intervolt DCC Pro User manual

INSTALLATION & OPERATION MANUAL
DCC Pro
In-Vehicle DC-DC
Battery Charger
12VDC 25 AMPS
(VERSION R2.0)

WELCOME
Thank you for choosing an interVOLT product...
Intervolt Pty Ltd is a wholly Australian owned and operated private
company and the proud owner of the interVOLT brand, a trademark
which is registered in over 20 countries worldwide.
We have been producing specialised power conversion products for over
15 years. All our products are designed, developed and assembled
in-house at our premises in Perth, Western Australia from both local
and imported components.
Our design ethos is based on quality, performance and value, and we are
committed to product development in the DC power, control and
conversion field. With roots in the commercial marine, transport, alternate
energy and allied industries, we have expanded into the consumer market
with dedicated products such as the DCC Pro.
InterVOLT products are designed to cope with the demands of the
harshest applications in high temperature and high humidity environments.
They are constructed of quality materials and designed to provide many
years of continuous service.
Again, thank you for choosing an interVOLT product and supporting
Australian innovation, technology, intellectual property and of course, jobs.

1
CONTENTS
OVERVIEW .............................................................. 2
Introduction ............................................................ 2
Outline ................................................................... 3
Application.............................................................. 4
Kit Contents............................................................ 5
FUNDAMENTALS .................................................... 6
Charging Methods ................................................... 6
Control Modes ........................................................ 7
Layout - the Charging Device ..................................... 8
Layout - the Remote Display ...................................... 9
Standard Wiring Diagram ....................................... 10
Wiring using two Charging Devices........................... 11
INSTALLATION ...................................................... 12
Planning the Installation .......................................... 12
Installation Essentials ............................................. 13
Installing the Charging Device .................................. 14
Installing the Data Cable ......................................... 15
Installing the Remote Display ................................... 16
Wiring the Charging Device ..................................... 17
Connection and Configuration .................................. 18
Installation Steps ................................................... 19
OPERATION........................................................... 25
Operating Brief ...................................................... 25
Operator Control and Monitoring.............................. 27
Operator Convenience Settings ................................ 30
System Status....................................................... 32
TROUBLESHOOTING .............................................. 33
Alert Conditions..................................................... 33
Error Conditions .................................................... 34
Frequently Asked Questions..................................... 35
SPECIFICATIONS ................................................... 36
DIMENSIONS ........................................................ 37
APPENDIX ............................................................ 38
Fundamentals in Detail ........................................... 38
WARRANTY POLICY .............................................. 41

OVERVIEW
2
Introduction
Following its release in 2015 the DCC Pro has enjoyed outstanding success in
the overland vehicle market both in Australia and overseas. We are now pleased
to introduce version 2.0 which features a number of functionality and
performance upgrades oering even greater‘value for money’ than the original.
Just some of the great features on the new DCC Pro 2.0:
• Designed to charge an auxiliary battery using the main battery and/or solar
power as input sources, quickly and eciently.
• Proven three stage charging methodology in both‘battery to battery’and
'solar to battery’ charging processes, including MPPT.
• Solar charging is now current limited to 25 Amps so input is no longer
restricted to the number of panels connected (total Wattage).
• Double stacked printed circuit boards provide a compact footprint allowing
for easy location and xing in an engine bay.
• All external components are designed to operate under high ambient/humid
conditions and are rated to IP67 for dust and moisture protection.
• Capable of charging a wide range of battery chemistry types including a
specic curve for LiFePO4 Lithium batteries (with inbuilt battery management
system).
• The exibility to adapt to almost any application in any vehicle, old or new,
simple or complex with or without an ECU controlled electrical system.
• A truly universal ‘Plug and Play’ system which allows multiple set-up and
conguration options for simplied installation and operation.
• Provides the operator with the ability to monitor the charging status of the
auxiliary battery from the comfort of the cabin.
• A true stand-alone charging system which can be implemented without
interference or modication to the host vehicle’s factory wiring.

