Progressive Dynamics PD9100 Power Converter User Guide

Progressive Dynamics PD9100 Power Converter

Product Information

The PD9100 / 9200 Series Power Converter is a versatile device designed for installation and use in recreational vehicles (RVs) and other similar applications. It features a 2-stage charge profile (available on select models) and is manufactured by Progressive Dynamics, a leading provider of power conversion solutions.

Features

• Multiple Battery Charging: The INTELIPOWER converters have the capability to charge multiple batteries simultaneously, including a combination of batteries with different capacities.
• GFCI Protection: The INTELI-POWER converters offer the lowest ground fault leakage, ensuring safe utilization of the RV’s AC outlets without interrupting the power source.
• Reverse Battery Protection: The converter is equipped with reverse battery protection, preventing damage in case of cross-connected battery leads. In such instances, only the fuses will blow, avoiding converter damage. Replacement fuses are readily available at automotive stores.

General Operation: The INTELI-POWER series converter is designed to provide clean power from input voltages ranging between 105-130 VAC. While primarily intended for use with a battery, it can also supply filtered DC voltage to power sensitive electronics without the need for a battery or additional filtering. The converter delivers its full load rated capacity at normal input voltages, but may not provide full output capacity at input voltages below 105 VAC.

Caution: The 9100AL series converter/chargers are specifically designed for recharging lithium iron phosphate batteries. They should not be used to recharge lead/acid batteries. When storing the vehicle for extended periods, it is recommended to disconnect the batteries unless a TCMS Charge Wizard is attached. Reconnecting the battery once a month helps maintain a full charge.

Warning: To prevent fire or explosion, do not install the power converter in compartments containing batteries or flammable materials.

INSTALLATION INSTRUCTIONS

NOTES:

• Horizontal mounting of the power converter, is recommended although it can be mounted in any position that provides unobstructed ventilation to the fan and vent holes.
• The OEM should test the power converter under full load conditions in its intended mounting location. This will insure that there is sufficient unobstructed ventilation to the converter allowing it to operate at its maximum rated load. Failure to provide adequate ventilation to the converter will cause the converter output to be reduced as it responds to ambient conditions.
• The INTELI-POWER converters are not designed for zero clearance compartments.
• Use a 5/32” hex driver to tighten the output screws. Do not exceed 50 in-lbs. torque on the output terminals.
• The INTELI-POWER converters are not weather tight or designed for wet mounting locations. They must be protected from direct contact with water.
• Avoid the introduction of foreign materials into the case as this could damage or cause a malfunction of the converter.

Installation Steps

1. Secure converter firmly to mounting surface.

2. Connect chassis ground lug (found on unit base) to chassis.

   • Ground wire to be between 6 and 12AWG wire.

3. Disconnect battery from both positive (+) and ground (-) cables.

4. Connect battery ground (-) to converter NEG (-) lug.

   • Conductor to be between 2 and 14AWG (follow all applicable codes when sizing conductor)

5. Disconnect any optional pendants or modules.

6. Plug converter into appropriate outlet.

7. Using a DC voltmeter, verify converter output. If no output is present, refer to the trouble shooting guide in this manual and on the website.

8. Disconnect power to converter

9. Connect battery positive (+) to converter POS (+) lug.

   • Conductor to be between 2 and 14AWG (follow all applicable codes when sizing conductor)
     Note: When connecting battery to converter POS (+), a spark may occur. This is normal.

10. Reconnect cables.

11. Reconnect any optional pendants or modules.

12. Reconnect power to converter.

Torque Data

• DC Lugs: 30 – 50 IN LBS
• Battery Ground Lug: 25 – 35 IN LBS

DO NOT REMOVE TERMINAL BLOCK SCREWS

FEATURES

• MULTIPLE BATTERY CHARGING… INTELI-
  POWER converters have the capability of charging multiple batteries at the same time! They can even charge a combination of different capacity batteries.

• GFCI PROTECTION… INTELI-POWER converters have the LOWEST ground fault leakage. The user can confidently utilize the RV’s AC outlets without concern of ground fault interruption of the facilities power source.

• REVERSE BATTERY PROTECTION prevents damage if battery leads are cross connected. Since the only consequence of cross connection is a blown fuse, damage to or possible replacement of the converter is avoided. Cross connection of battery leads is the only thing that will blow these fuses. Replacement fuses are available at any automotive store.

GENERAL OPERATION

• The INTELI-POWER series converter will supply “clean” power from input voltages that range from 105-130 VAC.

• The INTELI-POWER series of converters are designed for use with a battery; however, filtered DC voltage can power sensitive electronics without the need for a battery or other filtering.

• At normal input voltages the full load rated capacity is available. At input voltages less than 105 VAC the converter may not supply full rated output capacity.

  • 9100 / 9100L/9100AL – The full rated load is available for load, battery charging or both. When charging the battery, the converter has a nominal voltage output of 13.6 VDC (14.6 VDC for 9100L series) for 12 volt models and 27.2 VDC
    (28.55 VDC for 9100L series) for 24 volt models.

  • 9100L/9100AL (2-Stage) – When charging the battery, the converter has a nominal voltage output of 14.6 VDC. When the converter senses an output current drop below a preset level, the converter will automatically switch to IDLE mode and the voltage output will drop to 13.6VDC

CAUTION

• The 9100AL series converter/chargers are designed to recharge lithium iron phosphate batteries.
• DO NOT USE TO RECHARGE LEAD/ACID BATTERIES!
• When storing the vehicle for extended periods of time, disconnect the batteries unless a TCMS Charge Wizard is attached. Reconnect battery once a month to maintain a full charge.

