PROJECTA PMDCS30 DC-DC Battery Charger Instruction Manual

PROJECTA PMDCS30 DC-DC Battery Charger

Product Information

The INTELLI-GRID 12V DC-DC Charger is a versatile charger designed to integrate with INTELLI-RV or INTELLI-GRID battery/powermanagement systems. It can also be used as a standalone dual battery charger. The charger comes with stripped and tinned, labelled input and output wiring for easy installation.

Charging Efficiency
The charging efficiency of the PMDCS is up to 96%. PMDCS units also support communication of RS485.

Multi-Stage Charging Algorithm
The charging algorithm is microprocessor-controlled with a variable absorption charging timer to ensure optimal charging for batteries with varying degrees of discharge.

Battery Temperature Compensation
The PMDCS charger has a built-in Battery Temperature Sensor (BTS) for temperature compensation. It monitors the battery temperature and adjusts the charging process accordingly.

De-rate Curve Against Temperature Increase
The PMDCS charger will de-rate its output power against temperature increase. The following curve shows how the output power changes with an increase in temperature.

Product Usage Instructions

Connectors and Terminals

sensing
7| V-Sen| Connects to BTS’ white cable for voltage sensing
8| RED| Ring Terminal connects to Battery +ve

Fuse Specification

If you require technical assistance, please contact Projecta on 1800 294 294.

GENERAL & SAFETY INFORMATION
This section contains important safety and operation instructions. Please read and retain this manual for future reference. The DC-DC charger should be installed by a qualified Auto Electrician with knowledge of automotive electrical systems. The following recommendations are to be conducted before installation:

• The unit MUST not be disassembled for Safety and Warranty
• The DC-DC charger is designed for internal installation
• Recommended cable size for input and output connections to the unit need to be Output charging current of the DC-DC charger will depend on the wire size of the auxiliary circuits in the Charging Vehicle.
• Check and verify the input voltage is within the specifications of the (Refer to Specification table).
• Check and confirm the circuit connections to the Alternator or Vehicle battery and Input to the INTELLI-GRID / INTELLI-RV (if connected) and that the polarity is correct.
• Use the shortest possible cable lengths to connect the Input and Output circuits to the unit.
• Ensure there is sufficient ventilation around the heatsink of the

INTRODUCTION

GENERAL INTRODUCTION
PMDCS DC-DC chargers are designed to integrate with INTELLI-RV or INTELLI- GRID battery/power management systems, but they can also function as standalone dual battery chargers. They come with stripped and tinned, labeled input and output wiring for ease of installation.

FEATURES

• Adaptive charge – adapts to smaller cables or excessive runs by adjusting the charge rate to avoid overloading wiring.
• Non-isolation design with a maximum efficiency of 96%.
• Euro-6 engine (smart alternator) compatible.
• Built-in multi-stage charging algorithm.
• Built-in automatic temperature and voltage-compensated charging.
• 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, and battery over temperature.
• Adjust current outputs and select battery type via dip switches.

BLOCK DIAGRAM

The charging efficiency of the PMDCS is up to 96%. PMDCS units also support the communication of RS485.

PMDCS will treat it as a conventional engine rather than a Euro 6 engine.

Alternator type| Alternator input voltage| Working state
---|---|---
Conventional alternator| 13.2V with 10-second delay on| ON
12.8V with 60-second delay off| OFF
D+ wired| 11.7V| ON
11.7V| OFF

Note : If D+ is used and you want to switch to conventional alternator mode, disconnect D+ disconnect the PMDCS from the house/auxiliary battery, and reconnect. This will reset the system.

MULTI-STAGE CHARGING ALGORITHM
The charging algorithm is microprocessor-controlled with a variable absorption charging timer to ensure optimal charging for batteries with varying degrees of discharge.

BATTERY TEMPERATURE COMPENSATION
Correct charging of the battery is affected by its temperature, so the charging formula must be adjusted automatically and in real time based on the actual battery temperature to ensure that the battery is fully charged but not overcharged or undercharged. All charging voltages recommended by battery manufacturers are applied at 20°C – 25°C.

The BTS (Battery Temperature Sensor), terminated to the PMDCS, measures the temperature of the battery and automatically makes adjustments in real time to properly charge the batteries at the default compensation rate of -3mV/°C/cell. If the BTS is not present or connected, the PMDCS will use 25°C as the default temperature setting.

DE-RATE CURVE AGAINST TEMPERATURE INCREASE
The PMDCS charger will monitor the internal temperature to decide output power. It will de-rate its output power against temperature increases. The following curve shows how the output power changes with an increase in temperature

STRUCTURE AND DIMENSION

EXTERIOR AND DIMENSION

CONNECTORS AND TERMINALS

Table 3-1: Connectors and terminals guide

No.| Print| PMDCS| Remarks| Circuit colors and labeling
---|---|---|---|---
__

1

| Alternator| Connects to positive of Alternator| Connects to the positive battery post| Red + Label “Aux+”
BAT-| Connects to the negative of the Alternator| Connects to the negative battery post| Black – Label “Aux-”
__

2

| AUX BAT| Connects to positive of the auxiliary battery| | Red + Label “Vehicle Batt+”
BAT-| Connects to negative and negative of the auxiliary battery| | Black – Label “Vehicle Batt-”
3| COM| For communication of RS485| Not Connected|
__

__

4

| 1| Only used on PMDCS30-20| __

Details of the setting can be found in Chapter 4.6

|
2| Set on for 30Amp, off for 15Amps
3| Used to set battery chemistry
4
__

5

| BAT-| Connects to BTS’ black cable| For battery temperature sensing| RED Ring Terminal connects to Battery +ve
Temp| Connects to BTS’ white cable
V-Sen| Connects to BTS’ red cable| For voltage sensing

