, 3308, VCC 2412-25 IUoU-Li, VCC 1212-45 IUoU-Li Operating Manual
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Installation and Operating Manual
Charging Converter, B2B Battery to Battery, Battery Charging During Driving:
VCC 1212-25 IUoU-Li Input Voltage 12 V Charging Capacity 12 V / 25 A No. 3306
VCC 1212-45 IUoU-Li Input Voltage 12 V Charging Capacity 12 V / 45 A No. 3308
VCC 2412-25 IUoU-Li Input Voltage 24 V Charging Capacity 12 V / 25 A No. 3314
VCC 2412-45 IUoU-Li Input Voltage 24 V Charging Capacity 12 V / 45 A No. 3315
Please read the mounting instructions and the operating manual including the safety
instructions attentively. Particularly observe page 2 "Safety Regulations and Appropriate
Application", prior to starting connection and start-up.
Fully automatic Battery Charging Converter for special purpose vehicles, campers, boats.
The charging converters (boosters) had been developed according to the latest regulations for supply battery charging in
lead-acid, lead-gel, lead-AGM or LiFePO4 technology from the generator during driving.
In case of long supply lines or insufficient cross-sections of the cables, the charging voltage will be increased according to
the default charging values and losses will be compensated. Charging converters with 24 V input voltage allow charging of
the 12 V supply battery without installation of a second generator.
Thus, the charging converter ensures the known high-quality battery charging of the VOTRONIC chargers also during
driving. Due to the intelligent microprocessor charging control with charging characteristic lines "IU1oU2" and dynamic
charging time calculation an automatic, quick and gentle full charging is ensured, as well as subsequent 100 % trickle charge
of the connected batteries from any charging state. At the same time, simultaneous supply of 12 V consumers, which are
connected in parallel, is ensured. Overcharging or excessive gassing of the batteries is avoided, even in case of extremely
long driving times. Any consumed energy will be compensated immediately.
The charging converters excel by their compact design, low weight (high-frequency switch mode technology), powerfully
dimensioned power components and consequently full charging capacity, even with long charging cables or strong voltage
fluctuations at the generator / starter battery (EURO standard 6, 6 + plus vehicles).
Information see page 9, table 2, switch position "D".
Battery Output OUT "I", Charging Programs:
Depending on the battery type, select one of the 4 charging programs, see table 1:
a) "Lead Acid/AGM1": Closed and open acid/lead-acid-lead batteries, as well as AGM 14.4 V (factory adjustment)
b) "AGM 2": Closed, gas-tight AGM batteries (absorbed glass mat, lead-fleece technology)
c) "Gel": Closed, gas-tight Gel batteries, (dryfit, determined electrolyte)
d) "LiFePO4": Charging voltage 14.4 V for lithium LiFePO4 batteries with completely integrated electronic system
and safety circuit (BMS).
Further Characteristics of the Unit:
The charging voltage is free from peaks and is controlled in such a way, that overcharging of the batteries is excluded.
Fully automatic operation by means of control input (ignition, running engine), as well as voltage control.
No intervention into the electric system of the vehicle. The charging converter acts like a consumer at the generator.
Automatic, adjustable power control giving priority to charging of the starter battery by the generator in case of
overloaded vehicle mains to ensure that the vehicle can be started at any time.
No discharge (current 0.000 A) of the batteries during stand-by or with switched-off charging converter.
Parallel and Floating Operation: In case of simultaneous consumption, the battery will either continue to be charged
or maintained via trickle charging. Calculation and control of the adaptation of the charging time is effected
automatically by the charging converter.
Unattended Charging: Multiple protection against overload, overheating, overvoltage, short circuit, reverse battery at
the output, incorrect behaviour and back discharge of the battery by electronically controlled gradual reduction down
to complete separation of charging converter and battery by integrated safety relays.
Galvanic isolation between input and output: Complete separation of the battery circuits, even in case of failure
(particularly important for 24 V/12 V mixed systems) and neat ground ratio, also in case of long supply lines.
Charging aid for deeply discharged lead batteries or switched-off LiFePO4 batteries: Gentle preliminary charging of
the (lead-acid, gel, AGM) battery or automatic reactivation of the Li battery in case of possibly switched-on consumers.
- 2 -
Lead Temperature Equalization: The delivered battery temperature sensor effects an automatic adaptation of the
charging voltage to the battery temperature. In case of low outside temperatures, full charging of the weaker battery is
improved, and in case of summery temperatures unnecessary battery gassing will be avoided.
