Progressive Dynamics PD9145AL 45 Amp Lithium Power Converter Installation Guide

PD9145AL 45 Amp Lithium Power Converter

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Specifications

• Model: PD9100 / 9200 Series Power Converter

• Manufacturer: www.progressivedyn.com

• Input Voltage Range: 105-130 VAC

• Output Voltage: 13.6 VDC for 12V models, 27.2 VDC for 24V
  models

• Charging Modes: Normal, Boost, Storage

Product Usage Instructions

Installation Instructions

1. Secure the converter firmly to the mounting surface.

2. Connect chassis ground lug to the wire found on the unit
   base.

3. Disconnect the battery from both positive and ground
   cables.

4. 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

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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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