Modul-System Modul-Connect DC-DC 30A User manual

Modul-Connect
Battery Charger DC-DC 30A
Owner’s Manual

For safe and optimum performance, the Modul-Connect Battery Charger DC-DC 30A must be used
properly. Carefully read and follow all instructions and guidelines in this manual and give special
attention to the CAUTION and WARNING statements.
PLEASE KEEP THIS MANUAL FOR FUTURE REFERENCE
Disclaimer
While every precaution has been taken to ensure the accuracy of the contents of this guide,
Modul-System assumes no responsibility for errors or omissions. Note as well that specifications and
product functionality may change without notice.
Important
Please be sure to read and save the entire manual before using your Modul-Connect Battery Charger
DC-DC 30A. Misuse may result in damage to the charger and receiving vehicle and/or cause harm or
serious injury.
Product Number
21500-04 Modul-Connect Battery Charger DC-DC 30A
Additional part/s
21006-04 DC-DC Charger mounting plate
Document Part Number
MSDCDC_2.0_WS_rev1
Service Contact Information
E-mail: [e-mail]
Phone: [phone]
Web: www.modul-system.com

Contents
1. Introduction ............................................................................................................................. 1
1.1 Important safety information.........................................................................................................1
2. Product description .................................................................................................................. 3
3. Installation ............................................................................................................................... 3
4. Battery charger DC input connection......................................................................................... 6
5. Charger operation .................................................................................................................... 8
6. Troubleshooting ...................................................................................................................... 9
6.1 Understanding the error codes ......................................................................................................9
7. Technical specification.............................................................................................................10
8. Warranty.................................................................................................................................11

1
1. Introduction
Thank you for purchasing the Modul-Connect Battery Charger DC-DC 30A.
This battery charger unit allows you to charge an auxiliary battery from a vehicle starter battery. The
unit is suited for all light commercial vehicles, including vehicles with Euro 5 and Euro 6 engines,
smart alternators, regenerative braking technology and start/stop functionality.
This battery charger unit is configured for optimum operation with any AGM or lead acid battery.
Please read and follow these instructions and precautions carefully.
1.1 Important safety information
This section contains important safety information for the Modul-Connect Battery Charger DC-DC
30A. Each time, before using the product, READ ALL instructions and cautionary markings on or
provided with the charger, and all appropriate sections of this guide.
The battery charger contains no user serviceable parts. See Warranty section for how to handle
product issues.
DANGER: Fire and/or Chemical Burn Hazard.
Do not cover or obstruct any air vent openings and/or install in a zero-clearance compartment.
DANGER: Failure to follow these instructions can result in death or serious injury.
•When working with electrical equipment or lead acid batteries, have someone nearby in case of
an emergency.
•Study and follow all the battery manufacturer’s specific precautions when installing, using and
servicing the battery connected to the battery charger.
•Wear personal protective equipment including eye protection (that protects eyes from all angles)
and gloves.
•Avoid touching your eyes while installing the battery charger. Keep fresh water and soap on hand
in the event battery acid comes in contact with eyes. If this occurs, cleanse right away with soap
and water for a minimum of 15 minutes and seek medical attention.
•ALWAYS remove personal metal items (such as rings, bracelets, necklaces and watches) when
working with a battery. A short circuit through one of these items can melt it, causing a severe
burn. Batteries produce explosive gases. DO NOT smoke or have an open spark or fire near the
system.
•ALWAYS keep flames, matches, lighters, cigarettes or other ignition sources away from battery.
•Keep the battery charger away from moist or damp areas. Avoid dropping any metal tool or
object on the battery. Doing so could create a spark or short circuit, which goes through the
battery or another electrical tool, that may create an explosion.
•DO NOT put flammable material on, under or near the battery to be charged.
•ALWAYS remove grounded terminal from battery first.
•Some sealed, maintenance free batteries have a battery condition indicator. A light or bright
coloured dot indicates low water. Such a battery needs to be replaced, not charged or jump
started. Charge battery with caps in place. Most batteries are made with flame arresting caps.
DO NOT pry caps off sealed batteries.
•Make sure the area around the battery is well ventilated before and during charging process.
•NEVER position face near battery.
•ALWAYS keep other people away from the battery.
•Avoid contact with battery acid.