LiFePO4 temperature control and adaptation of the charging by the delivered battery temperature sensor, which allows
also charging beyond the recommended LiFePO4 battery temperatures below 5 °C and above 35 °C.
Integrated On-board Mains Suppression Filter: Unproblematic parallel operation of solar systems, wind and petrol-
driven generators, mains supply chargers etc. at a single battery.
Charging Cable Compensation: Automatic compensation of voltage losses on the charging cables.
Battery Lifetime and Efficiency:
Keep the batteries cool, LiFePO4 preferably above 0 °C. Choose an appropriate location
for installation.
Store only fully charged batteries and recharge them periodically.
Open lead-acid batteries and batteries being "maintenance-free according to EN / DIN":
Check the acid level periodically!
Recharge deeply discharged lead batteries immediately!
LiFePO4: Only use complete batteries with BMS and safety circuit.
! Deep discharge is to be absolutely avoided !
Safety Regulations and Appropriate Application:
The charging converter has been designed according to the valid safety regulations.
Appropriate application is restricted to:
1. Charging of lead-gel, lead-AGM, lead-acid or LiFePO4 complete batteries (with integrated BMS,
balancing, safety circuit and approval!) Charging of batteries of the indicated nominal voltage and
simultaneous supply of the consumers being connected to these batteries in fixed installed systems with
the indicated battery capacities and charging programs.
2. Connection in consideration of the indicated cable cross-sections at the inputs and outputs of the
charging converter.
3. With the indicated minimum battery capacity at the input of the charging converter.
4. Fuses of the indicated capacity are to be provided near the battery to protect the cabling between
battery and connections of the charging converter.
5. Technically faultless condition.
6. Installation in a well-ventilated room, protected from rain, humidity, dust, aggressive battery gases, as
well as in an environment being free from condensation water.
Never use the unit in locations where the risk of gas or dust explosion exists!
Open-air operation of the unit is not allowed.
Lay the cables in a way, that damage is avoided and observe to fasten them tightly.
Never lay 12 V (24 V) cables and 230 V mains supply cables into the same cable conduit (empty conduit).
Check live cables or leads periodically for insulation faults, points of break or loosened connections. Occurring
defects must be remedied immediately.
The unit is to be disconnected from any connection prior to execution of electrically welding or work on the
electric system.
If the user is not able to draw from the manual, which characteristic values are valid for a unit or which
regulations are to be observed, a specialist is to be consulted.
The user / buyer is responsible for the observation of construction and safety regulations of any kind.
The unit does not contain any parts, which can be replaced by the user. Even after having been switched-off,
the unit may be live for an extended period (particularly in case of failure).
Keep children away from the charging converter and the batteries.
Observe the safety regulations of the battery manufacturer; deaerate the battery room.
Non-observance may result in injury or material damage.
The warranty period is 36 months from the purchase date (against presentation of the sales slip or invoice).
The warranty will be void in case of any inappropriate utilisation of the unit, if it is used beyond the technical
specification, in case of improper operation or external intervention. We do not assume any liability for any
damage resulting hereof. The liability exclusion is extended to any service being executed by third, which has
not been ordered by us in writing. Service is to be effected exclusively by VOTRONIC Lauterbach.
- 3 -
Installation of the Unit:
The charging converter can be installed at any location, which is clean and which is protected from humidity and dust.
Choose an installation location ensuring that the length of the connection cable between starter battery (IN) and board
battery (OUT) is as short as possible. By this, unnecessary losses over the cables are avoided.
Despite the charging converter’s high efficiency, heat is produced, which is brought out of the casing by means of the builtin fans.
Ensure sufficient ventilation in the environment of the unit, so that the heat can be removed. Protect the unit from
aggressive battery gas.
The unit can be installed in any position. However, the vent holes of the casing (front panel and rear panel) should never be
covered to ensure the full charging capacity (minimum distance: 10 cm).
Ensure a solid and vibration reducing installation using rubber bushings on an even and hard mounting surface.
Connection and Settings:
Choose the suitable connection plan according to your application. Observe the indications, fuses, polarity
+/-!
Table Page 5: Observe the "Recommended Cable Cross-sections and Lengths of the Power Connection
Cable"!
First connect the charging converter, after that the batteries.
