KICK ASS KADCDC25A-AND User manual

®
25 AMP DC-DC CHARGER
WITH MPPT SOLAR CONTROLLER
V2 USER MANUAL
KADCDC25A-AND | KADCDC25A-BBK

ŸTo avoid injury or damage to your vehicle ensure the instructions are read carefully
and understood.
ŸBatteries can produce harmful vapour and explosive gases when being charged.
ŸEnsure batteries are mounted and stored in an area with good ventilation.
ŸAs this Charger has powerful output current, circuit protection such as fuses or circuit
breakers must be installed as near as possible to the batteries - refer to wiring
diagrams in this manual for correct fitting.
WARNINGS
This manual will give you all of the essential information you need to own and
operate your new KickAss 25 AMP - DC-DC Charger with MPPT Solar Controller.
The purpose & features of the KickAss 25 AMP - DC-DC Charger with MPPT Solar
Controller:
uCan charge multiple battery types:
Whether your battery is GEL, AGM, WET, CALCIUM or . Lithium LiFePO₄
uPrevent your auxiliary battery from draining your start battery:
Built-in voltage sensing will ensure your start battery charges your auxiliary battery
when the vehicle is running. It will then disconnect the start battery from the
auxiliary battery when the vehicle is not running.
uEnsure your auxiliary battery is being fully charged and maintained:
Most modern vehicles (especially those manufactured after 2010) do not provide the
correct voltages and charge control to safely and completely charge your auxiliary
battery. The Charger overcomes this issue by boosting the charge voltage to an
optimal output level while ensuring your auxiliary battery is safely charged via its
multi-stage charge algorithm.
uWhen your vehicle is not charging, charge from the inbuilt MPPT solar
controller:
Maximum power point tracking is the most efficient type of solar controller and
allows you obtain the maximum amount of charge from your solar panels. When
your vehicle is not doing the charging, the built-in MPPT solar controller will let your
solar panels do the work.
1

Stay safe and protect your assets with these protective features:
„Short circuit protection
The Charger will not turn on unless the batteries are connected correctly.
„Reverse polarity protection
If you connect positive and negative the wrong way around the Charger will show a
fault.
„Over voltage protection
If the Charger detects voltages connected to its inputs or outputs that are too high it
will shut down.
„Over temperature protection
The Charger will lower its output current if it senses that the unit will overheat.
„Temperature compensation:
The included temperature sensor will measure the battery temperature and adjust
current accordingly to prevent overcharging.
For more technical details, specifications & videos please visit
kickassproducts.com.au
2

SPECIFICATIONS
3
Charger model
Alternator input voltage
Input current (no load)
Efficiency
External LED output current
Max output current
Minimum auxiliary battery voltage
Input fuse rating
Output fuse rating
Maximum output power
Solar input voltage minimum voltage
Solar input maximum current
Solar input maximum voltage
Ambient operating temperature
Dimensions
Weight
9-32V DC
20mA
App.95%
4mA
Input 9-11V DC 20A
Input 11-32V DC 25A
9V DC
50A
50A
368W
9V DC
25A
23V DC
-10 deg C to +80 deg C
165 x 120 x 40 mm
1.11kg
KICKASS constantly improves and innovates its products and we may from time to
time discontinue or update product specifications without notice. For the latest
product information and specifications, please visit KICKASS.com.au
KADCDC25A-AND
Types of batteries
Battery capacity range
Battery operation voltage
Integrated isolator
cut in / cut out voltage
Integrated isolator
(ignition override on)
GEL, AGM, WET, CALCIUM
75-300AH
12V DC
CUT IN
13.2V
CUT IN
26.4V
CUT OUT
12.6V
CUT OUT
25.2V
CUT IN
12.2V
CUT OUT
11.6V
CUT IN
24.4V
CUT OUT
23.2V
LITHIUM
50-250AH
IP67
Time delay function
Certifications
IP rating
There is a 30 second delay before charger will cut in or cut out.
BATTERY TYPE SPECIFICATIONS
KADCDC25A-BBK
0.96kg

PRODUCT OVERVIEW
Charging Stage LEDs
Battery Type LEDs
Battery Mode Button
Charging LED
Alternator LED
Solar LED
Mounting Slots 4.5mm
Temperature Sensor Cable
Ext. LED Cable
Solar In (+) Cable
Ground (-) Cable
Output (+) Cable
Ground (-) Cable
Alt In (+) Cable
Ground (-) Cable
Ignition Override Cable
KADCDC25A-AND
ALT INALT INALT INSOLAR INSOLAR INSOLAR IN OUTPUTOUTPUTOUTPUT
4
KADCDC25A-BBK
KADCDC25A-BBK will be delivered with all cables connected, which is already installed
to a KickAss battery box. The button and indicators are the same as KADCDC25A-AND
model above.

