PROJECTA PMDC-30 DC to DC Charger Instruction Manual

: June 13, 2024
: Projecta

Table of Contents

PROJECTA PMDC-30 DC to DC Charger
Product Information
Product Usage Instructions
GENERAL & SAFETY INFORMATION
INTRODUCTION
- FEATURES
STRUCTURE AND DIMENSION
- STATUS INDICATORS
INSTALLATION
- DIP SWITCH SETTING
SPECIFICATION
WARRANTY STATEMENT
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

PROJECTA PMDC-30 DC to DC Charger

Product Information

Product Name: INTELLI DC-DC CHARGER (Intelli-Jay Integration)
Model Number: PMDC-30 (C4975F)
Manufacturer: Projecta

Product Features:

30 Amp output DC to DC charger
Designed to be integrated with the Intelli-Jay battery management system
Comes with stripped & tinned, labelled input and output wiring for ease of installation
Charging efficiency of up to 96%
Supports communication of RS485
Microprocessor controlled charging algorithm with variable absorption charging timer
Battery temperature compensation
De-rate curve against temperature increase

Product Usage Instructions

Connect the PMDC-30 to the positive and negative terminals of the alternator ( Connectors 1 and 2 )
If using an auxiliary battery, connect the positive terminal of the auxiliary battery to Connector 3 (AUX BAT) , and connect the negative terminals of both the auxiliary battery and the motor battery to Connector 4 (BAT-)
If using RS485 communication, connect the RS485 communication cable to Connector 5 (COM)
If using a battery temperature sensor, connect the black, white, and red cables of the sensor to Connectors 6, 7, and 8 (BAT-, Temp, and V-Sen) respectively
Set the desired output current using the dip switch located at Connector 9 (Dip switch for output current setting)
Set the battery type using the dip switch located at Connector 10 (Dip switch for battery type setting)
Ensure proper fuse specifications are followed for the alternator ( 30A/32VDC ) and the auxiliary battery ( 20A/32VDC )

Please refer to Chapter 4.6 of the user manual for detailed instructions on setting the output current and battery type. For more information and technical support, you can contact Projecta at 1800 294 294 or visit their website https://www.caravansplus.com.au.

GENERAL & SAFETY INFORMATION

This section contains important safety and operation instructions. Please read and retain this manual for future reference.

The PMDC-30 should be installed by a qualified Auto Electrician with knowledge of caravan electrical systems. The following recommendations are to be conducted prior to installation:

The unit MUST not be disassembled for Safety and Warranty reasons.
PMDC-30 is designed for internal installation ONLY.
Recommended cable size for input and output connections to unit is minimum 6mm2. Output charging current of the PMDC-30 charge booster will depend on wire size of the auxiliary circuits in the Charging Vehicle and Caravan.
Check and verify the input voltage is within the specifications of the unit. (Refer to Specification table)
Check and confirm the circuit connections to the Alternator or Vehicle battery and Input to the Intelli-Jay transformer polarities are correct.
Use the shortest possible cable lengths to connect the Input and Output circuits to the unit.
Ensure there’s sufficient ventilation around the heatsink of the unit

INTRODUCTION

GENERAL INTRODUCTION

The PMDC-30 is a 30 Amp output DC to DC charger, designed to be integrated with the Intelli-Jay battery management system.
It comes with stripped & tinned, labelled input and output wiring, for ease of installation.

FEATURES

Non-isolation design with max efficiency 96%.
Euro-6 engine (Smart alternator) compatible
Built in multi-stage charging algorithm.
Built-in automatic temperature and voltage compensated charging
Plug and Play for easy installation
Built-in fuse protection
Built-in Heat Sink for cooling
RS485 communication port for future options and upgrades
Protection against input/output over voltage, output over current, output short circuit, internal over temperature, battery over temperature
With adjustable current outputs 15A/20A/25A (Default)/30A via Dip Switches 1 & 2
With selectable Battery Type via Dip Switches 3 & 4

BLOCK DIAGRAM

Figure 2-1: Block Diagram of PMDC-30 $PROJECTA-PMDC-30-DC-to-DC-Charger-fig- $1$$

The charging efficiency of the PMDC-30 is up to 96%.
PMDC-30 also supports communication of RS485.

PMDC-30 will treat it as conventional engine rather than Euro 6 engine.

Alternator type	Alternator input voltage	Working state
Conventional alternator	12.8V	ON
12.0V	OFF

MULTI STAGE CHARGING ALGORITHM
PMDC-30 is able to charge House battery through the Intelli-Jay transformer quickly and fully. Microprocessor controlled charging algorithm with variable absorption charging timer to guarantee the optimal charging for batteries of different discharged states.

Figure 2-2: Charging Algorithm

$PROJECTA-PMDC-30-DC-to-DC-Charger-fig- $2$$

BATTERY TEMPERATURE COMPENSATION
Battery temperature is a key factor in correct charging, the charging formula must be adjusted (automatically and in real time) according to the actual battery temperature to ensure that battery are fully charged but not overcharged or undercharged. All charging voltages recommended by battery manufacture are in fact only applied at 20°C – 25°C. The BTS (Battery Temperature Sensor) terminated to PMDC-30 measures the temperature of battery and automatically makes adjustments at real time to properly charge your batteries at the default compensation rate of -3mv/°C/cell.
If the BTS is not present/connected, the PMDC-30 will use 25°C as default setting.

