Renogy DCC-1212 Series User manual

DC-DC On Board Battery Charger
DCC1212-20-40

This manual contains important safety, installation, and operating instructions for the DC1212 Battery
Charger. Do NOT operate the battery charger until you have read and understood the contents of this
manual. Renogy recommends that the charger be installed by a qualified professional. The following
symbols are used throughout the manual to indicate potentially dangerous conditions or important
safety information.
General Information
The DCC12 Series battery chargers are the most effective way to charge your auxiliary or house batteries
from the alternator/starter battery. Compatible with a multitude of alternator types, the DCC12 offers
correct charging for AGM, Flooded, Gel, and even Lithium deep cycle batteries! Featuring a 3-stage
battery charger and multiple electronic protections, owners can feel confident that their batteries are
being charged optimally and automatically. Easily install the compact yet sturdy DC1212 on RV’s,
commercial vehicles, boats, yachts and many more applications
Key Features:
•Compatible with multiple 12V batteries: AGM, Flooded, Gel, and Lithium*
•Smart protections features including Over-voltage, Over-Temperature, and reverse polarity!
•Battery Isolation and Battery Charger in one
•Compact yet built tough for all conditions
•3-Stage Battery Charger get your batteries to 100%
*Note: Check the charging requirements from the battery manufacturer before charging your battery
with this unit.

Product overview
Identification of Parts
Alternator / Starter Battery Input Side
Output / House Battery Side

Key Parts
Key Part #
Labeling
Notes
1
Input (-)
Negative (-) Input Terminal of
Starter Battery/Alternator
2
Input (+)
Positive (+) Input Terminal of
Starter Battery/Alternator
3
DCDC Power Indicator
4
DCDC Fault Indicator
5
S1 S2 S3 S4 S5
DIP Switches (1-5) Set Charging
Voltage and Float Voltage for
Battery
6
RJ11
Battery Temperature Sensor
(SKU: RTSDCC-G1) Port; uses
this data for accurate
temperature compensation
and charge voltage adjustment
7
D+
Alternator/Starter Battery
Control terminal for turning on
the vehicle with on-board
battery or Ignition
*Note requires wired to turn
on DCDC; 18-16AWG
recommended.
8
LC
Current Limit: Limits the
Charging Amperage to 50% of
the Rated DCDC Output
9
Output (+)
Positive (+) Output Terminal for
House Battery
10
Output (-)
Negative (-) Output Terminal for
House Battery
Package Includes
1
DCDC Battery Charger
1
Manual
Please Note: Please Note: You will find the most
up to date manual at www.renogy.com under
the download section.

Accessories
The following accessories are not included in the packaging, but available for purchase.
Battery Temperature Sensor (SKU: RTSDCC-G1)
Battery Temperature Sensor
(SKU: RTSDCC-G1)
The proper battery charging voltage is important for optimum
battery performance and longevity. This Remote Temperature
Sensor measures temperature at the battery, allowing the DC-
DC charger to use this data for accurate temperature
compensation and charge voltage adjustment. Improve your
battery charging system with a Renogy Temperature Sensor.
No temperature compensation when charging
lithium battery.
Installation
Location Considerations:
•The battery charger can be installed horizontally as well as vertically.
•The battery charger must be installed in a place that is protected from moisture.
•The battery charger may not be installed in the presence of flammable materials.
•The battery charger may not be installed in a dusty environment.
•The place of installation must be well ventilated. A ventilation system must be available
for installations in small, enclosed spaces. The minimum clearance around the battery
charger must be at least 5cm
•The device must be installed on a level and sufficiently sturdy surface.

