Renogy RBC40D1S Manual

IMPORTANT SAFETY INSTRUCTIONS

This manual provides detailed instructions; however, it may not encompass and situations. Users are therefore urged to exercise common sense and caution.

General Safety Guidelines

• This product is not suitable for individuals with reduced physical, sensory, or mental capabilities, or those lacking experience or knowledge. Children must be supervised to prevent any unauthorized use of the product.
• Routinely examine the charger for any signs of damage. If any damage is detected, refrain from using the battery charger until it has been duly repaired. When operating electrical equipment or handling lead acid batteries, ensure that someone is nearby to provide assistance in case of emergencies.
• Always wear appropriate personal protective equipment, including comprehensive eye protection and gloves, to safeguard against potential hazards.
• Prolonged exposure to extreme heat or freezing temperatures can diminish the product's lifespan. Avoid subjecting the unit to such conditions.
• This product is not designed for use with life support systems or any other medical equipment or devices.
• Before cleaning or modifying the circuit, disconnect the product from the battery to prevent accidents.
• Install and store the product in a dry and cool environment. Keep it away from any liquids, and refrain from exposing it to direct sunlight or other sources of heat.
• Do not utilize the product if it displays any signs of physical damage or if its cables are visibly cracked. Contact the manufacturer's customer service to address potential safety concerns.
• Do not attempt to disassemble the charger, as doing so may result in damage to both the unit and the user, and will also invalidate the warranty.
• Ensure adequate ventilation during operation to prevent overheating and to maintain efficient charging.
• This product should only be repaired by qualified personnel.
• Always disconnect the charger before performing any maintenance or cleaning procedures.
• Avoid striking or throwing the product to prevent damage.
• Ensure all cables and connections are firmly secured to maintain optimal performance and safety.

Battery Safety Guidelines

• The acid or fluid within a lead acid battery is corrosive and poisonous, capable of producing flammable and toxic gases during recharge, and may explode if ignited
• ALWAYS wear goggles, gloves, or protective clothing when handling these batteries. Remove personal metal items such as rings, bracelets, necklaces, and watches. Ensure adequate in the working area.
• In case of spills, the acid can cause severe burning to eyes and skin, as well as corrosion to metals. Disconnect power from nearby appliances and promptly wash affected areas with water.
• Keep fresh water and soap readily available for immediate use in case of contact with battery acid. If acid comes into contact with eyes, cleanse with soap and water for at least 15 minutes and seek medical attention promptly.
• In very cold weather, a discharged battery may freeze. NEVER attempt to charge a frozen battery, as gases may form, causing the case to crack and battery acid to spray out.
• Use only rechargeable deep cycle batteries. NEVER attempt to charge a known faulty, frozen, defective, or non-rechargeable battery.
• Ensure batteries are mounted and stored in areas with good ventilation to minimize the risk of gas buildup.
• Periodically check batteries and charging systems to detect any potential faults or issues.
• DO NOT place tools on top of a battery or allow them to fall onto the battery, as this could cause a short circuit and sparks.
• DO NOT smoke or have any open sparks or flames near the battery.
• Reverse protection is available for AGM, Gel, Calcium, and Lead Acid batteries, except for LiFeP04 batteries.

Installation Safety Precautions

• DO NOT install this charger near heat sources such as fire, heaters, or where it may be exposed to flammable chemicals, vapors, corrosive gases, liquids, or materials.
• DO NOT mount the product in areas where there is a risk of a gas explosion.
• Ensure the product is firmly fastened to prevent it from falling down or tipping over.
• Before and during the charging process, ensure the area around the battery is well ventilated.
• It is recommended to mount this product as close as possible to your auxiliary battery to ensure maximum performance.
• DO NOT lay AC and DC cables in the same conduit, and avoid pulling on the cables to prevent damage.
• When setting up the connection to the DCDC controller, observe the following sequence: start by connecting the auxiliary battery, ensuring correct polarity, and then connect the input source.

Operation Safety Guidelines

• Avoid dropping any metal tool or object on the battery, as this could create a spark or short circuit. Such incidents could lead to explosions or damage to electrical tools.
• DO NOT operate in salty, wet, or damp environments, or in areas with corrosive fumes or combustible materials. Avoid locations with risks of explosions.
• Be aware that parts of this product may continue to produce voltage even after disconnection or fuse activation.
• DO NOT disconnect cables while the product is operating to prevent potential hazards or damage.

IN THE KIT

• 1 PC(s) RENOGY 40A DC-DC Charger
• 7 PC(s) Heat-shrink tubings
• 4 PC(s) self-tapping screws
• 1 PC(s) User Manual

IDENTIFICATION OF PARTS

INSTALLATION

Location Considerations

When selecting a location for the DC-DC charger, ensure it is positioned as close as possible to the auxiliary battery being charged. Possible mounting locations include the cabin of the vehicle, along a chassis rail, inner guard, behind the grille or headlight, or on the side of the radiator.