Figure 2-3: Battery Temperature Sensor (BTS)

DE-RATE CURVE AGAINST TEMPERATURE INCREASE
PMDC-30 will monitor internal temperature to decide output power. It will de- rate its output power against temperature increasing. Below is a curve to reflect the change of output power with temperature increase.

Figure 2-4: De-rate curve against temperature increase

STRUCTURE AND DIMENSION

EXTERIOR AND DIMENSION

Figure 3-1: PMDC-30 front view

$PROJECTA-PMDC-30-DC-to-DC-Charger-fig- $5$$

Figure 3-2: PMDC-30 dimensions

$PROJECTA-PMDC-30-DC-to-DC-Charger-fig- $6$$

CONNECTORS AND TERMINALS

Figure 3-3: Connectors and terminals

Table 3-1: Connectors and terminals guide

No.| Print| PMDC- 30| Remarks| Circuit colours and labelling
---|---|---|---|---
__

1

2

__

4

| 1| Dip switch for output current setting| __

Details of setting can be found as Chapter 4.6

|
2
3| Dip switch for battery type setting
4
__

5

Table 3-2: Fuse specification

No.| Print| Specification| Colour| Quantity| Protection for
---|---|---|---|---|---
6| Alternator| 30A/32VDC for PMDC-30| Amber| 2| Input from alternator
7| AUX BAT| 20A/32VDC| Yellow| 2| Output to charge auxiliary battery

STATUS INDICATORS

Table 3-3: LED codes

No.	Print	Colour	Status	Description
1	Power	Green	ON	Working normal
OFF	No working or Low Power Mode

__

3

| __

Alternator

| __

Green

| ON| Motor battery voltage in the range
Flashing| Motor battery voltage high
OFF| Motor battery voltage low
__

4

| __

Charge

| __

Green

| ON| Charging battery at bulk or absorption stage
Flashing| Charging battery at float stage
OFF| No charging to auxiliary battery
__

__

5

| __

__

Fault

| __

__

Red

| __

ON

| 1. PMDC-30 over temperature

2. Motor battery voltage high

3. Output to auxiliary battery short circuit

Flashing| 1. Auxiliary battery over temperature or under temperature
OFF| No fault

INSTALLATION

MATERIAL CHECKING
Before installation, check that the product is in good physical condition.

Please check the item with the list attached in the box.

PROPER INSTALLATION LOCATION

PMDC-30 is designed with IP20 and for internal installation ONLY.
The temperature at the casing and heat sink of PMDC-30 can be as high as 60°C during operation.
Ensure PMDC-30 is installed away from flammables and explosives.
Please have the installation away from inflammable and explosive goods.
Ensure PMDC-30 is installed out of reach of children.
Ensure mounting surface is flat and rigid.

Never install PMDC-30 in a sealed enclosure with battery.

INSTALLATION SPACE
For adequate ventilation, it is important to leave space around where the PMDC-30 is installed. See recommended spacing dimensions below.

Figure 4-1: The required dimensions for ventilation

$PROJECTA-PMDC-30-DC-to-DC-Charger-fig- $8$$

MOUNTING HOLES
Find an appropriate mounting surface, flat and rigid. Drill mounting holes per the dimensions below.

Figure 4-2: Drill holes for mounting

$PROJECTA-PMDC-30-DC-to-DC-Charger-fig- $9$$

DIP SWITCH SETTING

Table 4-1: Dip switch setting for output current

Output Current settings

Pin 1| Pin 2| Charge current (Max Amps)
OFF| OFF| 30
OFF| ON| 25 (Default)
ON| OFF| 20
ON| ON| 15

Table 4-2: Dip switch setting for battery type

Dip switch for battery type setting| Battery type| Absorption charging voltage| Float charging voltage
---|---|---|---
Pin 3| Pin 4
OFF| OFF| AGM| 14.6V| 13.5V
OFF| ON| GEL| 14.2V| 13.8V
ON| OFF| LFP| 14.4V| 13.5V
__

ON

| __

ON

| WET

(Default setting)

| __

14.8V

| __

13.8V

Do not connect PMDC-30 to AC Mains
Please ensure the connections are tight and have correct polarity.
Damages caused by improper installation may void warranty.

SPECIFICATION

Model Number	PMDC- 30

• Over load

• Short circuit

WARRANTY STATEMENT

Brown & Watson International Pty. Ltd. (“BWI”) of 1500 Ferntree Gully Road, Knoxfield, Vic., telephone 1800 294 294, warrants that all products described in its current catalogue will under normal use and service be free of failures in material and workmanship for a period of three (3) year from the date of the original purchase by the customer as marked on the invoice (see elsewhere for specific warranty period). This warranty does not cover ordinary wear and tear, abuse, alteration of products or damage caused by the purchaser.

To make a warranty claim the consumer must deliver the product at their cost to the original place of purchase or to any other place which may be nominated by either BWI or the retailer from where the product was bought in order that a warranty assessment may be performed. The consumer must also deliver the original invoice evidencing the date and place of purchase together with an explanation in writing as to the nature of the claim. If the claim is determined to be for a minor failure of the product then BWI reserves the right to repair or replace it at its discretion. If a major failure is determined the consumer will be entitled to a replacement or a refund as well as compensation for any other reasonably foreseeable loss or damage. This warranty is in addition to any other rights or remedies that the consumer may have under State or Federal legislation.

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 of acceptable quality and the failure does not amount to a major failure.

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