When selecting a location for the DCDC, make sure that the unit is as close as possible to the battery you
will be charging (auxiliary battery). The charger may be mounted on the cabin of the vehicle, along a
chassis rail, the inner guard of a vehicle, behind the grille or headlight or even on the side of the
radiator. However, you want to make sure that the area is not susceptible to moisture or other
substances as well as potentially high temperatures. The DCDC would operate best if there is some air
flow.
Mounting Battery Charger
Tools Required
Figure 1

Figure 2
Cable Cross Section
*The following is a reference and may not cover all the unique applications that may exist.
Consult your installer for further questions.
Important Note: When the battery charger is sending full amps, the input side will experience
a higher draw.
Cable
Cable Length/ Min AWG
Recommended
Fuse
DCC-
1212-20
To starter
Battery (input)
2FT /
10AWG
8FT /
10AWG
16FT /
8AWG
32FT /
4AWG
30A
To house
Battery
(output)
2FT / 14-
12AWG
8FT / 14-
12AWG
16FT /
10AWG
32FT /
6AWG
25A
DCC-
1212-40
To starter
Battery (input)
2FT /
6AWG
8FT /
6AWG
16FT / 6-
4AWG
32FT / 4-
2AWG
60A
To house
Battery
(output)
2FT /
8AWG
8FT /
8AWG
16FT /
6AWG
32FT /
4AWG
50A
DCC-
1212-60
To starter
Battery (input)
2FT /
4AWG
8FT /
4AWG
-
-
90A
To house
Battery
(output)
2FT /
6AWG
8FT /
6AWG
16FT /
4AWG
-
75A

Connecting the Battery Charger
The DCDC will not turn on without a D+ ignition cable. When connected, the DCDC will turn
on when the ignition is on. This means that even if your engine is not on, the starter battery
will immediately be used to power the DCDC and start charging the house battery. It is
recommended to have the vehicle completely on.
Note: battery charger has isolated input and output voltages, which means that the output voltage can
be kept stable without interference from the input circuit. When connecting the signal wires, the battery
charger will be on a stable 12VDC voltage.
1. Identify the correct side of the DCDC corresponds to the correct battery. The Input side will be
the Alternator/Starting Battery and the output side will be the Auxiliary/House Battery.
IMPORTANT: A D+ ignition cable is required to turn the unit on. Although the D+ terminal is
in the output side, this will be connected to the INPUT Alternator/Starter Battery common
positive.
Alternator / Starter Battery Input Side
Output / House Battery Side
2. Unscrew the terminals, connect the common negative and common positive wires from the
starter battery to the input of the DCDC in the appropriate negative and positive terminals. Then
screw the terminals for a tight fit. Refer to Figure 3 and Figure 4.

Important Note: The Alternator will not be connected directly to the input of the DCDC.
The alternator must be connected to the starter battery and from this connection there will
be a bus connection to the input of the DCDC. See Figure 3
Figure 3
Figure 4
3. Connect a copper signal cable (not provided), 18-16AWG, to the D+ slot on the DCDC output
side and run the cable to the positive terminal of your alternator/starter battery common
positive. Refer to figure 5. The unit should then turn on.

Caution: The DCDC will turn on when the ignition is on. This means that even if your engine is
not on, the starter battery will immediately be used to power the DCDC and start charging the
house battery. It is recommended to have the vehicle completely on.
IMPORTANT: A D+ ignition cable is required to turn the unit on. Although the D+ terminal is
in the output side, this will be connected to the INPUT Alternator/Starter Battery.
Figure 5
Operation
When the input and output batteries as well as the signal wire is connected, the DCDC will power on
with green LED.
IMPORTANT: The DCDC will not turn on without a D+ ignition cable.
LED Indicator
Color, Behavior
Status
Description
Off
No Load
Unit is off; If abnormal, see
troubleshooting for more detail.
Green
Operation Normal
Red
Fault
There is an error in your system,
see troubleshooting for more
detail
18-16AWG, copper
cable recommended