CAUTION: IF THE REVERSE BATTERY PROTECTION FUSES ARE BLOWN DURING INSTALLATION, CHECK TO SEE THAT THE BATTERY HAS BEEN CONNECTED PROPERLY BEFORE REPLACING THE FUSES. REPLACE THE FUSES ONLY WITH THE SAME TYPE AND RATING AS THE ORIGINAL FUSES. USING OTHER FUSES MAY RESULT IN CONVERTER DAMAGE, VEHICLE DAMAGE, INJURY OR OTHER CONSEQUENCES (SEE WARRANTY).

WARNING:: THIS EQUIPMENT EMPLOYS COMPONENTS THAT TEND TO PRODUCE ARCS OR SPARKS – TO PREVENT FIRE OR EXPLOSION DO NOT INSTALL IN COMPARTMENTS CONTAINING BATTERIES OR FLAMMABLE MATERIALS.

9200 – The full rated load is available for load, battery charging or both. When charging the battery, the converter has a nominal voltage output of 13.6 VDC for 12 volt models and 27.2 VDC for 24 volt models. The system will sense voltage on the battery and automatically select one of three operating modes (normal, boost and storage) to provide the correct charge level to the batteries.

• BOOST MODE: If the voltage drops below a preset level the output voltage is increased to approximately 14.4 VDC (28.8 VDC for 24 volt models) to rapidly recharge the battery.
• NORMAL MODE : Output voltage set at approximately 13.6 VDC (27.2 VDC for 24 volt models).
• STORAGE MODE: If there is no significant battery usage for 30 hours the output voltage reduces to 13.2 VDC (26.4 VDC for 24 volt models) for minimal water usage. In storage mode, the output voltage increases to 14.4 VDC (28.8 DC for 24 volt models) for approximately 15 minutes every 21 hours to help prevent sulfation of the battery plates.

CAUTION: IT IS IMPORTANT THAT THE FLUID LEVEL OF ANY CONNECTED BATTERIES BE CHECKED ON A REGULAR BASIS. ALL BATTERIES WILL “GAS” AND LOSE SOME FLUIDS WHEN CONTINUOUSLY CONNECTED TO ANY CHARGING SOURCE

PD9130(L)

Input: 105-130 VAC 60 Hz

500 Watts

Output: 13.6 VDC, 30 Amps

(9130L) – 14.6 VDC, 30 Amps

Dimensions: 4.5H x 8.25L x 7.25W Weight: 4.5lbs

| PD9_45(L)

Input: 105-130 VAC 60 Hz

725 Watts

Output: 13.6 VDC, 45 Amps

(9145L) – 14.6 VDC, 45 Amps

Dimensions: 4.5H x 8.25L x 7.25W Weight: 4.5lbs

| PD9_60(L)

Input: 105-130 VAC 60 Hz

1000 Watts

Output: 13.6 VDC, 60 Amps

(9160L) – 14.6 VDC, 60 Amps

Dimensions: 3.6H x 8L x 9W Weight: 5.8lbs

| PD9_70

Input: 105-130 VAC 60 Hz

1250 Watts

Output: 13.6 VDC, 70 Amps

(9170L) – 14.6 VDC, 70 Amps

Dimensions: 3.6H x 8L x 9W Weight: 5.8lbs

---|---|---|---
PD9_80A(L)

Input: 105-130 VAC 60 Hz

1300 Watts

Output: 13.6 VDC, 80 Amps

(9180AL) – 14.6 VDC, 80 Amps

Dimensions: 3.6H x 8L x 9W Weight: 6.0lbs

|  | PD9_25- 24(L)

Input: 105-130 VAC 60 Hz

900 Watts

Output: 27.2 VDC, 25 Amps

(9125-24L) – 28.55 VDC, 25 Amps

Dimensions: 4.5H x 8.25L x 7.25W Weight: 4.5lbs

| PD9_40- 24A(L)

Input: 105-130 VAC 60 Hz

1300 Watts

Output: 27.2 VDC, 40 Amps

(9140-24AL) – 28.55 VDC, 40

Amps Dimensions: 3.6H x 8L x 9W

Weight: 6.0lbs

TROUBLE SHOOTING GUIDE

Check AC distribution panel for proper operation
External Fuses Blown| Check for reverse polarity
Replace fuses with same type and rating
Short Circuit| Trace circuits for possible fault
Unit has shutdown due to overheating| Check air flow
Allow unit to cool
Unit has shutdown due to over voltage (Also see Item 4 below)

(No over voltage protection for 230V units)

| Check input voltage
Converter will shut down if the input voltage exceeds 132 Volts
Correct input voltage
2. External Fuses Blown| Reverse Battery Hook Up| Correct hook up and replace fuses with same type and rating
3. Low Output| Excessive load for converter| Reduce load requirements or install larger converter
Input voltage not between 105-130 VAC| Correct input supply voltage
Bad battery cell(s)| Replace battery
Mild Overheating| Check air flow
Allow unit to cool
4. Intermittent or no Output on Generator, works on Shore Power| Unit has shutdown due to over voltage.| Add another load to the generator, this may reduce the “spikes” to an acceptable level
Some generators exhibit excessive voltage spikes on the AC power output, this may cause the over voltage protection to shut the unit down| Contact generator manufacturer for possible defect in the generator

Please refer to website for further trouble shooting information.
See website www.progressivedyn.com for more troubleshooting information and return instructions.

WARRANTY

LIMITED WARRANTY: Progressive Dynamics, Inc. warrants its power control center to be free from defects in material or workmanship under normal use and service for a period of two years from the original date of purchase; and limits the remedies to repair or replacement.

This warranty is valid only within the continental limits of the United States and Canada.
See website www.progressivedyn.com for more warranty information and return instructions

References

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