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•Battery posts may have acid corrosion. DO NOT get corrosion in your eyes. Avoid touching eyes
while working near battery.
•In very cold weather a discharged battery may freeze. NEVER charge a frozen battery. Gases may
form, cracking the case, and spray out battery acid.
•DO NOT modify the charging system circuitry without written confirmation from Modul-System.
•If a fuse needs replacing, only use the same rating as removed.
•Locate the leads so that they will not be stepped on, tripped over, or otherwise subject to damage
or stress. DO NOT lay the leads on the battery. DO NOT operate the system with damaged cables
or plugs –have them replaced immediately.
•This system is designed specifically for charging automotive lead acid batteries. DO NOT use with
dry-cells that are commonly used with home appliances, flashlights, etc. These batteries may
burst and cause injury to persons and damage to property.
•This system is not intended to supply low-voltage power for applications other than battery
charging.
DANGER: Shock Hazard. Keep away from children!
•The battery charger’s internal components are conformal coated to cope with lower
temperatures. It is advisable to avoid moisture.
•Never expose unit to snow, water etc.
DANGER: Explosion hazard!
• DO NOT use the Modul-Connect Battery Charger DC-DC 30A in the vicinity of flammable fumes or
gases (such as propane tanks or large engines).
• AVOID covering the ventilation openings. Always operate unit with a minimum of 30mm ‘free air
gap’ around the unit.
• Prolonged contact to high heat or freezing temperatures will decrease the working life of the unit.
CE EMC INFORMATION
This equipment has been tested and found to comply with the limits for CE EMC standard. These
limits are designed to provide reasonable protection against harmful interference in a residential
installation.
LIMITATIONS ON USE
Do not use in connection with life support systems or other medical equipment or devices.

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2. Product description
The Modul-Connect Battery Charger is a 30A, 3-stage DC-DC charger with enhanced battery charging
capabilities for charging of an AGM type auxiliary battery or batteries. The charger will work on all
light commercial vehicles, including vehicles with Euro 5, 6, 6.1 and 6.2 engines, smart alternators,
regenerative braking technology and/or start/stop functionality.
The Modul-Connect Battery Charger package (21500-04) includes the items listed below.
• Battery Charger DC-DC 30A
• Connection pack
• Owner’s manual
3. Installation
WARNING: Modul-System recommends that all wiring be done by a certified technician or electrician
to ensure adherence to the applicable electrical safety wiring regulations and installation codes.
Failure to follow these instructions can damage the unit and could also result in personal injury or
loss of life.
CAUTION: Before beginning your installation, please consider the following:
•The Modul-Connect Battery Charger should be used or stored in an indoor area, away from direct
sunlight, heat, moisture or conductive contaminants.
•When installing the unit, allow a minimum of 30 mm of space around the unit for optimal
ventilation.

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NOTE! Charger must be installed between the vehicle STARTER and AUXILIARY battery
•The use of an AGM battery is highly recommended for the second auxiliary battery.
•For battery size, you need to identify how much you will be using them between charges.
•Modul-System recommends you purchase as much battery capacity as possible.
Fuse or Circuit Breaker:
•DC-rated fuse or DC-rated circuit breaker connected along both of the DC positive lines are
required.
•The battery charger is supplied with 1 off in-line 50A fuse for the chassis battery and the auxiliary
battery connection has a 50A fuse mounted on the charger.
•A 2A mini blade fuse and several connection options for the ignition sensing cable are also
supplied.
•Never replace a fuse with one that has different amperage than the original on the DC Input,
Output and ignition positive cables.
Cable:
•Use the low resistance cable that is supplied with the charger for all the DC connections between
the battery charger and the battery bank.
•The battery charger is supplied with input (red) and output (white) 10mm² cables, with a length of
5 meters on the input and 4 meters on the output.
•The input (red) and output (white) 10mm² cables can be cut down to length to suit the
installation.
•If the input (red) 10mm² cable needs to be extended beyond 5 meters, it should be replaced at
the battery charger by 16mm² cable (up to a maximum total length of 10 meters).