OVERVIEW
3
Outline
In a standard dual or multiple battery arrangement, the system will consist of a
starting (or main) battery and secondary (or auxiliary) batteries. For clarity and
conciseness we will refer to these throughout the manual as the main and
auxiliary batteries.
Our vision for the DCC Pro was a device which would not only provide an
autonomous charging method for any auxiliary battery, but would reliably,
accurately and repeatedly provide feedback to the operator on the status of the
charging and maintenance process. In order to provide this information we
integrated a visual display. The addition of a remote display also provides a level
of operator input, allowing some control of the device, such as selection of
battery types for example. The development of a true remote user interface
enabled the concept to evolve into the product you have purchased today.
The DCC Pro consists of three main components. Together, these form a
stand-alone charging system and are all that is necessary, aside from the
external wiring, to implement a fully operational charging and maintenance
system for one auxiliary battery or bank (batteries in parallel). These
components are:
1. The Charging Device. This is the power conversion component of the
system. It is a high power, yet compact package which is designed to be
installed in the engine bay of the vehicle.
2. The Remote Display. This is the separate control and monitoring device
which is designed to be installed in the vehicle cabin in easy view and reach of
the operator. It has a backlit LCD display and four control buttons.
3. The Data Cable. This is the interconnect harness that enables the Charging
Device and Remote Display to communicate with each other.
This manual contains comprehensive information on the installation,
set-up and use of the DCC Pro and is applicable to this model only (version
R2-0). Whilst every care has been taken in the preparation of this manual,
Intervolt Pty Ltd oers no guarantee, express or implied, and accepts no
liability for any inaccuracies, errors or omissions in its content.
Specications are subject to change without notice.

OVERVIEW
4
Application
The DCC Pro has been designed specically for use in 4WDs, RVs, buses,
coaches, caravans, campers or any vehicle with a 12VDC electrical system
where there is a requirement to charge one or more secondary (auxiliary)
batteries using the starting (main) battery as the primary source. It is not
designed or warranted for use in marine applications.
The DCC pro utilises the three step or‘stage’charging principle for maintaining
an auxiliary battery by using the main battery as the primary source and solar
power as the supplementary source. The three stages combined represent a full
charging cycle. Although there are many variants of this concept, the basic
three stages, when implemented correctly, are all that is required to ensure
proper charging of any auxiliary battery. The stages are categorised as boost,
absorption and oat, details of which are explained in the appendix of this
manual. In boost stage the charger is operating in constant current (CC) mode
and in absorption and oat stages it is in constant Voltage (CV) mode.
The DCC Pro is pre-programmed with charging regimes for the following
battery types which can be selected in the conguration (set-up) process:
• Standard Lead Acid – sealed and ooded cell versions
• Absorbed Glass Mat – aka AGM
• Gelied Electrolyte – aka GEL
• Lead Calcium
• LiFePO4 – with Battery Management System (BMS) only (not suitable for
other Lithium battery types).
The information on the following pages of this manual detail the functions of
the DCC Pro and the settings which are best suited for your application and
installation. If you are performing the installation it is important to read this
manual in its entirety. If you are the operator it is only necessary to read the
‘Operation’section. The appendix section contains specic information on the
fundamentals of the DCC Pro and is optional but recommended reading.
NOTE: It is not essential to use the Remote Display included. The DCC Pro’s
Charging Device is autonomous and will operate with or without the
Remote Display connected. It is necessary to use the Remote Display for
programming purposes, however it is not necessary to permanently install
the display if it is not desired.

OVERVIEW
5
Kit Contents
You have purchased the DCC Pro retail package code number DCC1225ACK-RP.
The package contains the components depicted below:
DCC Pro 4mtr Data Cable
Code: DCC4000CTR
DCC Pro Printed Manual
Code: DCCAUTG1 R2-0
DCC Pro Remote Display
Code: D
CC0001ARD
DCC Pro Charging Device
Code: D
CC1225ACD
OK
All components are available to purchase separately. Data Cables are available
in a range of optional lengths. In the event you wish to add in a second
charger for example, it would not be necessary to purchase another display
but simply order another Charging Device and Data Cable of the appropriate
length.
The code numbers for the components are detailed below:
• DCC1225ACD: Automotive Charging Device 12 Volts DC 25 Amps
• DCC0001ARD: Automotive Remote Display complete with bracket
• DCC3000CTR: Data Cable 3 metres Charging Device to Remote Display
• DCC4000CTR: Data Cable 4 metres Charging Device to Remote Display
• DCC6000CTR: Data Cable 6 metres Charging Device to Remote Display
• DCC9000CTR: Data Cable 9 metres Charging Device to Remote Display