5
„The KickAss Charger has been engineered to charge 12 Volt GEL, AGM, WET, CALCIUM
or Lithium LiFePO only. Do not use this charger for any other purpose or with any
4
other battery types.
„Do not attempt to charge known faulty, damaged, frozen or broken batteries.
„Ensure charger is close to battery, however never mount the charger directly on the
battery.
„Ventilation is very important in battery charging, always ensure battery positioning is
in a well ventilated area to allow charging gases to dissipate.
„Keep sparks or flames away from batteries being charged as they could emit
explosive gases.
„Always check the batteries and charging system periodically to ensure no faults
occur.
„Ensure all cabling is secure and cannot be cut, broken or short circuited.
„Battery acid is corrosive. If acid comes into contact with skin or eyes, please seek
medical advice.
„Never connect this charger to mains supply.
„We recommend fitting a 50-75 amp fuse on both the input and output sides of the
charger such as the SKU: KAMAXIFHAND or SKU: KAFUSECOVER-KIT to protect
cables from short circuits etc.
INSTALLATION GUIDE
MOUNTING
It is most important to mount your KickAss Charger as close as possible to your auxiliary
battery and be sure to keep your charger away from sources of heat. eg. Turbos and
exhaust pipes. This will ensure maximum performance out of your charger.
unit:mm
165
40
4.5
110
142
85
120
DIMENSIONS
SAFETY FIRST!

WIRING SIZE
To make sound electrical connections, the battery cable should be the correct size and
the correct terminals should be crimped or soldered.
WIRES
Alternator output cable (red)
Solar input cable (green)
Output cable (brown)
Common ground (black)
Ignition override (blue)
External LED indicator (brown)
CABLE SIZE
2
8mm (8 B&S)
2
8mm (8 B&S)
2
8mm (8 B&S)
2
8mm (8 B&S)
2
1.5mm
2
1.5mm
Note:
The above recommendation is for cable length up to 8 meters.
For more information or assistance, see installation videos at
kickassproducts.com.au
6

WIRING INSTALLATION:
KADCDC25A-AND
The KADCDC25A-AND features quick connecting 50A Anderson style connectors and a
single 3 pin Anderson style connector. We recommend using this with our
KADBWK8MMPP wiring kit for fast and easy installation.
FOR SOLAR PANEL ONLY INSTALLATION
The KickAss Charger can be used with a solar only input so you can take advantage of the
inbuilt MPPT solar regulator. Please refer to page 9 for the wiring diagram for solar panel
only installation.
NOTE: The maximum solar input is 25 Amps.
Any existing regulators inline with the solar panels should be removed or
bypassed.
Once installation is completed you will need to set the battery type, please refer to
“CHOOSING YOUR BATTERY TYPE” on page 10 to ensure your KICKASS Charger is
operating correctly.
7

WIRING DIAGRAM - KADCDC25A-AND
NOTE: Ignition override used only if required
CAUTION: Max solar input should be 25 Amp
CAUTION: Always ensure fuses are installed
Recommended products for easy installation
(not included):
KAMAXIFHAND - Kickass Inline Maxi Fuse Holder
with Anderson Style Plug
KADBWK8MMPP - KickAss Plug and Play dual
battery wiring kit
KA8M5-A2A - KickAss 8B&S 5.5M Anderson Style
Extension Lead
AUXILIARY
BATTERY
2
BLUE - IGNITION OVERRIDE 1.5mm
2
BROWN - EXTERNAL LED 1.5mm
BLACK - TEMPERATURE SENSOR
KICKASS DUAL BATTERY
WIRING KIT - KADBWK8MMPP
KICKASS 5.5M EXTENSION
LEAD - KA8M5-A2A
KICKASS INLINE
MAXIFUSE
- KAMAXIFHAND
KICKASS INLINE
MAXIFUSE
- KAMAXIFHAND
25 AMP FUSE
MOUNT DC-DC CHARGER
AS CLOSE AS POSSIBLE
TO THE AUXILIARY BATTERY
SOLAR PANEL
8
OUTPUT
SOLAR
ALT. IN
I

