Progressive Dynamics PD9145AL 45 Amp Lithium Power Converter Installation Guide
- September 24, 2024
- Progressive Dynamics
Table of Contents
PD9145AL 45 Amp Lithium Power Converter
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Specifications
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Model: PD9100 / 9200 Series Power Converter
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Manufacturer: www.progressivedyn.com
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Input Voltage Range: 105-130 VAC
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Output Voltage: 13.6 VDC for 12V models, 27.2 VDC for 24V
models -
Charging Modes: Normal, Boost, Storage
Product Usage Instructions
Installation Instructions
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Secure the converter firmly to the mounting surface.
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Connect chassis ground lug to the wire found on the unit
base. -
Disconnect the battery from both positive and ground
cables. -
Connect battery ground (-) to converter NEG (-).
Features
-
Multiple Battery Charging: The converter can
charge multiple batteries simultaneously and even different
capacity batteries. -
GFCI Protection: Provides low ground fault
leakage, allowing safe use of RV’s AC outlets. -
Reverse Battery Protection: Prevents damage
due to cross-connected battery leads, with blown fuses as the only
consequence.
General Operation
The converter provides clean power from input voltages ranging
from 105-130 VAC. It can be used with a battery or power sensitive
electronics directly with filtered DC voltage. Ensure proper input
voltage for full rated capacity output.
Cautions
-
Use the converter only to recharge lithium iron phosphate
batteries, not lead/acid batteries. -
When storing the vehicle for extended periods, disconnect the
batteries unless using a TCMS Charge Wizard; reconnect monthly to
maintain charge.
9200 Series Details
The 9200 series provides full rated load for load, battery
charging, or both. It offers nominal voltage outputs of 13.6 VDC
for 12V models and 27.2 VDC for 24V models, with three operating
modes (normal, boost, storage) based on battery voltage levels.
FAQ
Q: What should I do if the reverse battery protection fuses are
blown?
A: Check battery connection before replacing fuses and ensure
using the same type and rating as the original fuses to prevent
damage.
Q: Can I install the converter in compartments with batteries
or flammable materials?
A: No, prevent fire or explosion by not installing in
compartments containing batteries or flammable materials.
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Installation and Operation Guide for PD9100 / 9200 Series Power Converter
www.progressivedyn.com
110953F
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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.
Torque Data DC Lugs: 30 50 IN LBS Battery Ground Lug: 25 35 IN LBS DO NOT
REMOVE TERMINAL BLOCK SCREWS
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.
And PD9100L 2 stage)
CAUTION RISK OF FIRE:
Chassis bonding wire must be a separate wire ran directly
from the grounding lug provided on the converter. DO
NOT connect output negative to chassis using the same
wire.
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FEATURES
MULTIPLE BATTERY CHARGING… INTELIPOWER 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 (14.4 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 14.4 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 Wizardis 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
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PD9130(L) Input: 105-130 VAC 60 Hz
500 Watts Output: 13.6 VDC, 30 Amps (9130L) 14.4 VDC, 30 Amps Dimensions:
4.5H x 8.25L x 7.25W
Weight: 4.5lbs
PD9_80A(L) Input: 105-130 VAC 60 Hz
1300 Watts Output: 13.6 VDC, 80 Amps (9180AL) 14.4 VDC, 80 Amps Dimensions:
3.6H x 8L x
9W Weight: 6.0lbs
PD9_45(L) Input: 105-130 VAC 60 Hz
725 Watts Output: 13.6 VDC, 45 Amps (9145L) 14.4 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) 14.4 VDC, 60 Amps Dimensions: 3.6H x 8L
x 9W Weight: 5.8lbs
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
TROUBLE SHOOTING GUIDE
PD9_70 Input: 105-130 VAC 60 Hz
1250 Watts Output: 13.6 VDC, 70 Amps
(9170L) 14.4 VDC, 70 Amps Dimensions: 3.6H x 8L
x 9W Weight: 5.8lbs
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
PROBLEM 1. No Output
POSSIBLE CAUSES Proper AC power not connected
External Fuses Blown
ACTION Connect power supply Check AC distribution panel for proper operation
Check for reverse polarity
Replace fuses with same type and rating
2. External Fuses Blown 3. Low Output
Short Circuit Unit has shutdown due to overheating
Unit has shutdown due to over voltage (Also see Item 4 below) (No over voltage
protection for 230V units)
Reverse Battery Hook Up Excessive load for converter Input voltage not between
105-130 VAC
Trace circuits for possible fault Check air flow Allow unit to cool Check input voltage Converter will shut down if the input voltage exceeds 132 Volts Correct input voltage Correct hook up and replace fuses with same type and rating Reduce load requirements or install larger converter 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 Unit has shutdown due to over voltage. Generator, works on Shore Power
Add another load to the generator, this may reduce the “spikes” to an acceptable level
Some generators exhibit excessive voltage Contact generator manufacturer for possible defect in the spikes on the AC power output, this may cause generator the over voltage protection to shut the unit down
Please refer to website for further trouble shooting information. See website www.progressivedyn.com for more troubleshooting information and return instructions.
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
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