Operating / Installation Instructions

40A DC TO DC CHARGER
WITH SOLAR INPUT

This unit is designed to automatically

cycle charge your auxiliary 12V battery
system up to 40A from a 12V vehicle
source.

When vehicle charging is unavailable,

you also have the ability to charge DUAL
from a solar panel source up to 400W -
giving you a complete battery charging solution. CONTROLLER
TECHNICAL DATA
Max Charge Current: 40 Amps
Features Include Input Operating Voltage Range: 11V to 16V
• 12V DC to DC plus solar input Max Charge Voltage Type A: 14.4V
Max Charge Voltage Type B: 14.6V
• Smart alternator compatible Max Charge Voltage Type C: 14.8V
• 40A DC to DC charger Solar Panel Power: 50W to 400W
Solar Panel VMPmin / VOCmax: 16V / 32V
• Solar input 50W to 400W panel
Standby Current: 0.03A
• MPPT and PWM solar controller Max Operating Temperature: 70ºC
• Built-in 15 second delay Automatic Derating Above 40ºC: 1.3A/ºC
Dimensions: 162 x 90 x 40mm
• Pre wired for battery monitor Weight: 890g
• Built in LED charge indicator
• Suits lithium, GEL/AGM and flooded batteries
• Over current and temp protection
• Low voltage cut-off
• Full polymer encapsulation protects from water, dust ingress and vibration
• IP67 rating

Important Notes
• Prior to installation, you must determine the suitability of the product to ensure correct application
• Always check with the battery manufacturer for the suitability of this product for your installation
• Where lithium battery banks are involved, check that the BMS system is compatible with this product
• To initiate solar operation, the input from a solar panel needs to be greater than 1A
• Avoid shorting the output when the unit is operational to prevent damage
• Solar panel lowest maximum power voltage 16V (Vmp) with a maximum open circuit votage at 32V (Voc)
• Do not use solar regulator when connecting solar panels
• Suitable for silicon-based panels such as polycrystalline, monocrystalline and amorphous ranging from 50W to 400W
• Type A (14.4V) generally suits gel and AGM batteries
• Type B (14.6V) generally suits lead and lithium batteries
• Type C (14.8V) generally suits calcium and lead crystal batteries

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 Operating / Installation Instructions

40A DC TO DC CHARGER
WITH SOLAR INPUT
Installation
Important: Connect the wires in the following sequence: Ground/common negative (BLACK); Main battery positive + (RED); Solar panel
positive + (WHITE); Chemistry (ORANGE); Ignition (BLUE); Auxiliary battery positive + (BROWN)

WARNING: Ensure that you select the correct gauge and heat resistant wiring suitable for where the unit will be installed

1. Disconnect the battery supply.

2. Choose a mounting position - as close to the auxiliary battery while selecting a position with good ventilation where air can pass freely
around the unit. Avoid locations such as fuel lines, where external heat is produced or where it may be exposed to rain. Ensure the unit
is installed away from flammable fumes, liquids or materials.
3. Choose an orientation that allows the built-in LED to be visible to confirm operation after installation.
4. Connect wires as per our recommended connection sequence above.

WIRING GUIDE FOR INSTALLATION OPTIONAL

DUAL
BATTERY
Battery
Selection Options MONITOR
1. To Ground 14.4V
2. To 12V+ 14.8V
SOLAR FUSE 3 3. Unconnected 14.6V
16VMP min
32VOC max ORANGE
50 to 400W WHITE Black Earth / Ground
Red 12V output for monitor enable
Yellow Main
Violet Auxiliary
To Vehicle
Ignition Source
BLUE
BROWN RED LED Indications
FUSE 1 FUSE 2 ON / Solid (Orange)
DCDC Mode / Aux Battery > 13.5V

ON / Flashing (Orange)
AUXILIARY MAIN DCDC Mode / Aux Battery < 13.5V
BATTERY BLACK BATTERY
12V 12V ON / Solid (Green)
Solar Mode / Aux Battery > 13.5V

FUSE RATINGS ON / Flashing (Green)

Fuse 1 & 2 50A Solar Mode / Aux Battery < 13.5V
Fuse 3 To suit solar
panel
NOTE: Fuses are not supplied ON / Flashing (Red)
Aux Battery < 12V

Typical Operation
The auxiliary battery is charged from the vehicle system when the engine is running. This is detected via the ignition wire. There is a 15
second delay to allow the vehicle to start before drawing power from the main battery. The unit will automatically select Boost or Reducer
depending on the vehicle’s voltage levels to give maximum output. When the vehicle is off and the charger is drawing power from the
solar panels, it will require over 1A from the solar panels to charge properly. If the battery reaches full capacity while in Solar Mode the
charger will switch to a float mode for the continuation of the charge for that day. When the vehicle is not running and there is no daylight
available, the unit reverts to Standby Mode (<0.03A).
DCTDCCIM040920

Warranty Conditions: Our products come with guarantees that cannot be excluded under the Australian Consumer Law. The customer is entitled to a replacement or refund for a major failure and compensation for any other
reasonably foreseeable loss or damage. The customer is also entitled to have the products repaired or replaced if the products fail to be of acceptable quality and the failure does not amount to a major failure. Ironman 4x4
warrants that its products will, under normal use and service, be free of defects in material and workmanship for a period of three (3) years from the date of the original purchase by the customer
as marked on the customer’s original invoice. Please refer to our website for full warranty information which can be found at http://www.ironman4x4.com/warranty-terms

www.ironman4x4.com PART NO: IDCDCSOLAR