5
•If the output (white) 10mm² cable needs to be extended beyond 4 meters, it should be replaced
at the battery charger by 10mm² cable and can be extended up to 9 meters.
•Beyond 9 meters, it should be replaced at the battery charger by 16mm² cable (up to a maximum
total length of 10 meters).
The 1mm² ignition positive (+) (brown) cable can be extended beyond 5 meters by the same 1mm²
cable, as this cable draws very little load.
Modul-Connect Battery Charger Installation:
•Choose an appropriate mounting location.
•All fuses, fuse holders and connecting cables are supplied with the product.
•This battery charger shall be mounted and connected as close to the auxiliary battery (which is
being charged) as possible.
•The battery charger must be securely mounted on a metal or non-combustible surface.
•Use a mounting template to mark the positions of the mounting screws.
•The battery charger has 4 off fixing holes (6.5mm diameter) and 4 off fixing slots (6mm x 10mm)
for ease of mounting.
•It is recommended to use a minimum of 4 off M5 fixings to secure the battery charger.
•Drill the 4 mounting holes, place the charger in position and fasten it to the mounting surface.
IMPORTANT: Connection Procedure / Power up sequence to ensure normal operations:
1. Remove all in-line fuses from the fuse holders.
2. Connect the charger negative cable (black) to the battery negative or chassis earth.
3. Connect the charger input cable (red) to the chassis battery.
4. Connect the positive remote input cable (brown) to the ignition supply using supplied cables and
fuse holder.
5. Connect the auxiliary battery positive cable (white) to the auxiliary battery.
6. Insert 50A chassis battery fuse.
7. Insert the 2A fuse into the ignition feed.
If this order is not followed the unit may flash amber for up to 10 minutes at key on (even if the
auxiliary battery is fully charged). After the elapsed time the Modul-Connect Battery Charger will
resume normal function.

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4. Battery charger DC input connection
CAUTION: Reversing the DC Input terminal will damage the unit and cannot be repaired.
Damage caused by reverse polarity connection is NOT covered by the warranty.
Ignition Supply (brown 1mm² cable)
The ignition supply cable (brown) is a positive (+) signal supply to the battery charger. The charger
will operate when this cable is powered. This cable must be fused (2A) to protect the charger and the
cable run.
The Modul-Connect Battery Charger DC-DC 30A is supplied with 3 options of connection:
• Option 1: A mini blade ‘ignition jumper’ fuse.
• Option 2: An ‘in-line’ fuse.
• Option 3: Installer option.
OPTION 1: Most manufacturers use mini blade fuses or Micro2 blade fuses in their OEM fuse boxes.
The mini blade ‘ignition jumper’ fuse can be located in the fuse box of the vehicle to ‘piggy back’
from an ignition (+) circuit without cutting into any cables on the vehicle.
The mini blade ‘ignition jumper’ has two circuit slots on one side and a fuse plug on the other. When
plugged into one of the vehicle's circuit slots, the fuse tap provides space for an additional fuse. The
mini blade ‘ignition jumper’ MUST NOT be used to replace the fuse in any primary vehicle safety
system. i.e. ABS, EBD, airbag, fuel system control, vehicle ECU or BCM feeds.
The mini blade ‘ignition jumper’ is rated at a maximum of 10A and the removed ignition feed fuse
must not be rated at more than this. The mini blade ‘ignition jumper’ must be inserted into the fuse
box in the correct orientation. If a fuse is removed it must be inserted from the fuse box into the
‘ignition jumper’ to make the circuit. The jumper MUST have the OEM fuse and accessory fuses
fitted. After fitting, make sure that the circuit which the OEM fuse was protecting is still functioning
correctly.

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Example:
1. Identify ignition (+) fuse circuit i.e. radio. DO NOT 3. Place selected fuse in lower jumper terminal. Place
connect to any primary vehicle safety systems. 2A fuse, which supplies the ignition feed to the DC-DC
charger, in top terminal. Be mindful of orientation
2. Open fuse box and remove selected fuse. 4. Insert fuse jumper into fuse box.
OPTIONS 2 & 3:
Connect to a vehicle positive (+) ignition supply via the supplied 2A fuse using OEM vehicle
manufactures recommendations.
Further connection information for vehicle makes and models is available from Modul-System.
NOTE! When removing the ignition fuse
from the fuse box, test for the positive
terminal out of the fuse box. The positive
terminal needs to be connected to the
positive input of the fuse jumper.

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5. Charger operation
The Modul-Connect Battery Charger DC-DC 30A operates with an input voltage between 9-32V.
•The battery charger is turned on and off with the vehicle ignition.
•The output current is limited to 30A for the charger.
•In case of a low input voltage (<9V), the output voltage is reduced to prevent damage to the
charger.
The charger is protected against overheating and resumes normal operation when it cools down.
•The 3-colour status LED on the battery charger end panel shows the status of the charger. In
‘normal’ operation the LED will either be off (ignition key off), flashing amber (charging) or green
(charged).
•The 3-colour status LED also shows the status of the charger as follows:
Status LED colour
Status LED output
Mode
Note
Off
Off
Off
Ignition off.
The charger is switched off.
Red
Flashing
Fault mode
Refer to the codes below for the number of short
flashes followed by number of long flashes.
Amber
Constant flashing
Charging
Current/boost charging.
Green
Constant flashing
Charging
Float charging.