FUNDAMENTALS
6
Charging Methods
There are two methods the DCC Pro utilises for charging an auxiliary battery.
Although employing the same three stage process for both battery and solar
input sources, the methodology is dierent. Both methods can be utilised at the
same time thus providing a complete charging solution for your vehicle’s
auxiliary battery system.
Charging the auxiliary battery from the main: The battery to battery
charging method employs power conversion to step up the source Voltage to a
higher level before being regulated at a Voltage determined by the battery type
(chemistry) selected. In topology terms, this is dened as a boost/buck
conversion process where the input Voltage is stepped up in the boost process
and stepped down (regulated) in the buck process. The main battery is the
priority charging source if and when available. This is because, by comparison,
the vehicle’s alternator can generally deliver much higher current when the
engine is running than most solar power installations.
Charging the auxiliary battery from solar power: The solar to battery
charging method uses the higher available Voltage (18–28 OCV) to extract the
maximum power from a solar source by employing Maximum Power Point
Tracking algorithms (MPPT). The MPPT function provides a benet of up to 30%
greater eciency in performance over a standard (PWM) type regulator. It
should be noted at this point that the solar panel is directly connected and
should be unregulated. Use of a regulator will not allow the MPPT charging
control to operate correctly and as a result will be detrimental to the charging
and maintenance of your auxiliary battery.

FUNDAMENTALS
7
Control Modes
There are two optional modes which control how the charging system operates.
These modes are selectable in the initial set-up process when installing the
device and control the charging process in dierent ways. The control modes
can always be changed if necessary but the initial set-up and installation steps
need to be repeated in order to do so. The control modes are dened and
explained as follows:
Voltage Control Mode: Voltage mode is the default (factory) mode and allows
the charging process to operate automatically, independent of the host vehicle.
This mode is recommended for installations where it is not viable or necessary to
use the host vehicle’s ignition switch to enable/disable the Charging Device.
Voltage mode would primarily be used where the Charging Device is located in a
caravan or camper trailer for example, and thus a long way from a switched
ignition source.
Ignition Control Mode: Ignition mode is selectable at the set-up stage of the
installation process and is the alternative to Voltage mode. This mode is
recommended for installations where the auxiliary battery is mounted in the
host vehicle, in the engine bay or under the tray for example. In Ignition mode a
control wire is permanently connected to the Charging Device from the vehicle’s
electrical system to allow dependent control via the host vehicle’s ignition
switch. In this mode the Charging Device can be enabled or disabled when the
ignition switch is turned on or o respectively.
MAIN
BATTERY
AUXILIARY
BATTERY
CHARGING
DEVICE
IGNITION
SWITCH
FUSEFUSE
MAIN
BATTERY
AUXILIARY
BATTERY
CHARGING
DEVICE
FUSEFUSE

FUNDAMENTALS
8
Layout - Charging Device
LED
GLOW
RING
Top View With
Terminal Cover
interVOLT Model
DCC1225ACD
Battery to Battery
Charging Device
12VDC - 12VDC
25 Amps max.
COMMON
NEGATIVE
TERMINAL
REMOTE
DISPLAY
OUTPUT
IGNITION
CONTROL
TERMINAL
MOUNTING
FEET
SOLAR
PANEL
POSITIVE
TERMINAL
MAIN
BATTERY
POSITIVE
TERMINAL
AUXILIARY
BATTERY
POSITIVE
TERMINAL
Top View Without
Terminal Cover
Note: Images above shown approximately half actual size.

FUNDAMENTALS
9
Layout - Remote Display
‘DOWN’ SELECTION
OR LOW
BRIGHTNESS
CONTROL. ALSO
USED TO TURN OFF
BACKLIGHT.
‘UP’ SELECTION
OR HIGH
BRIGHTNESS
CONTROL.
CONFIRMATION
SELECTION BUTTON.
ALSO USED TO
TOGGLE BETWEEN
DEFAULT AND
ALTERNATE SCREEN.*
FOR SWITCHING
BETWEEN TWO
CHARGING DEVICES.
ALSO USED AS
BACK AND EXIT
BUTTON.
Front View
Back View
CHARGING
DEVICE
INPUT
A
CHARGING
DEVICE
INPUT
B
Note: Images above shown approximately actual size.
* See Page 28 for further information.