Output Side:
1. Connect the board/supply battery to the large terminals "Battery I OUT" "-" and "+" observing the correct
polarity. Recommended in case of a cable length exceeding 2 m:
Lead a voltage sensor line with fuse directly from the positive pole of the board battery to the terminal
"+ Sense Out". Recommended in case of a cable length of less than 2 m: The terminal "+ Sense Out" can be
left free.
2. Terminals "T T Temp. Sensor": Connect the temperature sensor (included in the delivery scope) for
battery temperature equalization and control. See "Option Temperature Sensor", page 7.
Input Side:
3. Connect the vehicle's starter battery to the large terminals "Battery II IN" "-" and "+" observing the
correct polarity! Reverse battery (mixing up) +/- at this place will result in serious damage of the unit!
4. Terminal "Sense In+": Lead a voltage sensor line with fuse directly from the positive pole of the starter
battery. Without connection, the unit does not work!
For further details (such as operation without separate sensor line) please refer to table 2, page 9.
5. Terminal "Kl.15/D+", control input for activation of the unit:
Connection preferably to the signal D+ "Generator active" of the vehicle.
If this signal does not exist, the signal "Ignition ON" (vehicle terminal 15) can be used for automatic unit
control.
6. Terminal "EBL Start In": Refer to connection plan "EBL" and "EVS", otherwise leave it free.
Settings for Start-up:
7. Output Side of the Charging Converter:
Set the type, design (lead-acid, AGM, gel or Lithium-LiFePO4) of the board battery "I" to be charged using
the switches "Battery Type". See table 1, page 8.
8. Input Side of the Charging Converter:
Set the installation operating mode IN at the starter battery "II" to be supplied by means of the switches
"Input Type". See table 2, page 9.
9. Start-up and function test, see page 10. Further details, see page 11.
Further operation of the unit is not required during normal automatic mode.
- 4 -
General Connection Plan Charging Converter, All Types:
If possible, the unit should always be installed as close as possible to the board battery I.
Observe the cable cross-sections, lengths and fuses according to the table on page 5!
Possibly existing cables, which do not have the required cross-sections must be adapted to the
minimum requirements in any case!
Reverse battery (+/-) at the IN II (Start) side will result in serious damage of the unit!
Input and output side of the charging converter are separated by galvanic isolation, i. e. there is no conductive
connection between the input II side (START) and the output I side (BOARD).
Thus, the two battery circuits are completely independent of each other, and a mutual influence or disturbance
is avoided.
Therefore, the minus (-) terminals I and II must imperatively be connected observing the indicated cable crosssections. Refer to connection plan.
If required, the two sensor lines "Sense In +" and "+ Sense Out" (see table2) must be led separately and as
separate line to the + poles of the battery!
This is the only way to achieve a correct voltage measurement at the batteries.
The sensor lines near the battery must be protected with a fuse (cable protection)!
- 5 -
Recommended Cross-sections and Lengths of the Power Connection Cables:
Cable
Cross-
sections,
each
+ / - Pole
VCC 1212-25
VCC 1212-45
VCC 2412-25
VCC 2412-45
START
Batt.
BOARD
Batt.
START
Batt.
BOARD
Batt.
START
Batt.
BOARD
Batt.
START
Batt.
BOARD
Batt.
Fuse II:
40 A
Fuse I:
30 A
Fuse II:
80 A
Fuse I:
50 A
Fuse II:
30 A
Fuse I:
30 A
Fuse II:
40 A
Fuse I:
50 A
Cable
Length:
Cable
Length:
Cable
Length:
Cable
Length:
Cable
Length:
Cable
Length:
Cable
Length:
Cable
Length:
4 mm²
-
0.5 - 2.0 m
-
-
up to
6.0 m
0.5 - 2.0 m
-
-
6 mm2
up to
5.5 m
1.5 - 3.5 m
-
0.5 - 2.0 m
up to
11.0 m
1.5 - 3.5 m
up to
6.0 m
0.5 - 2.0 m
10 mm2
up to
9.0 m
3.0 - 6.5 m
up to
5.0 m
1.5 - 3.5 m
up to
18.0 m
3.0 - 6.5 m
up to
10.0 m
1.5 - 3.5 m
16 mm2 - -
up to
8.0 m
3.0 - 5.0 m
-
-
up to
16.0 m
3.0 - 5.0 m
* * Insert the cable into the terminal without wire-end ferrule
View Front Panel Input
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