Setting Battery Charger
Please Note: The battery charger is for lithium-iron phosphate battery types with a built in BMS system.
Do not use the device under any circumstances to charge other types of batteries
(ex. NiCd, NiMH, etc.).
WARNING: Danger of Explosion! *Note: Check the charging requirements from the battery
manufacturer before charging your battery with this unit.
*Note, make sure to abide by the safety instructions in the beginning of the manual
The DCDC is equipped with 5 DIP switches which determine the boost charge and float charge profiles,
depending on your battery specifications. Refer to the diagram for ON/OFF position respectively.
DIP Switch
Description
S5
Determines whether the charging
profile will be for Lithium batteries or
for others battery types
S1, S2
Determines the Constant Voltage for
your battery charging profile
S3, S4
Determines the Float Voltage for your
battery charging profile
*This will not be used for lithium
batteries
Start with SW5 to determine whether you are charging a lead-acid battery or lithium
ON
ON
OFF

SW5 ON
If SW5 is set to ON, then you will follow the lead acid charging profiles in the following charts. SW1/SW2
will determine the desired absorption voltage and SW3/SW4 will determine the desired float voltage.
*Please note that the charging profile will automatically bulk before approaching the user-defined
absorption and float stage.
Set Absorption Charge

SW5 OFF
Please Note: The battery charger is for lithium-iron phosphate battery types with a built in BMS system.
Do not use the device under any circumstances to charge other types of batteries
(ex. NiCd, NiMH, etc.).
If SW5 is set to OFF, then you will follow the lithium-iron phosphate charging profiles in the following
charts. For lithium charging the switches will combine bulk/absorption charging voltages and omit float
voltage. There will not be a float voltage that you set for your lithium battery as it is generally
unnecessary for Lithium-Iron Phosphate batteries. Because of this, you will only use SW1/SW2 to
determine LFP charging profiles.
Start by setting SW3/SW4 to ON position. This will disregard the Type 1 chart. Utilize the Type 2 Chart to
select your lithium-iron phosphate battery charging profile using SW1/SW2
Current Limiting
The DCDC chargers feature a current limiting option utilizing the LC port on the output side of the DCDC.
Simply connect a copper signal cable (not provided), 18-16AWG, to the LC slot on the DCDC output
side and run the cable to the positive terminal of your alternator/starter battery common positive.
IMPORTANT: The DCDC will not turn on without a D+ ignition cable so you will still need to
have this connected when and if utilizing the LC terminal.

Although the LC terminal is in the output side, this will be connected to the INPUT
Alternator/Starter Battery common positive.
LC+

The manufacturer accepts no liability for damage in the following cases:
•Faulty assembly or connection
•Damage to the product resulting from mechanical influences and excess voltage
•Alterations to the product without expressed permission from the manufacturer
•Use for purposes other than those described in the operating manual

Do not open the device. You risk exposing yourself to an electric shock by doing this.
If you have detailed questions about the battery charger, please contact our customer
support (addresses on the back of the instruction manual).
Behavior
Troubleshoot Steps
Green LED not turning on,
but the batteries are connected
1. Check the D+ signal wire and make sure it is connected to
the input alternator/battery positive and the D+ port on the
DCDC
2. Make sure the alternator/starter battery is connected to the
input terminals of the DCDC and the house battery is
connected to the output terminals on the DCDC
3. Check to make sure your connections are tight and secured
and that it is connected to the correct terminals.
4. There may be a break in your connection so Inspect all wires
for tears or breaks and if all is well on the surface, then
conduct a continuity test using a multi-meter to check for
adequate flow. This will depend on your model.
5. Use a multi-meter to check that the both the starter and
house batteries are within the DCDC voltage specification. It
should not be under 8V or over 16V.
6. Use a multi-meter to also verify whether your poles are
reversed. Setting your multi-meter to DC Volts, probe the
positive line onto the positive battery terminal and probe
the negative line to the negative battery terminal. If the DC
reading is negative, your poles are reversed.
7. You may need to conduct a battery test at your local auto
shop
Unit was working,
but then shutdown.
If the DCDC is not functioning properly, it may be undergoing an
automatic protection function. This does not mean the DCDC is
defective, but it requires some adjustments to commence normal
system operation. The red indicator may or may not be on,
depending on the circumstance.