FUNDAMENTALS
10
interVOLT Model
DCC1225ACD
Battery to Battery
Charging Device
12VDC - 12VDC
25 Amps max.
+IGNITION SWITCH SUPPLY
FUSE
12V
AUX
FUSE
12V
MAIN
FUSE
REMOTE
DISPLAY
CHARGING
DEVICE
DATA CABLE
SOLAR
PANEL
OPTIONAL
IGNITION
SWITCH
TO AUXILIARY
EQUIPMENT
TO
ENGINE
Standard Wiring Diagram
NOTE: Do not connect auxiliary battery to Charging Device
until system has been congured.

FUNDAMENTALS
11
12V
AUX 2
FUSE
12V
MAIN
FUSE
interVOLT Model
DCC1225ACD
Battery to Battery
Charging Device
12VDC - 12VDC
25 Amps max.
12V
AUX 1
FUSE
FUSE
interVOLT Model
DCC1225ACD
Battery to Battery
Charging Device
12VDC - 12VDC
25 Amps max.
REMOTE DISPLAY
CHARGING
DEVICE B
CHARGING
DEVICE A
TO AUXILIARY
EQUIPMENT
TO
ENGINE
TO AUXILIARY
EQUIPMENT
Wiring using two Charging Devices
NOTE: Do not connect auxiliary battery to Charging Device
until system has been congured.
DATA CABLE B
DATA CABLE A

INSTALLATION
12
Planning the installation
IMPORTANT: In order to ensure safety, high performance and
long life the DCC Pro should only be installed by a suitably
qualied tradesperson.
Plan the installation according to the location of the main and auxiliary
batteries. The Charging Device can be situated anywhere in the circuit (subject
to using the appropriate cable size) and does not need to be located directly
next to either battery. Please consider the number of cables required when
planning the install as the location could result in extra wiring. For example if
the DCC Pro is required to charge a battery in a caravan it may be better to
mount the Charging Device in the caravan itself rather than the vehicle but this
may depend on where the Remote Display needs to be located.
Consideration should be given to the wiring layout. The DCC Pro has been
designed so that cables can enter the device from any direction, even from one
side only, without having to cross over. Crimp terminals are recommended over
soldered lugs and should be terminated to automotive quality standards.
Incorrect or poor crimping is not only a mechanical issue (wire separating from
terminal) but will also cause Voltage drop and potential overheating of the
conductor as a result. Using the correct wire size for the application is
imperative. The table on page 17 details the minimum conductor size according
to the run length.
For complete protection it is necessary to fuse each positive conductor. The fuse
should be installed as close as possible to the battery. Fusing is required to
protect the vehicle in the event of a short circuit – a cable coming o a terminal
and contacting the chassis for example. The DCC Pro itself is fully protected by a
range of internal protection devices. The fuse should be no smaller in rating
than recommended in the chart on page 17 and no larger than the rating of the
cable being used.
NOTE: All wiring should be terminated and routed but not
connected to the Charging Device at this time. In order to
congure the device the connection must be made in
conjunction with the set-up steps depicted on pages 18–24.

