ArSilicii DCC-530 User manual

ADVANCED ELECTRONIC ENGINEERING FOR AUTOMOTIVE
Automotive 3-stage Smart
Battery to Battery Chargers
DCC-530 and DCC-850

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DCC Family
The DCC family is meant to charge batteries takig energy from a variable source, like a battery or an
alternator adopting a user selectable charging cycle in accordance to the type (i.e. chemistry) of the
battery and to battery manufacture’s specifications.
It is able to reach the optimal charge level and to maintain it. It is designed to be used in conjunction
with standard alternators and also with new smart and variable output alternators of modern low
emission vehicles, including vehicles equipped with START and STOP devices.
An important feature of this family is that the unit works as a standard step-up or step-down
stabilized power-supply for a load also in absence of the auxiliary battery connected drawing
energy from the alternator.
WARNING & SAFETY INSTRUCTIONS
This manual contains IMPORTANT SAFETY INSTRUCTIONS for the DCC-530 and DCC-850 battery
chargers.
DO NOT OPERATE THE BATTERY CHARGER UNLESS YOU HAVE READ AND UNDERSTOOD THIS
MANUAL AND THE CHARGER IS INSTALLED AS PER THESE INSTALLATION INSTRUCTIONS. ARSILICII
RECOMMENDS THAT THE CHARGER BE INSTALLED BY A SUITABLY QUALIFIED PERSON.
RISK OF EXPLOSIVE GASES:
WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE
EXPLOSIVE GASES DURING NORMAL OPERATION. FOR THIS REASON, IT IS OF UTMOST
IMPORTANCE THAT YOU FOLLOW THE INSTRUCTIONS WHEN INSTALLING AND USING THE
CHARGER.
1. 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. Children should be supervised to ensure that they do not play with the Battery Charger.
2. Do NOT alter or disassemble the Battery Charger under any circumstances. All faulty units
must be returned to ARSILICII or repair. Incorrect handling or reassembly may result in a risk of
electric shock or fire and may void the unit warranty.
3. Only use the Battery Charger for charging Standard Automotive Lead Acid, Calcium Content,
Gel, AGM, Deep Cycle or Lithium Ions batteries. Check the manufacturers data for your battery and
ensure that the ‘Maximum’ voltage of the profile you select does not exceed the manufacturers
recommended maximum charging voltage. If the ‘Maximum’ voltage for your battery type is too
high, please select another charging profile.
4. NEVER smoke or allow a spark or flame in vicinity of battery or engine. This may cause the
battery to explode.
5. PERSONAL SAFETY PRECAUTIONS
To assist with the safe operation and use of the Battery Charger:
a) Wear complete eye protection and clothing protection. Avoid touching eyes while working
near a battery.
b) If battery acid contacts your skin or clothing, remove the affected clothing and wash the
affected area of your skin immediately with soap and water. If battery acid enters your eye,
immediately flood the eye with running cold water for at least 10 minutes and seek medical
assistance immediately.

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CONTENTS
DCC FAMILY...........................................................................................................................................2
WARNING & SAFETY INSTRUCTIONS.......................................................................................................2
SPECIFICATIONS.....................................................................................................................................4
GENERAL DESCRIPTION ..........................................................................................................................4
SYSTEM LOGIC .......................................................................................................................................4
CHARGING CYCLE WHEN IN CHARGER MODE..........................................................................................5
CUSTOM CHARGE CYCLE...................................................................................................................................... 5
CUSTOM SYSTEM LOGIC ......................................................................................................................................6
FRONT LEDS...........................................................................................................................................6
CONNECTORS.........................................................................................................................................6
INSTALLATION DIAGRAM .......................................................................................................................8
POWER LINES..................................................................................................................................................... 8
3-WIRES CONNECTION ........................................................................................................................................8
4-WIRES CONNECTION ........................................................................................................................................9
CONTROL SIGNAL LINES....................................................................................................................................... 9
FIAT /STELLANTIS DUCATO CABLING....................................................................................................... 10
FORD TRANSIT CABLING .......................................................................................................................... 10
BASIC ENGINE RUN SIGNAL ONLY............................................................................................................ 10
BUS LINE..............................................................................................................................................10
CABLE SIZING....................................................................................................................................... 11
WIRING................................................................................................................................................ 12