WIRING DIAGRAM - SOLAR PANEL ONLY
CAUTION: Max solar input should be 25 Amp
CAUTION: Always ensure fuses are installed
Recommended products for easy installation
(not included):
KAMAXIFHAND - Kickass Inline Maxi Fuse Holder
with Anderson Style Plug
KA8M5-A2A - KickAss 8B&S 5.5M Anderson Style
Extension Lead
AUXILIARY
BATTERY
25 AMP FUSE
MOUNT DC-DC CHARGER
AS CLOSE AS POSSIBLE
TO THE AUXILIARY BATTERY
KICKASS 5.5M EXTENSION
LEAD - KA8M5-A2A
SOLAR PANEL
2
BROWN - EXTERNAL LED 1.5mm
BLACK - TEMPERATURE SENSOR
KICKASS INLINE
MAXIFUSE
- KAMAXIFHAND
9
OUTPUT
SOLAR
I

CHARGING STAGE PROFILE
BULK
ABSORPTION
FLOAT
PULSE
GEL
100%
Current
Until
14.1 V
AGM
100%
Current
Until
14.4 V
WET
100%
Current
Until
14.7 V
CALCIUM
100%
Current
Until
15.4 V
LITHIUM
100%
Current
Until
14.4 V
Constant
14.1 V
Until 3.8A
Constant
14.4 V
Until 3.8A
Constant
14.7 V
Until 3.8A
Constant
15.4 V
Until 3.8A
Constant
14.4 V
Until 3.8A
13.7V at 100% Current Max
STAGE DESCRIPTION
CHOOSING THE BATTERY TYPE
The default battery setting is AGM.
When the auxiliary battery is connected, press and hold the mode button for 5 seconds or
until the battery light starts flashing. Then select from either GEL, AGM, WET, CALCIUM
or LITHIUM and wait for the battery light to stop flashing. When this occurs, your
selection is saved.
1234
MODE
BATTERY TYPE
WETGEL AGM CALCIUM LITHIUM
BULK ABSORPTION FLOAT PULSE
SOLAR
ALTERNATOR
CHARGING
12V 25A DC 4-STAGE
10
NOTE: When in float stage, the battery is fully charged. At float stage, when battery
voltage drops to 12.7V, the charger will restart charging from BULK stage.
Begins after a continuous float stage of 10 days and pulses power
through the battery using the same current and voltage as the
absorption stage to maintain charge and desulphate. During this
time, if the voltage of the auxiliary battery drops below 12.6V, the
charger will restart the charge cycle at Bulk. Once pulse is
completed, the charger reverts to float stage.

Alternator LED indicator
Alternator voltage 12V Alternator voltage 24V Alternator LED
Alternator LED indicator with ignition override wire connected
Alternator voltage 12V Alternator voltage 24V Alternator LED
0-8.9 Volts
9-11.6 Volts
11.7-12.1 Volts
12.2 Volts
12-17.9 Volts
18-23.2 Volts
23.3-24.3 Volts
24.4 Volts
OFF
Flash 1 sec on 5 sec off
Flash 1 sec on 1 sec off
Solid on
Solar LED status
Solar voltage Solar LED
0-8.9 Volts
9 Volts
OFF
Solid on
Status
Under operating voltage
Status
Under cut-out voltage
Under cut-in voltage
Cut-in voltage reached, charging will
start after 30 second delay
0-8.9 Volts
9-12.6 Volts
12.7-13.1 Volts
13.2 Volts
12-17.9 Volts
18-25.2 Volts
25.3-26.3 Volts
26.4 Volts
OFF
Flash 1 sec on 5 sec off
Flash 1 sec on 1 sec off
Solid on
Under operating voltage
Under cut-out voltage
Under cut-in voltage
Cut-in voltage reached, charging will
start after 30 second delay
Status
Under cut-in voltage
Cut-in voltage reached, charging will begin after 10 sec
delay (please note alternator has priority over solar)
11
SOLAR
ALTERNATOR
CHARGING
Charging light will flash when unit is charging.
Solid on - cut-in voltage reached.
(see table below for other indications)
Solid on - cut-in voltage reached.
(see table below for other indications)
UNDERSTANDING SOLAR, ALTERNATOR
& CHARGING LIGHTS
• Alternator has priority over solar therefore, if both solar and alternator are connected, only alternator LED is
solid and alternator is charging.
• 30 sec delay between cut-in voltage being reached and charging beginning & a 60 second delay before
disconnecting when under cut-out voltage.
NOTE