Table 3-2: Fuse specification

No.| Print| PMDCS30| PMDCS30- 20| PMDCS60| Protection for
---|---|---|---|---|---
6| Alternator| 30A/32VDC| 40A| Internal| Input from alternator
7| AUX BAT| 20A/32VDC| 20A| Internal| Output to charge auxiliary battery
N/A| Fridge| N/A| 15A| N/A| Fridge output

STATUS INDICATORS

Table 3-3: LED codes

No.| Print| Power| Fridge/Load| Alternator| Charge| Fault
---|---|---|---|---|---|---
4-2| Alternator Present| Green Light On| Green Light      Green Light Green Light Off                 Off                  Off|
4-3| Charger faulty| Green Light| Green Light| Green Light| Green Light| Red Light
On| Off| Off| Off| On
4-5| Alternator over voltage| Green Light| Green Light| Green| Green Light| Red Light
On| Off| Light Flash| Off| Flash
4-6| Fridge/Load Short Circuit| Green Light On| Green Light Flash| Green Light On| Green Light Off| Red Light On
4-7| Fridge/Load Output| Green Light| Green Light| Green Light| Green Light| Red Light
Overload| On| Flash| On| Off| On
4-9| Bulk Time out| Green Light| Green Light| Green Light| Green Light| Red Light
On| Off| On| Flash| Flash
4-12| Output Overvoltage| Green Light On| Green Light     Green Light Off Off| Green Light Flash| Red Light Flash
4-13| Fridge/Load output| Green Light On| Green Light     Green Light On On| Green Light On| Red Light Off
4-14| Softstart Charging| Green Light On| Green Light On| Green Light Flash| Green Light Flash| Red Light Off
4-15| Bulk charging| Green Light On| Green Light Off| Green Light On| Green Light Flash| Red Light Off
4-16| Absorption charging| Green Light On| Green Light Off| Green Light Flash| Green Light On| Red Light Off
4-17| Float charging (charged)| Green Light On| Green Light Off| Green Light On| Green Light On| Red Light Off
4-18| Recycle Mode| Green Light On| Green Light Off| Green Light Flash| Green Light Flash| Red Light Off

INSTALLATION

CHECK YOUR PRODUCT
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

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

Never install the DC-DC charger in a sealed enclosure with a battery.

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

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

WIRING DIAGRAM

PMDCS30 Recommended cables:

• Alternator positive/negative cable: 8 B&S, 8mm2 up to 9m, Fuse 80A
• Auxiliary positive/negative cable: 8 B&S, 8mm2 up to 9m
• D+ signal: >0.64mm2, Fuse 5A

PMDCS30-20 Recommended cables:

• Alternator positive/negative cable: 6 B&S, 14mm2 up to 9m, Fuse 125A
•  Auxiliary positive/negative cable: 8 B&S, 8mm2 up to 9m
• Load cables: 8 B&S, 8mm2, Fuse 80A
• D+ signal: >0.64mm2, Fuse 5A

PMDCS60 Recommended cables:

• Alternator positive/negative cable: 4 B&S, 20mm2 up to 9m, Fuse 175A
• Auxiliary positive/negative cable: 6 B&S, 14mm2 up to 9m, Fuse 125A
• D+ signal: >0.64mm2, Fuse 5A

DIP SWITCH SETTING

Table 4-1 : Dip switch setting for fridge operation for PMDCS30-20

when car not running) Ideal for Compressor fridges
ON| Load Relay On with Ignition Input (Vehicle Charging) Ideal for 3-way fridges

Table 4-2 : Dip switch setting for output current

Output Current settings

Pin 2| PMDCS30 & **PMDCS30- 20| PMDCS60**
OFF| 15A| 45A
ON| 30A (Default)| 60A (Default)

Table 4-3: 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 (Default setting)| 14.4V| 13.5V
OFF| ON| GEL| 14.1V| 13.5V
ON| OFF| LFP| 14.2V| 13.5V
ON| ON| WET| 14.7V| 13.5V

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

FRIDGE BYPASS MODE (PMDCS30-20 ONLY)

CONTINUOUS POWER MODE

NON-CONTINUOUS POWER MODE

SPECIFICATION

Electrical
Alternator input voltage range (Intelligent type)| 12~16VDC
Automatic activation D+| Yes
Absorption charge voltage| Default Setting: 14.4VDC
Float charge voltage| Default Setting: 13.5VDC
Charge current| <30A| <60A| <30A
The total current of load and charging| <30A| <60A| <50A
Maximum charging efficiency| 96%
Temperature compensation| Default Setting: -3mV/°C/cell
Voltage compensation| Yes
Charge algorithm| Premium II Multi-Stage
Protection| • Battery charger over temperature

• Overload

• Short circuit

Communication| RS485, RJ45 connector
Storage temperature| -40°C ~70°C
Operating temperature| -40°C ~70°C
Enclosure
Battery Connection| Cable with connector
Protection category| IP20
Weight| 1.0kg
Dimensions (hwd)| 18114852mm
Standards
Emission| ECE 10R-06, EN61000-6-1, EN61000-6-3

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 catalog will under normal use and service be free of failures in material and workmanship for two (2) years 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 so 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.

Distributed by AUSTRALIA Brown & Watson International Pty. Ltd. Knoxfield Victoria 3180 Phone : (03) 9730 6000 Fax : (03) 9730 6050 National Toll – Free : 1800 113 443

NEW ZEALAND OFFICE Griffiths Equipment Ltd. 19 Bell Avenue, Mount Wellington, Auckland 1060, New Zealand Phone : (09) 525 4575

IS528
Issue 1 13.02.23

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