TJM 032TJMPDC25A User manual

TAKE THE LEAD.
TJM4x4 www.tjm.com.au
WARNING: This is a HIGH current device.
It is the installer’s responsibility to ensure all cabling meets the
requirements as stipulated on page 6 of this installation manual to ensure a
SAFE installation, particularly when upgrading with a higher capacity unit.
Failure to comply with the supplied installation instructions will void the warranty.
TJM DC CHARGER 25A.
INSTRUCTIONS & SPECIFICATIONS

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IMPORTANT SAFETY INFORMATION.
Please read this manual thoroughly before use and store in a safe place for
future reference.
WARNINGS.
• Explosive gases may escape from the battery during charging. Prevent flames and
sparks and provide adequate ventilation.
• Before charging, read the instructions.
• FOR CHARGING 12 VOLT AUTOMOTIVE BATTERIES ONLY.
• Do not attempt to charge non-rechargeable batteries.
• Never charge a frozen battery.
• Corrosive substances may escape from the battery during charging and damage
delicate surfaces. Store and charge in a suitable area.
• This appliance is not intended for use by young children or infirm persons unless they
have been adequately supervised by a responsible person to ensure that they can use
the appliance safely.
• Young children should be supervised to ensure that they do not play with the
appliance.
• Fit fuses as close to the batteries as possible to protect the cable in case of short
circuit.
FEATURES.
The DC-DC Charger is Intelli-Charge’s next generation in DC-DC charging. It has
been designed with next generation technology to ensure your DC-DC charging
experience is unrivalled. The DC-DC Charger features everything needed to maintain
the auxiliary battery to its optimum condition and to prolong battery life.
DUAL INPUT OPERATION
• The DC-DC Charger allows for simultaneous dual battery charging from both solar
and alternator inputs (9-32V) with no manual switching required. The unit prioritises
solar charging as its default and automatically adjusts to the alternator if sunlight is
insufficient, reducing the power usage placed on the vehicle’s electrical system.
TOUGH & RELIABLE
• DC-DC Charger is rated to IP68 & IP69K, ensuring it can withstand the toughest
of conditions. All connections into the DC-DC Charger are done via brass posts
and crimped terminals. Ideal for mounting in the engine bay. DC-DC Charger use
temperature compensation to ensure the battery receives the correct charge voltage
regardless of ambient temperatures. Raises the voltage in cooler climates while
reduces the voltage in warmer climates to ensure the battery does not boil.

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SMART DC-DC CHARGING
• DC-DC Charger paired with Intelli-IQ supports advanced control of the dual battery
system including Bluetooth connectivity to an iOS or Android device. Note Intelli-IQ is
sold separately.
MULTI-CHEMISTRY CHARGING
• The DC-DC Charger range of charger’s suits today’s different battery technologies,
including everyday automotive batteries and the newer lithium battery technology.
For automotive batteries, multi-chemistry technology enables the user to tailor the
charging profile to suit the battery type: AGM, GEL, WET, Calcium and LiFePO4
batteries. For other types Lithium batteries, please check the battery’s datasheet and
see if DC-DC Charger is suitable for the charging profile before connecting.
PARALLEL CHARGING
• DC-DC Charger can be wired in parallel to provide more charging current for larger
systems. This flexibility gives users the option to add another DC-DC Charger into
their system should power requirements change. For example, two DC-DC Chargers
would provide a total charging current of 50A.
FUTURE PROOF
• DC-DC Charger was designed to stand the test of time. When DC-DC Charger is paired
with an Intelli-IQ, the firmware can be updated via Bluetooth ensuring DC-DC Charger
software is always up to date with the latest features.
SOLAR MPPT
• The DC-DC Charger utilises sophisticated MPPT (Maximum Power Point Tracking)
solar regular technology. MPPT maximises the power generated from the solar
panels to the auxiliary battery.
PROTECTIVE FEATURES.
SPARK-FREE PROTECTION
• The DC-DC Charger will not start charging the battery (no output) unless the load
is securely connected. It prevents the output leads from sparking due to accidental
short circuit making the charger safer to use around batteries.
REVERSE CONNECTION PROTECTION
• Reverse connections on input and output terminals does not damage DC-DC
Charger’s internal circuit. The DC-DC Charger detects reverse connection condition
and indicates whether input or output connection is reversed.
OVER AND UNDER VOLTAGE PROTECTION
• The charger will automatically shut down if there is an over voltage or under
voltage problem.
OVER TEMPERATURE PROTECTION
• The charger will lower its output current if the temperature of the unit begins to
overheat.

