Intelli-Charge 25 Amp DC-DC Battery Charger

Troubleshooting Guide 

This guide helps diagnose common issues with the Projecta IDC25X DC-DC charger in vehicle, caravan, and off-grid installations.

1. Charger Will Not Turn On

Possible Causes

• No input voltage from alternator or solar
• Blown fuse or circuit breaker
• Incorrect wiring or poor earth
• Input voltage below minimum threshold

Checks & Fixes

1. Verify input voltage is between 12.8-32 V DC at the charger terminals.
2. Check fuses on both input and output (typically 40–50 A).
3. Confirm ground connection is clean, secure, and connected to chassis or battery negative.
4. Inspect wiring for loose terminals or undersized cable.
5. If using a smart alternator, ensure the vehicle is running and producing sufficient voltage.

2. Charger Turns on but Does Not Charge the Battery

Possible Causes

• Battery type incorrectly selected
• Battery already fully charged
• Battery voltage outside safe operating range
• Lithium battery BMS has shut down

Checks & Fixes

1. Confirm the correct battery chemistry (AGM, GEL, WET, Calcium, Lithium) is selected.
2. Measure auxiliary battery voltage:

• Above absorption voltage → charging may pause normally.

3. For lithium batteries, activate Lithium Wake-Up Mode if the BMS has disconnected the battery.
4. Inspect output wiring and fuse between charger and battery.

3. Reduced Charging Current (Less Than 25 A)

Possible Causes

• High operating temperature
• Low alternator input voltage
• Long cable runs causing voltage drop
• Solar input limiting combined output

Checks & Fixes

1. Check ambient and under-bonnet temperatures — the IDC25X derates output when extremely hot to protect itself.
2. Measure input voltage while charging:

• Low voltage = reduced output.

3. Upgrade cable size if runs exceed recommended length (typically 6–8 AWG / 8–13 mm²).
4. Remember total output is 25 A maximum, even when solar and alternator are combined.

4. Charger Shuts Down 

Possible Causes

• Over-temperature protection triggered
• Over-voltage or under-voltage condition
• Loose or intermittent wiring
• Faulty or unstable alternator supply

Checks & Fixes

1. Improve ventilation or relocate charger away from direct heat sources.
2. Inspect all terminals for tight, corrosion-free connections.
3. Check alternator voltage stability with a multimeter.
4. Ensure battery voltage does not exceed charger limits for the selected chemistry.

5. Solar Charging Not Working

Possible Causes

• Solar voltage outside MPPT range
• Incorrect solar polarity
• Solar panels not producing power
• Shading or damaged panels

Checks & Fixes

1. Measure solar input voltage at the charger — must be within the supported DC range.
2. Confirm correct polarity at the solar input terminals.
3. Test panels directly in sunlight to verify output.
4. Remove shading and inspect solar cables and connectors.

6. Charger Gets Hot During Operation

Normal Behaviour

• The IDC25X is designed to run hot, especially at high load or under-bonnet installations.

When to Act

• If output repeatedly derates or shuts down.

Fixes

1. Ensure charger is mounted to a solid surface for heat dissipation.
2. Avoid enclosing the unit without airflow.
3. Keep clear of exhaust manifolds, turbo piping, or radiator airflow paths.

7. Lithium Battery Not Charging

Possible Causes

• BMS protection active
• Incorrect lithium profile selected
• Battery voltage too low or too high

Checks & Fixes

1. Select LiFePO₄ battery mode.
2. Use Lithium Wake-Up Mode to reset charging if the BMS has shut down.
3. Measure battery voltage directly at the terminals.
4. Confirm the lithium battery is compatible with external DC-DC chargers.

8. Charger Works on Solar but Not While Driving (or Vice Versa)

Possible Causes

• Alternator or solar wiring fault
• Input priority misunderstanding
• Ignition or voltage sensing issue

Checks & Fixes

1. Test alternator input voltage with engine running.
2. Verify solar input independently in sunlight.
3. Inspect input wiring and fuses for both sources.
4. Remember: the IDC25X automatically manages inputs — no manual switching required.

9. Error Indicators or Unexpected Behaviour

Possible Causes

• Firmware mismatch (with Intelli-IQ systems)
• Electrical noise or voltage spikes
• Incorrect installation configuration

Checks & Fixes

1. If using Intelli-IQ (IQD2 Screen), ensure firmware is up to date.
2. Check for shared earth points with high-current devices (winches, inverters).
3. Reboot the system by disconnecting all power for 60 seconds, then reconnect.

10. When to Contact Support

Contact Projecta technical support if:

• The charger shows no signs of life with confirmed correct input voltage
• Persistent shutdowns occur under normal conditions
• Physical damage or water ingress is suspected

Call us on 1800 422 422 OR

Click here to Submit a Support Request

Warranty: Typically, 5 years, subject to correct installation and use.