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6. Troubleshooting
To troubleshoot the Modul-Connect Battery Charger DC-DC 30A, please note the LED display and
review the “Understanding the Error Codes” in section 6.1. Also:
•Check that the voltage at the output pins is the same as the batteries and that the polarity is
correct.
•Check that all the fuses are OK.
•Check LED flashes status as the power is applied to the ignition feed (brown wire).
•If the battery charger LED flashes AMBER but the battery voltage is not increasing, wait 10
minutes and re-check your readings.
6.1 Understanding the error codes
Status LED colour
Short flashes
Long flashes
Fault
Red
3
0
Force idle (check connection and fuses to chassis
battery and auxiliary battery)
Red
3
1
Starter battery voltage below 9 volts (<9V)
Red
3
2
Starter battery voltage over 36 volts (<36V)
Red
3
3
Starter battery voltage over 33 volts (<33V)
Red
3
4
Internal charge controller temperature MT over 70°C
Red
3
5
Internal charge controller temperature FT over 115°C
Red
3
7
Thermistor disconnected
Red
3
8
Damaged battery detected

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7. Technical specification
Note: The specifications are subject to change without notices.
21500-04 Modul-Connect DC-DC Charger
PARAMETERS
MINIMUM
Float Charge
MAXIMUM
CHARGER PERFORMANCE
DC input voltage operating range
9 Vdc
32 Vdc
DC output voltage operating range
0 Vdc
13.8 Vdc
14.1 Vdc
Operating temperature
-20°C ambient
70°C ambient
Relative humidity
5% non-condensing
90% non-condensing
IP Rating
IP60 in any mounting
position
IP65 mounted vertically
with the cable connections
at the bottom of the
charger
SAFETY AND ENVIRONMENTAL
CE EMC & LVD EN61000-4-5:2014
EN61204-3:2000 EN61000-4-6:2014
EN61000-4-2:2009 CISPR16-2-3:2006
EN61000-4-3:2009 + A1:2008 + A2:2010 EN50581:2012
DIMENSIONS AND WEIGHTS
Shipping Weight
3.2 Kg
Dc-Dc Charger Weight
1 Kg
Dc-Dc Charger Loom Weight
2.2 Kg
Dc-Dc Charger Dimensions
Excluding connection studs
L –180 mm
D –144 mm
H –56 mm
Dc-Dc Charger Dimensions
Including connection studs
L –205 mm
D –144 mm
H –56 mm

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8. Warranty
TWO YEAR LIMITED WARRANTY
The limited warranty program is the only one that applies to this unit, and it sets forth all the
responsibilities of Modul-System. There is no other warranty, other than those described herein. Any
implied warranty of merchantability of fitness for a particular purpose on this unit is limited in
duration to the duration of this warranty.
This unit is warranted, to the original purchaser only, to be free of defects in materials and
workmanship for two years from the date of purchase without additional charge. The warranty does
not extend to subsequent purchasers or users.
Manufacturer will not be responsible for any amount of damage in excess of the retail purchase price
of the unit under any circumstances. Incidental and consequential damages are specifically excluded
from coverage under this warranty.
This warranty does not apply to damage to units from misuse or incorrect installation/connection.
Misuse includes wiring or connecting to improper polarity power sources.
RETURN/REPAIR POLICY:
If you are experiencing any problems with your unit, please contact our customer service department
at [e-mail] or phone [phone] before returning product. After speaking to a
customer service representative, if products are deemed non-working or malfunctioning, the product
may be returned to Modul-System within 30 days of original purchase. Any defective unit that is
returned to manufacturer within 30 days of the date of purchase will be replaced free of charge.
If such a unit is returned more than 30 days but less than two years from the purchase date,
manufacturer will repair the unit or, at its option, replace it, free of charge. If the unit is repaired,
new or reconditioned replacement parts may be used, at manufacturer’s option. A unit may be
replaced with a new or reconditioned unit of the same or comparable design. The repaired or
replaced unit will then be warranted under these terms for the remainder of the warranty period.
The customer is responsible for the shipping charges on all returned items.
LIMITATIONS:
This warranty does not cover accessories, such as adapters and batteries, damage or defects result
from normal wear and tear (including chips, scratches, abrasions, discoloration or fading due to
usage or exposure to sunlight), accidents, damage during shipping to our service facility, alterations,
unauthorized use or repair, neglect, misuse, abuse, failure to follow instructions for care and
maintenance, fire and flood.
If your problem is not covered by his warranty, contact our Customer Service Department
[e-mail] or [phone] for general information if applicable.