12
Lithium BMS Sleep Mode & Recovery Feature:
Most lithium batteries are built with a Battery Management System (BMS) inside to
protect the battery from over charging, over discharging and extreme temperature
changes.
One of the key functions of the BMS is to protect your battery by internally disconnecting
the load¹ when voltage drops below specific parameters, this will then result in the
battery entering into a “sleep” mode.
¹ (Load includes any accessories and/or device/s drawing charge from the battery. Eg:
fridges, pumps, food sealers, etc)
The KickAss DCDC MPPT Solar Battery Charger has a lithium battery recovery function.
This function has been designed to recover lithium batteries from a sleep mode.
Lithium Battery Sleep Mode Indication:
When the lithium battery has entered sleep mode, the charger will show fault codes of
output open circuit, until all loads¹ are disconnected and a sufficient charge source is
connected.
(see "Battery Type Specification" on Page 3)
1234
MODE
BATTERY TYPE
WETGEL AGM CALCIUM LITHIUM
BULK ABSORPTION FLOAT PULSE
SOLAR
ALTERNATOR
CHARGING
12V 25A DC 4-STAGE
IMPORTANT : You must select 'LITHIUM' as the battery type by using the 'MODE' button
prior to connecting it to a lithium battery in sleep mode to attempt recovery.
How to Wake a Lithium Battery to Begin Recovery Mode:
First disconnect any load connected to the lithium battery.
Secondly connect Alternator Input or Solar Input² to the KickAss DCDC MPPT Solar
Battery Charger. Thirdly connect the output from the DCDC charger to the lithium
battery. The Charger will have all battery types (GEL, AGM, WET CALCIUM, LITHIUM)
flashing and the BULK and PULSE LED lights will remain on for 30 seconds (Indicated in
diagram above,) before entering Recovery Mode.
²(Alternator and Solar inputs must be above cut-in voltage for DCDC Charger - see
"Battery Type Specification" on Page 3)
Source will
Illuminate
solid

13
There are error codes that may be displayed. These will be displayed in the
following way:
FAULT CODES
If all battery type selection lights are flashing simultaneously please see troubleshooting guide below.
MODE
BATTERY TYPE
WETGEL AGM CALCIUM LITHIUM
Stage LED
Solar input
high voltage
Solar input
reverse
Alternator
high voltage
Alternator
input reverse
Output
fault mode
S1
LED Cause Remedy
Over voltage is detected
at solar input
Solar input is reversely
connected
Overvoltage is detected
at alternator input
Alternator input is
reversely connected
Output battery is
reversely connected
Overvoltage is detected
at output
Output open circuit
or dead battery
Check solar panel
open circuit voltage
Check solar input
connection
Check vehicle
battery voltage
Check alternator
input connection
Check output
cable connection
Check auxiliary
battery voltage
Check auxiliary battery
voltage & cable connections
S2
LED
S3
LED
S4
LED
NOTE: To activate the Charger when the auxiliary battery is below 9V, for a short period of time. You can then
remove the jumper cables.
Recovery Mode Indicator:
When the lithium battery has entered recovery mode, the KickAss DCDC MPPT Solar Battery
Charger display will have the source indicator illuminated (eg; SOLAR) and the battery type
LITHIUM will be flashing. See diagram below.
When the battery voltage has been recovered to 12V, the DCDC charger will automatically
change to normal stage charging programs and loads may be reconnected.
1234
MODE
BATTERY TYPE
WETGEL AGM CALCIUM LITHIUM
BULK ABSORPTION FLOAT PULSE
SOLAR
ALTERNATOR
CHARGING
12V 25A DC 4-STAGE
Source will
Illuminate solid

14
KickAss constantly updates
frequently asked questions,
troubleshooting, videos and
specifications, please visit:
kickassproducts.com.au
for the most up to date
information.
NEED HELP?

THANK YOU FOR CHOOSING
DC-DC CHARGERS
kickassproducts.com.au
For more informaon please visit us at: