KICK ASS KAPWM30A User manual

V0.3
SOLAR REGULATOR
PWM 12V 30A
MANUAL
KAPWM30A

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INTRODUCTION
KickAss is focused on bringing the luxury of home to the outdoors. Your one stop shop for 12V
products. All of our products are designed to be plug and play, for the ultimate camping experience.
Designed by the KickAss team in Australia.
The KickAss 12V PWM 30A Solar Regulator has been design to provide a compact plug and play
solar power solution, highly efficient power conversion to keep your battery safely charged. Our
team of dedicated engineers test every product to make sure they stand up to the tough Australian
outback. The KAPWM30A solar regulator uses a solid state design with Pulse Width Modulation
(PWM). Without the need of cooling fans, the unit is fully sealed, rated at IP65 making it dust and
water resistance for outdoor use.
IMPORTANT WARNING AND SAFETY INSTRUCTIONS!
DO NOT operate Solar Panel UNLESS YOU HAVE READ AND UNDERSTOOD THIS MANUAL and
the Solar Regulator is installed as instructed.
Working in the vicinity of Lead-Acid batteries is dangerous. During normal operation batteries
generate explosive gases. It is important that the battery is operated in a well ventilated area and
the Solar Regulator is installed as directed.
Check the battery manufactures guide for the recommended voltage profile for charging.
Failure to ensure the selected voltage does not exceed the recommend profile could damage your
battery. Change the selection if necessary before charging the battery.
Risk of injury and damage due to incorrect installation product:
ŸThis appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they are supervised
or have been properly instructed on how to use the appliance by a person responsible of their
safety.
ŸChildren should be supervised to ensure they do not play with the appliance.
ŸEnsure to use the Solar Panel with a regulator of the correct input rating and suitable charge
profile for the battery chemistry type being charged. Suitable battery types include; Lead Acid,
Gel, Calcium, AGM or Lithium.

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ŸDesigned with PWM technology.
ŸCommon negative grounding design and 100% solid state.
ŸSuitable for solar panels with max open circuit voltage of 25V
Ÿ7 Different Battery type charge profiles included:
• Lead crystal
• Calcium
• Gel
• AGM
ŸLithium BMS "Wake up" feature to automatically reactive BMS.
ŸHighly efficient charger that ensures your battery is charged to 100% every time.
ŸColoured LED's that indicate the charging status and battery conditions.
ŸBig Digital LCD to clearly display battery voltage, charge current, overall charged
capacity (Amp hour of charge into battery), battery type, charge percentage, battery
temperature and fault codes.
ŸPlug & Play connection that accepts Anderson plug connection.
ŸM5 Screw terminals for hardwired option.
ŸProtection features including: Overvoltage, Short Circuit, Reverse Polarity and
Thermal Protection
ŸOver voltage protection, Short circuit protection, Reverse polarity protection
ŸIncludes external battery temperature sensor.
ŸIP65 rated, suitable for indoor or outdoor use, surface panel mount
ŸRubber dust cover for terminal protection
ŸThe battery should be mounted in a well ventilated area, and a safe distance from any ignition
source. NEVER smoke or allow a spark or flame in the vicinity of the battery. This may cause the
battery to explode.
ŸIf battery acid comes in contact with skin or clothing, wash immediately with soap and water. If acid
enters eye, immediately flush eye with running cold water for at least 10 minutes and get medical
attention immediately.
ŸTo reduce risk; take when using any metal tool near the battery to avoid risk of shorting the
terminals.
ŸTo reduce the risk of sparks, connect or disconnect the Solar Blanket to the charge regulator
BEFORE exposure to sunlight. The Solar Blanket may generate voltage up to the rated open
circuit value, at the connection leads while unconnected.
ŸEnsure a fuse or circuit breaker is installed on connection from battery to regulator.
ŸDo not disassemble charger, contact KickAss customer support for trouble shooting advice.
ŸDo not reverse polarity connect the wires to the solar panel or battery.
FEATURES
• WET (Lead acid Flooded)
• Lithium Iron Phosphate battery (LiFePO4)
• LI-LION series

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INSTALLATION
The Solar Controller is mounted as shown below
The unit can be mounted on a flat surface using the 4 corner screw down points. Do this
by firstly removing the exiting 4x machine screws and backing plate. With the corner
screw down points free, mark the surface for the mounting points and pre drill your screw
holes or simply use a self tapping screw and directly mount the unit.
Rubber Dust Covers

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CONNECTION INSTRUCTIONS
There are two options for connecting your solar panels and battery to charger. These
include Plug and Plug using Anderson style quick connector or hardwired cable to screw
terminal connection. For either option, we recommend installing the regulator as close to
the battery as possible.
Option 1: KAPWM30 Regulator with anderson plug connection
Step 1. Remove rubber seals from regulator connection points and insert the appropriate
Anderson connection lead from battery into the regulator connection marked as battery
output. Ensure a fuse is installed one the positive cable as close to the battery positive
terminal a possible. Once Battery is connected to the regulator, the correct battery type
charge profile can be selected. See section "Operating Instructions" for Battery type
selection and LCD operation
Step 2. With Solar Panel in shade, connect Anderson extension lead from Solar Panel
into the regulator connection plug marked as Solar Panel input.
Optional Temperature sensor
Solar Panel
-
+
12V Battery
LITHIUM COMPATIBLE
Hold Battery
Type button
for 3 sec.
for settings
40A
LITHIUM COMPATIBLE
Hold Battery
Type button
for 3 sec.
for settings
Battery Output
Solar Panel Input

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Option 2. Hardwiring using screw terminal option.
Step 1. Mount regulator and battery in a suitable position. Ensure to carefully measure
the cable from the regulator to battery. Refer to Cable Size Cart below.
Note: Do not remove the rubber covers “4”, these are designed to create a seal and
protect the terminations from moisture and dust.
Step 2. Ensure cable sizing is appropriate for length of wire as per chart below. Wires to
connect the battery and solar panel to the regulator will be required to be crimped with
M5 ring terminals.
Step 3. Battery Connection: Terminate the battery positive and negative cables to the
regulator (2), ensuring bolts are securely tightened. Connect the negative cable to the
negative terminal on the battery. Using an inline 40A fuse of circuit breaker, connect the
positive wire to the positive terminal on the battery
Step 4. Solar Panel Connection. With the solar
panel unplugged from the solar connection lead,
terminate positive and negative solar cables to
regulator (3), ensuring bolts are securely
tightened. With the solar panel out of the sun,
connect all cables to solar panels, ensuring a
well sealed termination.
Note: Alway use the correct solar cable as directed by
solar panel manufacture and is a minimum of 4mm².
External Battery Temperature Sensor (1):
We recommend installing the external temperature sensor when battery and regulator
are installed in separate locations from each other or the temperature range where the
battery is installed may range outside of the normal operating range. The sensor is
designed to optimize the charging performance subject to the battery temperature
detected while also providing over temperature protection. If over temperature occurs,
the regulator will automatically stop charging.
Please refer to the cable size chart to determine the minimum size cable needed for
ensuring the best performance of regulator
Cable Size Chart - Distance of Regulator from Battery
Cable length (One way) 2 - 4M 4 - 6.5M
<2M

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KickAss 8B&S 2.5m Extension
Anderson Style connector
SKU: KA8M2.5A2A
KickAss 160W Folding Solar Blanket
KAPWM30A Regulator connected with KA Folding Solar Blanket and Power Station
r
KAPWM30A Regulator connected with KA Folding Solar Blanket and KickAss 120AH AGM Battery
KickAss 160W Folding Solar Blanket
Note: Please connect solar panels to regulator before exposing to direct sun
SKU: KASB160
SKU: KASB160