INSTALLATION
13
Installation Essentials
Common faults often arise as a result of the installation. A poor installation will
result in poor performance of the system, placing unnecessary stress (both
electrically and physically), on all the components involved. Furthermore, this can
result in safety issues such as breakdowns and in worst case scenarios even re.
This is why we state that the DCC Pro should only be installed by a suitably
qualied tradesperson.
Please observe the following protocols when undertaking a dual battery
installation:
1. To avoid Voltage drop, use correct wire gauge size according to the run length.
Using undersized wiring is the most common cause of Voltage drop. Copper is
expensive and it is tempting to reduce the cost of an installation by using smaller
gauge wire however this is detrimental to both performance and safety. Do not
be tempted!
2. Use bolt-down midi style fuses. Do not use blade fuse holders. Many
o-the-shelf style blade fuse holders use poor quality materials. The metal
contacts cannot handle thermal cycling and quickly become loose, thereby losing
conductivity. Manual reset circuit breakers are acceptable but check for de-rating
factor under elevated temperatures.
3. Use good quality copper compression lugs for all termination and correct
tooling to ensure proper crimping. Sub-standard crimping creates resistance in
the circuit which can produce a ‘hot spot’. Under heavy current, the heat
generated from this point can be enough to melt plastics. The high temperature
can also be conducted to other components causing failure.
4. Terminate all negative wiring at a common grounding point. Bad grounding
creates resistance in the circuit resulting in Voltage drop and can be dicult to
diagnose if the circuit is not under load. Ensure that all grounding points
connected to the body/chassis have good electrical conductivity and are
protected from corrosion.
5. Many installations use heavy duty connectors tted in the circuit, often
between the DC DC charger and a caravan/camper for example. Ensure any
connectors tted between the Charging Device and batteries are of high quality
and correctly rated for the wire size used. If a connector is required, we
recommend only Genuine Anderson brand. Poor quality connectors will result in
resistance in the circuit and a potential ‘hot spot’.

INSTALLATION
14
Installing the Charging Device
The DCC Pro Charging Device has been designed to cope with demanding
conditions and can be installed in the vehicle’s engine compartment. Care must
be taken when performing the installation to ensure performance, longevity and
of course, safety. Installing the device too close to a turbocharger for example
may not only force the device into thermal shut down but could also result in
catastrophic failure.
Select a suitable location where the Charging Device can be mounted ensuring
adequate ventilation to the heatsink ns, free from excessive vibration and heat.
The electronics are enclosed in a sealed housing however the device, where
possible, should be installed in a protected environment. The Charging Device is
NOT designed to be installed in a location where water can regularly ‘short’
between the terminals.
As it is of solid state design, the Charging Device can be mounted in any position
vertically or horizontally. It should be oriented so that the LED Glow Ring
indicator is clearly visible to the installer/operator. It must be installed on a hard
at surface – not an upholstered or insulated surface. Ensure at least 30mm of
clearance all around from any other equipment.
The Charging Device should be xed with appropriate fasteners ensuring all four
anchor holes are utilised. If mounted on a vertical surface the Data Cable
socket should be oriented to the side or downwards.
NOTE: Remove the terminal cover
before using any tools to fasten the
Charging Device in position.

INSTALLATION
15
Installing the Data Cable
The Data Cable is the communication link between the Charging Device and the
Remote Display. It has a sealed connection at the device end and unsealed
connector at the display end. If the Charging Device is installed in the engine
bay, a 10mm diameter feed-through hole must be drilled in the rewall for the
Data Cable.
DO NOT FORCE THE DATA CABLE THROUGH AN EXISTING FACTORY WIRING
GROMMET AS THIS COULD RESULT IN DAMAGE TO THE CONNECTOR.
The Data Cable must be fed through
the hole from the engine bay side as
the sealed connector will not pass
through the hole. A rubber grommet
is tted to the cable and must be
utilised to prevent damage to the
cable sheath from any sharp metal
edges.
The Data Cable is tted with a PVC
‘clamshell’protector over the Remote
Display connector plug. This is to
protect the plug from damage when
being routed into the vehicle cabin.
The protector should only be removed
when you are ready to plug into the
Remote Display.
There are two plastic clips located on
the Remote Display mounting base.
These are used to secure the Data
Cable and relieve any strain on the
connector. The cable can simply be
pushed into the clip after the
connector has been plugged in to the
socket on the rear of the Remote
Display but not until it is mounted
(see page 16).
10mm Ø
Connector protector
to remain in place
until ready to plug in
Data Cable
retaining
clips

INSTALLATION
16
Installing the Remote Display
The DCC Remote Display is designed to be installed in the cabin of the vehicle,
on the dash or console. It should be shielded from excessive heat and located
away from direct sunlight if possible.
A user adjustable ball joint allows for the housing to swivel through a range of
positions to best suit the operator.
A tensioning screw in the centre of the mounting bracket can be utilised to
adjust and maintain the Remote Display in the desired position. This screw
should not be over-tightened.
There are two methods provided for xing the mounting base to the surface,
details as follows:
Option A - Screw Fixing:
This method utilises two suitable
fasteners (not supplied) to attach the
mounting base to the surface as per
the diagram below.
Ball Joint
Tensioning
Screw
Option B – Adhesive Fixing:
This method utilises the self-adhesive
foam backing tape to adhere the
mounting base to the surface as per
the diagram below.
Peel o backing
lm to apply
The mounting base is designed to hold
the Remote Display. Place the display
bottom rst into the bracket and
pinpoint the two location tabs provided.
Tilt the display back until the top tab
locates in position with an audible‘click’.
The display can be removed at any time
by pushing the thumb lever gently back
and releasing the housing assembly. Do
not press on the lens as this may result in
it cracking.

INSTALLATION
17
COPPER LUG FOR
POWER TERMINATION
CRIMP LUGS FOR
IGNITION TERMINATION
Main/Auxiliary/Solar/Negative Ignition
5.0 NmMaximum torque rating 1.5 Nm
There are four large power terminals, one each for the main and auxiliary
batteries, one for the solar panel and one for the negative connection. A lug
with a 6mm diameter hole should be used for terminating these four cables.
There is a single, smaller control terminal which is used when Ignition Control
mode is implemented. Spring washers are not required.
DO NOT USE POWER TOOLS TO FASTEN TERMINAL SCREWS
All terminals should be fastened with hand tools and care should be taken not
to over-torque the screws. The torque settings are detailed in the table below.
The DCC Pro is fully protected electronically against catastrophic failure. It is
mandatory however that inline fuses are tted to protect the wiring in the event
of an external short circuit. The fuse rating should not be less than the
continuous current rating of the wiring. The table below details the
recommended fuse size for all required wiring.
All cable lugs must be properly terminated using appropriate tooling in
order to prevent poor contact which can result in overheating of the stud.
An example of the correct method of termination is depicted below.
Wiring the Charging Device
Using the correct cable gauge size for the task is paramount to performance
and safety. Please refer the table below for the minimum recommended cable
size (cross section) required in order to prevent Voltage drop.
Cable Run Length Minimum Conductor Size Recommended SAE Equivalent
1-5 Metres 6 mm² 8 B&S/AWG (7.91mm²)
5-9 Metres 10 mm² 6 B&S/AWG (13.56mm²)
Main Solar Auxiliary
40A minimumFuse rating To solar panel spec. 30A minimum

INSTALLATION
18
Connection and Configuration
A step-by-step guide
In some applications, the DCC Pro can be installed and connected straight out
of the box without any changes to the conguration. In other situations it is
necessary to change these defaults, a dierent battery type for example, as
detailed below (see Charging Methods section on page 6 for explanation).
For safety reasons, the battery type and control mode can only be changed
during set-up (conguration mode) before the auxiliary battery is connected.
Of course, these selections can be changed at any time but the auxiliary battery
must be disconnected in order to do so.
In default state the conguration is based on a standard battery to battery
charging installation and assumes the following:
1. The auxiliary battery is a standard lead acid type (sealed or unsealed).
2. The system is not controlled by the vehicle’s ignition circuit.
The Remote Display is initially used for conguring the Charging Device upon
installation. Most importantly the Remote Display allows for selection of
dierent battery types (chemistries) and the control mode, Voltage Sense or
Ignition Control (see explanation on page 7).
The following options are available for selection:
• Standard Lead Acid – displayed as 1LEAD ACID on the Remote Display
during set-up or SLA in short form.
• Absorbed Glass Mat – displayed as 2 AGM on the Remote Display during
set-up and in short form.
• Gelied Electrolyte – displayed as 3GEL on the Remote Display during
set-up and in short form.
• Lead Calcium – displayed as 4 CALCIUM on the Remote Display during
set-up or LCA in short form.
• LiFePO4 Lithium – displayed as 5 LFP BMS on the Remote Display during
set-up and in short form.
The following pages illustrate the step by step conguration process for
installing the Charging Device and Remote Display. If there is a need to
change the battery type and control mode, this process must be completed
in the order depicted for the DCC Pro to operate correctly.