Choose a location that is not susceptible to moisture or other substances, and avoid areas with potentially high temperatures.

The battery charger can be installed horizontally or vertically, providing flexibility in installation. Install the device on a level and sturdy surface to ensure stability and optimal performance.

Mounting Instructions

Maintain at least 5cm of clearance from all sides of the DC-DC charger to ensure proper ventilation for optimal performance. Use a pencil or pen to trace the mounting holes when placing the DC-DC against the desired mounting area.

Use 6 screws to securely fasten the DC-DC charger onto the chosen surface, ensuring stability and reliability.

WIRING

CHARGING CONTROL

CHARGING STAGE DIAGRAM

This charger employs a standard four-stage charging control:
When the battery voltage is below the constant current charging voltage, it undergoes a small current pre-charge. The Charging/Fully indicator flashes (on for 1 second, off for 1 second). When the battery voltage is higher than the constant current charging voltage, it undergoes constant current charging at maximum output current. The Charging/FulIy indicator flashes (on for 1 second, off for 1 second).

When the battery voltage reaches the constant voltage charging voltage, it undergoes constant voltage charging, during which the charging current gradually decreases.

Charging complete criteria: During the constant voltage stage, charging is considered complete when the charging current is < 4A, and charging stops. The Charging/FulIy indicator stays on continuously.

After reaching full charge, when the battery voltage drops below the float charge voltage, it undergoes float charge charging. The Charging/Fully indicator flashes (on for 1 second, off for 2 seconds).

When the battery voltage is lower than the recharging voltage, it enters the normal charging process. The Charging/FuIly indicator flashes (on for 1 second, off for 1 second).

DC INPUT

• The charger powers on when the input voltage meets the power-on conditions for continuously 15 seconds.
• During DC charging, the charger initiates a fast shutdown every 100 seconds. It checks the input voltage during shutdown to determine if it meets the power-off conditions, eliminating the effects of voltage drop during high-current situations. Shutdown detection is skipped when charging current is less than 5A.
• To prevent undervoltage during high-current charging, the controller will limit current in the undervoltage state to maintain the input voltage above approximately 11.2V. If this threshold cannot be sustained, an immediate shutdown is triggered.

SOLAR INPUT

• This controller is an MPPT controller, designed to maximize the efficiency of harnessing solar energy.
• In cases where both the solar panel and DC input meet power-on conditions simultaneously, the default priority is given to DC power. If set to solar priority, the charger continuously monitors the solar input even if DC input is already in the charging process. If solar conditions are met, it switches to solar power.

PROTECTIONS

Input Reverse Protection
Both the solar input and the DC input port are equipped with input reverse protection. Charging is not enabled in the event of reverse connection.

Input Overvoltage Protection
If the voltage at the solar input exceeds 30V or the DC input voltage exceeds 24V:
For DC input overvoltage, the 'Power On' indicator flashes once and pauses for 3 seconds.
For PV input overvoltage, the 'MPPT' indicator flashes once and pauses for 3 seconds.

Output Reverse Protection
Output port (battery port) is equipped with reverse polarity protection. If your polarity is reversed, the charger won't begin charging. It's important to note that in LiFeP04 mode, there is no output reverse protection, and connecting the battery with the wrong polarity may damage the controller.

Battery Overvoltage Protection
When the battery input port voltage exceeds 16V:
The battery type indicator flashes once and pauses for 3 seconds.
Release condition: Voltage drops below 15V.

Overtemperature Protection
When the circuit board temperature exceeds 700C, the charging current is automatically reduced.
When the circuit board temperature exceeds 800C, charging is halted. Charging resumes once the temperature drops below 680C. The 'Power On' indicator flashes twice and pauses for 2 seconds.

Charging Timeout Protection
Charging is stopped if the constant current charging stage exceeds 12 hours. The battery type indicator flashes twice and pauses for 2 seconds. The charger is locked and requires a restart.

Lithium Battery BMS Protection
When the battery type is selected as a lithium battery, if the battery port voltage suddenly drops during the charging process, it is considered an overcharge protection by the lithium battery BMS, and charging is immediately stopped. The battery type indicator alarms. After five minutes, it reassesses whether to resume charging. Alternatively, a short press of the button can manually silence the alarm and restart charging. The battery type indicator flashes three times and pauses for 1 second.

TECHNICAL SPECIFICATIONS

NOTE: ¹⁾ Exceeding this maximum value may compromise the safety of the product.

TROUBLESHOOTING

CHARGING STAGES

RENOGY.COM

Documents / Resources

References

• Renogy US Official | Trusted Energy Solutions

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