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OPERATION
LI THIU M C OM PAT IB L E
Hold Battery
Type button
for 3 sec.
for settings
Solar Input Indicator
Charge Indicator
Display selection button:
Charging Amps, Voltage
or Temp (if sensor connected)
Battery type selection button
Main Display
Battery charge level indicator
When unit first connected to the battery, the display will power on and enter a self test mode.
The screen will display the follow information:
Software version test
Self test for digital segment display
Rated Current
Rated Voltage
BATTERY TYPE SELECTION
IMPORTANT! Please select the correct battery type as damage can occur if incorrect
settings are used The default battery type is set for AGM. Press the “BATTERY TYPE”
button and hold for 3 seconds to enter the battery type selection mode. The available
selections will be shown on the LCD as indicated below. Once the correct battery type is
selected the regulator will automatically memorize your battery type setting. These include:
Setting Battery Type Max Voltage
CRYSTAL Lead Crystal crystalline silicon dioxide 14.7V
CALCIUM Calcium Lead-acid 14.9V
GEL Gel Lead-acid 14.1V
AGM AGM Lead-acid 14.4V
WET Flooded Lead-acid 14.7V
LFP Lithium Iron Phosphate (LiFePO4) 14.5V
LTO
LI-LION
Setting
Lithium titanite oxidized (Li4Ti5O12) 14.5V
12.6V
Lithium Managnese Oxide (LiMn2O4)
Lithium Nickel Manganese Cobalt
Oxide (LiNiMnCoO2)
Lithium Nickel Cobalt Aluminum
Oxide (LiNiCoAlo2)
Lithium Cobalt Oxide (LiCoO2)
Battery Type Max Voltage
LITHIUM COMPATIBLE
Hold Battery
Type button
for 3 sec.
for settings
CRYSTAL > CALCIUM > GEL > AGM > WET > LFP > LTO > LI-LION
Press and hold for 3 seconds to enter
“Battery Type” selection mode.

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LCD Display - Normal function
When the solar input is active and the charging process begins, the LCD will show the
charging status. This can be displayed as battery voltage, charging amps, charged
capacity (Amp hours) and battery temperature (if external temperature sensor
connected)
LITHIUM COMPATIBLE
Hold Battery
Type button
for 3 sec.
for settings
Press once to scroll through
selection mode.
CHARGING STAGE
The KAPWM30A 12V Regulator has a 6 stage charge algorithm
Diagnose * – Only for Lithium battery type, subjected to the Lithium battery initial voltage
which will determine if Soft start or Bulk stage is appropriate; if the Lithium battery is
protected by the BMS, the regulator will automatically send a voltage signal periodically
to the battery terminal to activate the BMS, and bring it out of low voltage protection.
Soft start - When batteries suffer an over-discharge, the regulator will softly ramp the
battery voltage up to 10V, before entering the Bulk Stage.
Bulk Stage - Maximum charging current will be delivered to batteries until the Absorption
stage reached. For Lead crystal battery type, the regulator will deliver a two step level of
Bulk charge. The first level rises the battery voltage up to 14.4V, then will switch into the
second level of the 50% of the first bulk charge rate, until the Lead crystal battery voltage
reaches

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Absorption Stage - Constant voltage charging until battery capacity reaches 85% for
Lead Acid type; Li-ion battery, LiFePO4 battery and L TO battery will be fully charged
after absorption stage. See specification table for Max voltage reached for different
battery types.
Equalization * - Only for WET or Calcium battery types, when the battery is deeply
drained below 10V or every 28 day charge cycle, the regulator will automatically run this
stage to bring the internal cells to an equal state and aim to remove any build up of
sulfation from inside the battery. (Equalization charge will not run when battery type is
selected as: Lead crystal, Li-ion, LiFePO4, LTO, Gel and AGM )
Float Stage or Re-Bulk Stage - Battery will enter this stage when fully charged and will
be maintained at a safe level. A fully charged Lead Acid battery (Crystal, GEL, AGM,
WET battery) has a voltage of more than 13.8 Volts; if the battery voltage drops to 12.8V
during the Float Stage, the regulator will return to Bulk charge; Li-ion,LiFePO4 and LTO
battery have no float mode; If a Li-ion battery voltage drops to 12.0V after absorption
stage, it will return to Bulk charge; if a LIFePO4 battery voltage drops to 13.4V, or LTO
battery voltage drops to 13.2V after Absorption stage, they will return to Bulk charge.
(Voltage x 2 for 24V use).
LED INDICATION
Solar voltage low (Low light)
Solar not detected
Solar voltage OK - Battery < 5V
Solar voltage OK, Battery reversed polarity
Solar voltage OK, Battery over-voltage
Solar not detected, Battery over-voltage
Solar voltage OK, Battery over 65 °C
Battery voltage OK, Solar reversed polarity
Battery voltage OK, Solar over-voltage

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▪ Reverse polarity solar and battery connection.
▪ Over temperature protection with charging current de-rated.
▪ Transient over voltage protection
▪ Safety and EMC compliance
▪ IEC/EN 60335, EN61000-4-2, EN61000-4-3, EN61000-4-4, EN61000-4-5 FCC
Class-B EN61000-4-6, EN61000-4-11, EN61000-3-3, CISPR14-1