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SPECIFICATIONS.
P/No. 032TJMPDC25A
Operating Conditions
Alternator Input Voltage 9-32V
Maximum Solar Input Voltage 32Vdc
Maximum Input Current 35A
Input Current (No Load) 2 mA
Back Drain on Auxiliary Battery INPUT: 9-11Vdc 20A
INPUT: 11-32Vdc 25A
External LED Output –
Constant Current 5mA
Input Fuse Rating 50A (Not supplied)
Output Fuse Rating 50A (Not supplied)
Maximum Output Power 385W
Solar Input Turn On Voltage 11V
Size (mm) 149 x 122 x 42
Weight (g) 1180
Charge Control
Charge Type 5 Stage
Constant current up to
BULK *20A at 9-11Vdc, 25A at 11-32Vdc
GEL AGM WET CALCIUM LiFePO4
14.1V 14.4V 14.7V 15.4V 14.2V
Absorption
Constant voltage until current drop to 3.8A:
GEL AGM WET CALCIUM LiFePO4
14.1V 14.4V 14.7V 15.4V 14.2V
Float GEL AGM WET CALCIUM LiFePO4
13.7V 13.7V 13.7V 13.7V 13.5V
Equalisation (Calcium Mode &
Periodic Use Only) 3.8A Constant Current Charge up to 16V then hold for 30 min (5 hour timeout)
Battery Range
Battery Capacity 50-300Ah
Type of Batteries Supported GEL, AGM, WET, CALCIUM & LiFePO4
Operating Mode
Vehicle Voltage Range 12Vdc 24Vdc
VSR Mode – Default (Ignition
Override Not Connected)
Turn On
13.4-16.5Vdc
Turn Off
<12.8Vdc
Turn On
26.8-32.0Vdc
Turn Off
<25.6Vdc
Low Voltage Mode – Ignition
Override cable connected to
ignition switch (Ignition On)
Turn On
12.2-19.0Vdc
Turn Off
<11.9Vdc
Turn On
24.4-32.0Vdc
Turn Off
<23.8Vdc
Output Current Input 9-11Vdc 20A
Input 11-32Vdc 25A
Standards
EMC AS/NZS CISPR11 Class B, R10
IP Rating IP68 & IP69K

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SPECIFICATIONS.
P/No. 032TJMPDC25A
Operating Conditions
Alternator Input Voltage 9-32V
Maximum Solar Input Voltage 32Vdc
Maximum Input Current 35A
Input Current (No Load) 2 mA
Back Drain on Auxiliary Battery INPUT: 9-11Vdc 20A
INPUT: 11-32Vdc 25A
External LED Output –
Constant Current 5mA
Input Fuse Rating 50A (Not supplied)
Output Fuse Rating 50A (Not supplied)
Maximum Output Power 385W
Solar Input Turn On Voltage 11V
Size (mm) 149 x 122 x 42
Weight (g) 1180
Charge Control
Charge Type 5 Stage
Constant current up to
BULK *20A at 9-11Vdc, 25A at 11-32Vdc
GEL AGM WET CALCIUM LiFePO4
14.1V 14.4V 14.7V 15.4V 14.2V
Absorption
Constant voltage until current drop to 3.8A:
GEL AGM WET CALCIUM LiFePO4
14.1V 14.4V 14.7V 15.4V 14.2V
Float GEL AGM WET CALCIUM LiFePO4
13.7V 13.7V 13.7V 13.7V 13.5V
Equalisation (Calcium Mode &
Periodic Use Only) 3.8A Constant Current Charge up to 16V then hold for 30 min (5 hour timeout)
Battery Range
Battery Capacity 50-300Ah
Type of Batteries Supported GEL, AGM, WET, CALCIUM & LiFePO4
Operating Mode
Vehicle Voltage Range 12Vdc 24Vdc
VSR Mode – Default (Ignition
Override Not Connected)
Turn On
13.4-16.5Vdc
Turn Off
<12.8Vdc
Turn On
26.8-32.0Vdc
Turn Off
<25.6Vdc
Low Voltage Mode – Ignition
Override cable connected to
ignition switch (Ignition On)
Turn On
12.2-19.0Vdc
Turn Off
<11.9Vdc
Turn On
24.4-32.0Vdc
Turn Off
<23.8Vdc
Output Current Input 9-11Vdc 20A
Input 11-32Vdc 25A
Standards
EMC AS/NZS CISPR11 Class B, R10
IP Rating IP68 & IP69K
PRODUCT OVERVIEW.
149
122
47
DC-DC Charger
LIN BUS
Input
Terminal
Ignition
Input
Terminal
Temperature 1
Input
Terminal
Auxiliary LED Input Terminal
– Provision for auxiliary LED to indicate
DC-DC Charger status
Power LED – Indicates
DC-DC Charger on/off status Alternator
Input Post
Solar LED – Indicates
solar input status
Ground Connection
Input Post
Alternator LED – Indicates
alternator input status
Auxiliary Battery
Input Post
Battery Chemistry
Setting LED
Solar Input Post
Temperature 2
Input
Terminal

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INSTALLATION.
MOUNTING
• DC-DC Charger’s IP68 & IP69K tough & rugged design allows for the unit to be
mounted where best suits the application. DC-DC Charger entire PCB is potted using
a high-quality thermal compound inside the aluminium extrusion; this ensures DC-DC
Charger is impervious to vibration, dust, moisture and extreme temperatures. Though
tough, it is advisable however to keep the charger as far away from exhaust, turbos,
or any other high temperature components to ensure improved performance.
WIRING
• To make reliable and durable electrical connections, battery cables will need to be
made to the correct length. Cable lugs should be crimped and insulated to the cable
before connection to the brass posts and spade terminals.
Minimal cable size for wiring up to 12m:
Input Name Recommended Cable Size
Alternator Input Post 8mm² (8 B&S)
Solar Input Post 8mm² (8 B&S)
Auxiliary Output Post 8mm² (8 B&S)
Common Ground Output Post 8mm² (8 B&S)
Ignition Input Blade Terminal 1.0 – 1.5mm²
LIN BUS Input Blade Terminal 1.0 – 1.5mm²
Battery Temperature 1 Input Blade Terminal 1.0 – 1.5mm²
Battery Temperature 2 Input Blade Terminal 1.0 – 1.5mm²
Auxiliary LED Input Blade Terminal 1.0 – 1.5mm²
Beyond 12m increase cable size as required. Contact Technical Support for assistance
on 1800 422 422.
1. Disconnect the negative battery cable (Earth) from the vehicle’s starting battery
or disconnect power to the trailer. Note: To prevent the loss of vehicles electronic
memories, radio pre-sets & security codes, it is recommended that an “Electrical
System Memory Protector” be used.
2. Connect the Auxiliary Battery positive (+) terminal to the Output Cable (brown
colour) from DC-DC Charger. Fit at a fuse (50A for DC-DC Charger) to the cable as
close as possible to the Auxiliary Battery positive (+) terminal.
3. Connect the Auxiliary Battery (-) terminal to the DC-DC Charger common ground
output post. Alternatively connect both Auxiliary battery negative (-) terminals and
DC-DC Charger common ground cable to the vehicle’s chassis ground.
4. Connect the Starter Battery positive (+) terminal to the DC-DC Charger Alternator
Input Post. Fit at a fuse (50A for DC-DC Charger) to the cable as close as possible to
the Starter Battery positive (+) terminal.

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5. If your vehicle has a fixed voltage or temperature compensating alternator installed,
do not make connection to the Ignition Input Blade Terminal.
If your vehicle has a smart (variable voltage) alternator installed, the Ignition Input
Blade Terminal must be connected to the vehicle’s ignition. The DC-DC Charger will
only operate when the vehicle’s ignition is turned on (may take up to 2 minutes
to start charging). Fit a 1-2A fuse to the cable as close as possible to the vehicle’s
ignition.
If solar panels are connected to the DC-DC Charger, the DC-DC Charger will operate
and only draw power from solar panels (assuming vehicles ignition is turned off).
Consult the vehicles manufacture for type of alternator installed in your vehicle.
6. When 12Vdc solar panels are present, connect the solar panel positive terminal (+) to
the DC-DC Charger solar input cable (green colour). Fit a fuse to the cable as close as
possible to the Solar Panel positive (+) terminal (refer to the table below for fuse size).
NOTE: No solar controller is required with the DC-DC Charger. If using
portable solar panels that include a solar controller, the controller will need
to be bypassed.
After the positive has been connected, connect the solar panel negative (-) terminal
to the DC-DC Charger Common Ground terminal ( ). Alternatively connect both Solar
Panel negative (-) terminals and DC-DC Charger common ground to the vehicle chassis
ground.
Solar Panel Size Fuse Size
120W 15A
160W 15A
200W 20A
240W 30A
360W 50A
7. The LED output terminal provides about 5mA constant current output. It can power an
LED panel mount indicator with or without an internal resistor.
This LED output terminal is not required to be wired into if you do not need an
external LED indicator. If an external LED indicator is required, connect the positive (+)
terminal of a LED Indicator to the LED input terminal ( L.E.D ).
Connect the negative terminal of the LED indicator to the vehicle chassis ground.
8. The TEMP1 & TEMP2 input terminals are used to provide temperature compensated
battery charging. Attach the provided temperature sensing loom blade terminals to
either TEMP1 & TEMP2 inputs on DC-DC Charger, the ports are dual polarity allowing
the negative and positive to be plugged into either port. The temperature sensing
loom is provided with 5m wire, please cut the excess length to minimize voltage drops
and noise.

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WIRING INSTRUCTION GUIDES.
1. FULL SYSTEM WITH INTELLI-IQ CONFIGURATION
* Read the instructions of Intelli-IQ
Display and Intelli-IQ Smart Relays
for further wiring details
* For vehicles fitted with
a Smart Alternator only
Alternator/Starter Battery-Red (8mm2)
Alternator/Starter Battery-Red (8mm2)
LIN Bus-Purple (1.5mm2)
Fuse
External LED-Pink (1.5mm2)
Output/Auxiliary Battery-Red (8mm2)
* Temp sensor mount
to battery casing
Temperature Sensing – Black-Red
Battery Charging
Mode
Solar-Green (8mm2)
Fuse
Ground/Chassis
Ground/Chassis
Battery 2
(Aux Battery)
Battery 1
(Starter Battery)
Ground/Chassis
Ground/Chassis
* LED Panel
Mount Indicator
Junction Box
Lighting
Accessory
12/24V
Accessory
12V Solar Panel
Connects to ignition feed if smart alt Ignition override-Blue(1.5mm2)

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2. FULL SYSTEM CONFIGURATION
* For vehicles fitted with
a Smart Alternator only
Alternator/Starter Battery-Red (8mm2)
Alternator/Starter Battery-Red (8mm2)
Fuse
External LED-Pink (1.5mm2)
Output/Auxiliary Battery-Red (8mm2)
* Temp sensor mount
to battery casing
Temperature Sensing – Black-Red
Battery Charging
Mode
Solar-Green (8mm2)
Fuse
Ground/Chassis
Ground/Chassis
Battery 2
(Aux Battery)
Battery 1
(Starter Battery)
Ground/Chassis
Ground/Chassis
* LED Panel
Mount Indicator
12V Solar Panel
Connects to ignition feed if smart alt Ignition override-Blue(1.5mm2)

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3. ALTERNATOR/STARTER INPUT ONLY CONFIGURATION
* For vehicles fitted with
a Smart Alternator only
Alternator/Starter Battery-Red (8mm2)
Alternator/Starter Battery-Red (8mm2)
Fuse
External LED-Pink (1.5mm2)
Output/Auxiliary Battery-Red (8mm2)
* Temp sensor mount
to battery casing
Temperature Sensing – Black-Red
Battery Charging
Mode
Fuse
Ground/Chassis
Battery 2
(Aux Battery)
Battery 1
(Starter Battery)
Ground/Chassis
Ground/Chassis
* LED Panel
Mount Indicator
Connects to ignition feed if smart alt Ignition override-Blue(1.5mm2)

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4. SOLAR & AUXILARY BATTERY INPUT CONFIGURATION
* For vehicles fitted with
a Smart Alternator only
Alternator/Starter Battery-Red (8mm2)
Fuse
External LED-Pink (1.5mm2)
Output/Auxiliary Battery-Red (8mm2)
* Temp sensor mount
to battery casing
Temperature Sensing – Black-Red
Battery Charging
Mode
Solar-Green (8mm2)
Ground/Chassis
Battery 2
(Aux Battery)
Ground/Chassis
Ground/Chassis
* LED Panel
Mount Indicator
12V Solar Panel
Connects to ignition feed if smart alt Ignition override-Blue(1.5mm2)

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HOW TO READ LED INDICATORS.
LED CHARGE INDICATORS
DESCRIPTION
Constant Green Solar Present
Constant Green Alternator Present
Constant Red DC-DC Charger Faulty
Constant Red Solar Input Reverse Polarity
Constant Red Alternator Input Reverse Polarity
Flashing Red Solar Overvoltage
Flashing Red Alternator Overvoltage
Flashing Green Constant Green Charging from Solar
Flashing Green Constant Green Charging from Alternator
Fast Flash Amber Bulk Time Out
Flashing Amber Flashing Amber Flashing Amber Over Temperature

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LED BATTERY CHARGE STATUS INDICATORS
SELECTED BATTERY CHEMISTRY LED DESCRIPTION
Constant Red FLASHING BLUE Output Reverse Polarity
Flashing Red FLASHING BLUE Output Overvoltage
Constant Amber FLASHING BLUE Output Open Circuit or Dead Battery
Flashing Amber CONSTANT BLUE Soft-start Timeout
Flashing Green CONSTANT BLUE Bulk Charging
Flashing Green FLASHING BLUE Absorption Charging
Constant Green FLASHING BLUE Equalisation Charging
Constant Green CONSTANT BLUE Float Charging (Charging Complete)
Constant Red ALL BATTERY MODE LED’S FLASHING Output Short Circuit
HOW TO SELECT BATTERY CHEMISTY
DC-DC Charger allows you to select the select the appropriate charge setting for
your auxiliary battery.
To adjust battery chemistry charge setting on DC-DC Charger, press & hold the
mode button ( ) for 3 seconds. The LED for the current battery setting will begin
to flash, press the mode button to cycle to the correct battery setting. To confirm
the battery chemistry setting, press & hold the mode button ( ) for 3 seconds or
leave the unit for 10 seconds.
To confirm you have selected the correct battery chemistry, press the mode button
().
OUTPUT OVERRIDE
If DC-DC Charger does not charge because the aux battery is with extremely low
voltage, then press and hold Battery Chemistry button for 10 seconds to override
auxiliary battery detection and go into bulk charge .

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FREQUENTLY ASKED QUESTIONS.
Q. Is the DC-DC Charger waterproof?
A. The DC-DC Charger was designed and engineered to the stringent ingress protection
rating of IP68 & IP69K. This allows the DC-DC Charger to meet the toughest of
challenges whether that be river crossings, engine bay washing or direct high
pressure washing of the unit.
Q. Why do the positive cables from the batteries need to be fused?
A. High-Capacity batteries can produce large amounts of power and are capable of
melting cable insulation and catching fire in the case of a short circuit. Each positive
(+) cable connected to the battery must be protected by a fuse located in close
proximity to the battery.
Q. Is the DC-DC Charger safe to use with modern ‘electronic’ vehicles?
A. The DC-DC Charger has been designed to work with all vehicles, including
new vehicles with EFI and computer management systems. The charger utilises
sophisticated electronics that ensures complete safety for you and your vehicle.
Q. How do I know if the battery is charged?
A. Refer to diagram “LED BATTERY CHARGE STATUS INDICATORS” on page 14 to
identify when the DC-DC Charger is indicating battery charging is complete.
Q. I have connected the DC-DC Charger properly but the power LED “ ” does
not come on?
A. Check the cable size. The DC-DC Charger is designed to power on and charge from
an input source as little as 9V. If small size cables are used for wiring, the voltage
might drop below 9V when DC-DC Charger is attempting to start up. Please refer to
Installation – wiring section for recommended cable size.
Q. I have connected the DC-DC Charger to solar “ ” and alternator inputs ”
”, but LEDs do not come on?
A. In some cases batteries can be discharged to the point where they have very little
or no voltage. This can occur if a small amount of power is used for a long time,
for example a map reading light is left on for a week or more. The DC-DC Charger
is designed to charge an auxiliary battery from as little as 5 Volts. If the voltage is
lower than 5 Volts use a pair of booster cables to connect between two batteries
to provide more than 5 Volts to the battery being charged. The DC-DC Charger can
then start to charge the battery and the booster cables can be removed.

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Q. Why does the DC-DC Charger indicate the battery is fully charged straight
away?
A. There are three possible reasons why the DC-DC Charger indicated the battery is fully
charged.
1. The battery is fully charged.
2. The battery has taken a surface charge.
3. The battery has a faulty cell.
Q. What is a “Surface Charge”?
A. Batteries unused or left discharged for some time build up a resistance to being
recharged. When the charger is first connected, these batteries will take a surface
charge, and the DC-DC Charger LED’s will indicate the auxiliary battery is fully charged
within a short period of time. The battery however is not fully charged. The charger
is voltage sensitive and cannot differentiate between a surface charge and a fully
charged battery. After a few hours, the battery may start to accept some charge but
most batteries with this condition may not recover.
Q. What is a “Faulty Cell”?
A. 12 Volt batteries contain 6 cells, and one faulty cell is enough to ruin your battery. If
after twelve hours of charging your battery is still accepting charge, you should test
the cells using a hydrometer. If one reading is lower than the rest, it indicates a faulty
cell. It is pointless to continue charging; the battery needs replacing.
Q. Why is there no output at the DC-DC Charger’s auxiliary battery output “ ”?
A. The DC-DC Charger incorporates short circuit protection that makes it much safer
to use. For this reason, the DC-DC Charger will only output power when properly
connected to a battery. To check if the DC-DC Charger is functioning, follow the
instructions to connect and operate the charger as normal on a flat battery. While the
battery is charging measure the battery voltage with a volt or multi-meter. Charging
can be confirmed if the voltage is increasing (within the voltage parameters set out in
the specifications).
WARRANTY STATEMENT.
For warranty information visit: www.tjm.com.au
IMPORTANT NOTE.
Our goods come with guarantees that cannot be excluded under the Australian Consumer
Law. You are entitled to a replacement or refund for a major failure and compensation for
any other reasonably foreseeable loss or damage. You are also entitled to have the goods
repaired or replaced if the goods fail to be acceptable quality and the failure does not
amount to a major failure.

Distributed by TJM Australia
17 Johnstone Road Brendale Q 4500