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SPECIFICATIONS
Part Number
DCC-530
DCC-850
Continuous Current Rating
30A
50A
Cooling Fan
No
Yes
Output SC Protecting
Yes (Electronic resettable)
Output Peak Power
500W
800W
DC Input Voltage Range
*1
9-32V
9-32V
Default Charging Profile
Standard Lead Acid, Calcium content, Gel & AGM
-Maximum Voltage
14.3-15.6V
-Float Voltage
13.3-13.8V
No Load Current
0 or <2 mA (according to cabling)
Standby Current
<200uA
Ambient Temperature
-20°C to +80°C
Weight
450g
Dimensions
100x120x37mm
Warranty
2 years
Standards
CE
GENERAL DESCRIPTION
The DCC family is family of multi stage, 12V DC-DC battery chargers that operates from an input
voltage starting from 9 volts to 32 volts and it adjusts dynamically the output to follow the charging
cycle selected by the user using a 3-stage charging strategy.
It is designed to work in conjunction with modern environmental compliant engines, therefore
accepts control signals from most of main vehicles manufacturers. In order to save quiescent current
when not in use, the unit may be powered only when the ignition is on or with a very low quiescent
current (<2mA), for always ON operations, where current drain is critical.
SYSTEM LOGIC
When the DCC is turned on, it analyses the load connected at its output (connector B, pole 2). This
phase lasts about 20 seconds, in order to determine if a battery is connected. If battery is detected,
it switches to CHARGER mode, otherwise, if only a standard load is detected, it switches to
STABILIZER mode in which deliver all the possible power at a steady output of 13.5.
As a charger, when the engine is running, according to operational status, the DCC optimize the
charge of the battery, if not expressly commanded by the vehicle’s ECU. Several kind of connections
are possible, using engine running and/or ignition key signals.

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CHARGING CYCLE WHEN IN CHARGER MODE
When the DCC is turned on in charging mode, it will maintain a constant current until the battery
voltage reaches the Absorption Voltage. The current during this stage may vary throughout
operation in order to maintain a safe operating temperature, or to limit the difference between
input and output voltages.
The charger will then maintain a constant voltage level for a predetermined period of time after
which the charger will enter Float stage.
Float stage maintains 13.5V on the output battery, keeping the battery topped up. This counteracts
the battery’s self-discharging. When the battery loses charge, due to excessive loads, the charger
will move back into the first stage.
Mount the unit to a flat surface close to the auxiliary battery and away from any heat sources. The
DCC has several connectors and should be installed as described over the following pages.
NOTE: The unit will operate optimally below 55°C air temperature provided a good airflow. At higher
temperatures, the unit will automatically de-rate output current.
NOTE: Appropriate connections must be made to the wires with a continuous current rating of at
least 80A (50A for the DCC-530). Failure to do so may cause damage to the unit and vehicle.
Pre-sets charging cycles can be selected using the dip switches located in the front panel according
to the table below.
DIP switch S
SW 1
SW 2
Battery Type
Vboost
Vfloat
ON
OFF
Lead/AGM
Low Temperature Lead
14.8 V
13.8 V
OFF
OFF
Wet Lead/AGM
14,5 V
13.8 V
OFF
ON
Lead/Gel
14.2 V
13.5 V
ON
ON
Lithium
14.5 V
13.6 V
Custom Charge Cycle
Charge Cycle can be customized for special needs by the user, through a serial communication
connection using a proprietary software that can be requested directly to ArSilicii s.r.l.

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Custom System Logic
System Logic can be customized for special needs by the user, reprogramming the unit through a
serial communication programmer. For information ask directly to ArSilicii s.r.l. Examples of custom
system logic:
Manage batteries with special chemistry, 24V-12V Voltage system converter, Power Filtering and
Stabilizing, Solar power Converter/Charger, special logic by handling signal and/or analogic measure
through connector D.
FRONT LEDS
These units are provided with 4 front LEDs to signal the state.
LED LABEL
LED state
Description of the State
Charge
Off (Not lit)
Unit is not powered
Blinking Green or
Orange
System check and Charging
Blinking Red
Limit Reached (i.e. max temperature)
Steady
Supply
Fault
Off (Not lit)
Flashing Red
Call Assistance.
Battery
Green
Battery Full.
Orange
Battery medium charge.
Red
Battery Empty.
Bus Status
Flashing Green
Communication OK
Flashing Red
Communication Problems
CONNECTORS
The drawing above show a schematic diagram of the connectors designated in red. Below follow
the tables with the details for each connector and the functional description.

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The connector A is the input of the power line from the alternator and negative reference.
The B connector groups to battery and to user load.
Connector C is the connector for basic signal and serial port to program the DCC.
Note: Optional Battery Temperature sensor NTC SK between pin 1 and 2.
Connector A Panel Front View
Pin
Description
1
Positive pole powerline from the alternator and car
battery
2
Negative Reference to car chassis.
Model: ARSILICII QC03000180 Mate with: ARSILICII QC03000180
Connector B Panel Front View
Pin
Description
1
To Positive pole Aux Battery.
2
To Positive pole User Loads.
Model: ARSILICII QC03000181 Mate with: ARSILICII QC03000181
Connector C Front Panel View
Pin
Name
Dir
Description
1
RTH/RX
IN
Battery Temperature Sensor / Serial RX
2
DC-
IN
Signal ground
3
LIN
OUT
Serial TX /Lin BUS
4
DC+
IN
Bus Supply
Model: Molex 87727 Mate with: Molex 39012040