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Absorption - Constant voltage charging and battery is over 85% for lead acid battery; a
Li-ion battery, LiFePO4 battery and LTO battery will close fully charging after absorption
stage, the absorption voltage level will reach 12.6V for Li-ion battery, 14.4V for LiFePO4
battery; 14.0V for LTO battery. 14.7V for Lead crystal battery.
Equalization * - Only for WET battery or Calcium battery type, when the battery is deeply
drained below 10V or every 28 days cycle, it will automatically run this stage to bring the
internal cells as an equal state and fully complement the loss of capacity. (Lead crystal, Li-
ion, LiFePO4, LTO, Gel and AGM battery do not run Equalization charge)
Float Charge or Re-Bulk charge - Battery is fully charged and maintained at a safe level.
A fully charged Lead acid battery (Crystal, GEL, AGM, WET battery) has a voltage of more
than 13.8 Volts; if the lead acid battery voltage drops to 12.8V at float mode, it will return
to Bulk charge; Li-ion,LiFePO4 and LTO battery have no float mode; If a Li-ion battery
voltage drops to 12.0V after absorption stage, it will return to Bulk charge; if a LIFePO4
battery voltage drops to 13.4V, or LTO battery voltage drops to 13.2V after Absorption
stage, they will return to Bulk charge. (Voltage x 2 for 24V use)
LED indications
LCD
Display
LCD
Backlight
LED Color RED BLUE BLUE BLUE BLUE GREEN WHITE
Soft-start charging ON FLASH FLASH OFF OFF OFF
Normal
Display
ON
Bulk charge (charged capacity < 25%) ON ON ON OFF OFF OFF
Bulk charge (charged capacity < 50%) ON ON OFF FLASH OFF OFF
Bulk charge (charged capacity < 75%) ON ON OFF OFF FLASH OFF
Absorption charging ON ON ON ON ON FLASH
Float charging ON OFF OFF OFF OFF ON
Solar weak (At dawn or dusk) FLASH OFF Subject to battery voltage OFF
In the night OFF OFF OFF OFF
Solar good, VB < 5V ON OFF FLASH OFF OFF OFF b03 / bLv FLASH
Solar good, battery reversed ON OFF FLASH OFF OFF OFF b0 2/ brc FLASH
Solar good, battery over-voltage ON OFF FLASH FLASH FLASH OFF b01 / bov FLASH
Solar off, battery over-voltage OFF OFF FLASH FLASH FLASH OFF b01 / bov FLASH
Solar good, battery over 65⁰C ON OFF
Subject to battery voltage
OFF b04 FLASH
Battery good, solar reverse FLASH OFF OFF P01 FLASH
Battery good, solar over-voltage FLASH OFF OFF P02 FLASH
Over Temperature Protection otP FLASH
Voltages are for 12V use, x 2 for 24V use
LED INDICATION

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ŸSpark-free protection.
ŸReverse polarity solar and battery connection.
ŸAgainst reverse current from battery to solar panel at night.
ŸOver temperature protection with charging current de-rate.
ŸTransient overvoltage protection, a varistor or transient voltage suppressor (TVS) at the
solar input and battery output against surge voltage.
ŸSafety and EMC compliance
IEC/EN 60335, EN61000-4-2, EN61000-4-3, EN61000-4-4, EN61000-4-5 FCC Class-B
EN61000-4-6, EN61000-4-11, EN61000-3-3, CISPR14-1
SAFETY PROTECTION
MAINTENANCE
Occasionally, clean the case using a damp cloth and mild cleaning agent. Check with
terminals without loose, rusty; If connecting cable is damaged, replace the cable by
qualified person.
SPECIFICATION
Voltages in below table are for 12V use, x 2 for 24V use.
1 Electrical Parameters
1-1 Rated solar panel amps 30/40 Max. AMP
1-2 Normal input Solar cell array voltage 15-22 VDC
1-3 Max. solar cell array voltage (output has no load) 25 Max. VDC
1-4 The controller lowest operating voltage at solar or battery side 8V Min VDC
1-5 Standby current consumption at night 5 Max mA
0.25 Max. VDC
1-6
Maximum voltage drop-Solar panel to battery

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Electrical Connections
M5 Terminal Screw/ Anderson style

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