PROJECTA Intelli Grid PMDC-30 DC Charger Instruction Manual
- June 13, 2024
- Projecta
Table of Contents
PROJECTA Intelli Grid PMDC-30 DC Charger
Product Information
- Product Name: INTELLI DC-DC CHARGER (Intelli-Jay Integration)
- Product Number: PMDC-30 (C4975F)
GENERAL & SAFETY INFORMATION
If you need technical help, contact Projecta on 1800 294 294.
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.
BLOCK DIAGRAM
Figure 2-1: Block Diagram of PMDC-30
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: Conventional alternator
- Alternator input voltage: 12.8V – 12.0V
- Working state: ON – 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
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.
| Print| Specification| Colour| Remarks
---|---|---|---|---
1| PMDC-30 Alternator| Connects to positive of Alternator| Red + Label Aux+|
Or connects to positive of motor battery
2| BAT-| Connects to negative of Alternator| Red + Label Vehicle Batt+| Or
connects to positive of motor battery
3| AUX BAT| Connects to positive of auxiliary battery| | Connect to IntelliJay
4| BAT-| Connects to negative and negative of auxiliary battery| | Connect to
IntelliJay
5| COM| For communication of RS485| | Not Connected
6| Dip switch for output current setting| | | Details of setting can be found
as Chapter 4.6
7| Dip switch for battery type setting| | |
8| BAT5 Temp| Connects to BTS’ black cable| | For battery temperature sensing
9| V-Sen| Connects to BTS’ white cable| | For voltage sensing
10| | Connects to BTS’ red cable| | RED Ring Terminal connect to Battery +ve
STATUS INDICATORS
| No. | Colour | Status | Description | |
|---|---|---|---|---|
| 1 | Power | Green | ON | Working normal |
| 2 | Power | Green | OFF | No working or Low Power Mode |
| 3 | Motor battery voltage | ON | In the range |
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
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
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
PMDC-30 dimensions
CONNECTORS AND TERMINALS
No.| Print| PMDC- 30| Remarks| Circuit
colours and labelling
---|---|---|---|---
__
1
| Alternator| Connects to positive of Alternator| Or connects to positive of
motor battery| Red + Label “Aux+”
BAT-| Connects to negative of Alternator| Or connects to positive of motor
battery| Black – Label “Aux-”
__
2
| AUX BAT| Connects to positive of auxiliary battery| Connect to IntelliJay|
Red + Label “Vehicle Batt+”
BAT-| Connects to negative and negative of auxiliary battery| Connect to
IntelliJay| Black – Label “Vehicle Batt-”
3| COM| For communication of RS485| Not Connected|
__
__
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
| BAT-| Connects to BTS’ black cable| For battery temperature sensing| RED
Ring Terminal connect to Battery +ve
Temp| Connects to BTS’ white cable
V-Sen| Connects to BTS’ red cable| For voltage sensing
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
| No. | 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
MOUNTING HOLES
Find an appropriate mounting surface, flat and rigid. Drill mounting holes per
the dimensions below.
Figure 4-2: Drill holes for mounting
DIP SWITCH SETTING
Output Current settings
Pin 1| Pin 2| Charge current (Max Amps)
OFF| OFF| 30
OFF| ON| 25 (Default)
ON| OFF| 20
ON| ON| 15
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 |
|---|
Electrical
Alternator input voltage range (Intelligent type)| 12~16VDC
Automatic activation D+| Yes
Absorption charge voltage| Default Setting: 14.8VDC
Float charge voltage| Default Setting: 13.8VDC
Charge current| 30A
Total current of load and charging| 30A
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
• Over load
• 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 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.
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
Fax : (09) 579 1192