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The D connector groups all the signal coming from the car.
Connector D Panel Front
View
Pin
Name
Dir
Description
Function in default logic
1
REF
IN
Signal Ground
Ref. Signal negative pole
2
EN+
IN
Activation
signal
Enable: Active High (12v)
3
AC
IN
Adaptive
Charging
Forces Low power mode
(disabled when GND)
4
LS
IN
Load Shedding
Forces stop charge when
high.
5
EN-
IN
Activation
Signal
Enable: Active Low (GND)
6
ER
IN
Engine Run
Engine Running: Active
Low
Model: Molex 35318-0620 Mate with: Molex 39012060
INSTALLATION DIAGRAM
Power Lines
The DCC has the power flow from Connector A to Connector B.
Basically, there are two kinds of connections possible of the DCC-0850 for use in leisure vehicles:
3-wires and 4-wires connection. The latter is highly recommended!
3-Wire connection
The 3-wire connection is more simple, in that, only one output is used both for the Service Battery
and for the motorhome loads.
This type of cabling does not allow the unit the current delivered to the load to that delivered to
the battery, making optimal battery charging quite difficult.

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4-Wire connection
The 4-wire connection, instead, separates the loads from the leisure battery. In this way is possible
to keep distinguish between the current delivered to/from external loads and sources from that
delivered to charge the leisure battery and optimize charging cycle. With the 4-wires connection
the unit can estimate precisely the charging status of the aux battery and deliver the proper voltage
and current in accordance to the charging algorith for the battery type selected.
Control Signal Lines
Regarding control signals from the vehicle, the connection strictly necessary is the activation signal
(either positive or negative), that is pin 2 (for switched to 12V) or 5 (for switched to gnd signals) on
connector D.
In most cases, you want to short-circuit pin 3 with pin 6 in order to disable Adaptive Charging (Low
power mode).
Unfortunately, every car manufacturer makes available slightly different signals and furthermore
uses a different naming convention.
On most of the vehicles signals are available notifying when the ignition key is turned and when the
engine is effectively running. Sometimes only one of the two signals is available.
Below some commented examples of how engine signals cabling.
Adaptive Charging
If pin 3 on connector D is not connected to reference ground (negative), then adaptive charging is
enabled. This mode limits the output current. This mode is to be used when input cabling size is
small, in order to avoid a too big voltage drop on the device input line.

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FIAT /STELLANTIS DUCATO CABLING
Short-circuiting pin 3 and 1 (red), adaptive charging is disabled, so maximum power charge mode is
enabled. For this car, the signal of engine running, is switched to ground (engine is active), so it is
attached to pin 6 (green). Key position signal is high when key is turned to active position and
therefore is attached to pin 2 (blue).
Charging stop is delayed after engine stops so to allow for short start/stop cycles. When engine is
not running and key is in off position, the unit turn off after a timeout.
FORD TRANSIT CABLING
For this car, Short-circuiting pin 3 and 1 disables adaptive charging. The engine running signal (green)
in this case is switched to ground when engine is active, so it is attached to pin 6.
Key position signal is high when key is turned to active position and therefore is attached to pin 2
(blue). This car provides a load shedding signal, to prevent draining current under some
circumstances, this signal goes high to stop charge and is attached to pin 4 (orange).
Charging stop is delayed after engine stops so to allow for short start/stop cycles. When engine is
not running and key is in off position, the unit turn off after a timeout.
BASIC ENGINE RUN SIGNAL ONLY
Short-circuiting pin 6,3 and 1 (red), disables Adaptive charging and enable the unit. For this car, the
signal D+ is switched high when alternator is active, so it is attached to pin 2 (blue). If this signal or
an equivalent engine run was switched low, then it should be connected on pin 5. The unit shuts off
when engine is not running.

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BUS Line
DCC-0850 operations can be controlled and monitored via a communication bus. Several standard
serial bus protocols are available. By default, when the unit is used in conjunction with ArSilicii
control panels the TTK bus is used. Below a simple system diagram.

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CABLE SIZING
Below is a table outlining the required cable size for a given cable install length. Always choose a
wire diameter equal to or greater than what is specified below.
WIRING
The wires on the DCC units carry peak high currents of many Amps and it is important to make a
good, low resistance, electrical connection that will not degrade over time. Failure to make a good,
reliable contact may result in breakdown of the wire insulation and cause a short circuit, or worst
case a fire. We recommend that this activity be undertaken by an appropriately trained person.
Crimping provides good mechanical connection; soldering provides a long lasting electrical
connection and forming of the heatshrink will prevent any shorting/ accidental contacts with your
vehicle chassis. As a general rule, avoid blade contacts of any size or colour.