Protection Function / Fixes
LED is Red, what do I do?
Protective Function
Potential Fixes
Over-Voltage Protection;
Under-Voltage Protection
1. Use a multi-meter to check the voltage of the battery bank to
confirm whether the starter battery or house battery is above
specification (16V) or below the specification (8V)
2. If above the voltage specification, disconnect all loads and
chargers from the battery and allow the battery to stabilize.
This may take a few hours.
3. If below the voltage specification, you will need an external
charger to bring the battery voltage to the minimum set point
on the DCDC. The under-voltage protection may not be
showing an indicator light.
Reverse-Polarity Protection
1. Use a multi-meter to also verify whether your poles are
reversed. Setting your multi-meter to DC Volts, probe the
positive line onto the positive battery terminal and probe the
negative line to the negative battery terminal. If the DC reading
is negative, your poles are reversed.
2. Switch the poles to resume normal operation
High-Temperature
Protection
1. If voltage checks out fine, then the installation area may be
too hot for the DCDC to operate.
2. Turn off any loads from the DCDC and if you have a
temperature sensor, measure the temperature to make sure it
is not outside of working specification (50®C)
3. Ventilate the installation area, or let the unit sit until it has
cooled down via temperature sensor or your touch.
4. The high-temperature protection is automatic and will resume
normal operation upon detecting lower
temperatures/operational temperatures.
Short Circuit Error
If the troubleshooting steps or protection function steps are
ineffective at fixing the DCDC, then it may be experiencing an internal
short circuit error. The LED will be permanently on and cease to
function, by which it will need to be replaced.
Disposal

Technical Specifications
DCC-1212-20
DCC-1212-40
DCC-1212-60
Transformation
12VDC -> 12VDC
Nominal Input Voltage
12 VDC
Input Voltage Range
8V ~ 16VDC
Rated Charging
Current
20A
40A
60A
Charging Voltage
Range
13.2V –14.7V, depending on DIP Switch
Max Rated Output
Power
250W
500W
750W
Residual ripple of
output voltage at
rated current
< 50 mV @20A/401/60A
Efficiency
up to 90 %
Idle power
consumption
< 0.4 A
Operational
temperature
–20 °C ~ +50 °C
-4°F ~122°F
Temperature
Compensation
(with sensor)
-3Mv/C®/2V (See Chart)
Humidity
≤95 % Non-condensing
Dimensions
211 x 175 x 68 mm
8.31 x 6.89 x 2.68in
261 x 175 x 68 mm
10.28 x 6.89 x 2.68in
311 x 175 x 68 mm
12.24 x 6.89 x 2.68
Terminal Size
M8 x 10mm, 1mm thread pitch
Weight
1.33 kg.
2.93 lbs.
1.88 kg
4.14 lbs.
2.40 kg
5.29 lbs.
Inspection /
Certification
Temperature Compensation
Please Note: The temperature compensation is not to be used with lithium batteries.
Model DCC-1212-20 DCC-1212-40
Transformation:
Nominal input voltage:
Input voltage range:
Charging current: 20A 40A
Charging voltage:
Output: 250W 500W
Residual ripple of
output voltage at rated
current:
Efficiency up to:
Idle power consumption:
Ambient temperature
for operation :
Ambient humidity:
Dimensions (W x D x H): 8.3 x 6.9 x 2.7 “ 10.3 x 6.9 x 2.7 “
Weight: 2.9 LBS 4.1 LBS
Inspection/certification:
< 95% Non-condensing
< 50 mVeff
12V ~
12V-12V
90%
< 0.4 A
–20 °C to +50 °C
13.2V-14.7V
8 V – 16 V

Protective Function Specifications
@ Input
High-Voltage, low-voltage,
reverse polarity, high-
temperature, short-circuit
Low Voltage cut-out
8V
Low-voltage restart
10V
High-voltage shutdown
16V
High-voltage restart
15.5V