D&R ELECTRONICS PDU-8S Bedienungsanleitung
Part NO: 212-0024-8S 1 September 24th, 2020
Power Distribuon Unit
PDU-8S
Installation / Operations Manual
Table of Contents
Applicable Models ........................................................ 2
Introduction ................................................................... 2
General Warnings.......................................................... 3
Unpacking &Pre-Installation Check ............................. 3
Installation & Mounting ............................................... 4
Wiring and Setup Instructions....................................... 4
Output Fuse Combinations............................................ 6
Timed Modes Of Operation ........................................ 12
Maintenance ................................................................ 13
Parts List ..................................................................... 13
Troubleshooting........................................................... 14
Product Specifications ................................................ 15
Warranty...................................................................... 16
Part NO: 212-0024-8S 2 September 24th, 2020
Applicable Models
PDU-8S
Introduction
The Power Distribution Unit (PDU) is a compact and convenient point of load power dis-
tribution product for installed electrical devices. By using this device and carefully plan-
ning the distribution of mobile equipment power feeds, complex independent wire runs
and unreliable fuse panel connections can be avoided.
The PDU-8S is directly connected to the vehicle battery and ground, thus providing a di-
rect easily traceable route to the input power source avoiding interfering with the vehicles
factory wiring harness. The specifics for safely connecting the PDU-8S to a vehicles
electrical system are outlined in the detailed instructions to follow.
Each circuit can be individually fused further reducing risk of damage to devices from
circuit overload. Each fused output has a red LED to indicate when a circuit fuse is
GOOD.
The PDU-8S unit provides two 50A high current outputs and up to 24 additional outputs
divided into “constant/battery”, “ignition controlled” and “timed” outputs to meet the
typical in-vehicle equipment installation requirements. These output features have the
following characteristics;
1) Constant/Battery Outputs:
There are 8 output connections each with individual fuses, that are on at all time
providing the PDU is connected to the battery.
2) Ignition Controlled Outputs:
The 8 output power connections, also individually fused provide +12V output
while the vehicle ignition is ON. Power will be immediately turned OFF at these
outputs when the vehicle is shut down and the ignition key removed (some vehi-
cles still maintain and “ignition ON” signal when the key is still in the ignition
switch) careful selection of the proper ignition control wire can help avoid this sit-
uation..
3) Timed Outputs:
There are 8 output power connections fit with individual fuses. These outputs are
ON while the ignition control signal is applied to the PDU, and will go through a
pre-set timed off sequence once the ignition is turned OFF. The time to OFF is us-
er selectable and is selected by the installer based on the system design.
The timed off sequence is also controlled by an onboard battery voltage monitor. If
the battery voltage becomes too low the timing sequence is interrupted and a shut
down of the timed outputs will begin. This feature prevents a total discharge of the
vehicle battery while the ignition is OFF and the equipment is in use.
Part NO: 212-0024-8S 3 September 24th, 2020
General Warning
1. The use of emergency warning devices does not ensure the safety of the operator. The
operator is responsible to ensure safe operation of the vehicle regardless of whether
the warning device is in operation or not
2. The effectiveness of this or any warning device is highly dependent on proper installa-
tion and maintenance. Read the manufactures instructions before installing and follow
all recommendations.
3. When in use the operator must ensure that the warning signal is visible and not ob-
structed by vehicle components (i.e. open trunk lid), people or other obstructions
4. This device is intended for use by authorized personnel only The user is responsibility
to ensure that all local, state/provincial and federal laws are being complied with.
D&R assumes no liability for any loss resulting from the use of this device.
5. The device must be installed so as not to reduce the output performance of vehicle sys-
tems
6. Placement of control switches must be so as to provide convenient reach for the opera-
tor without loosing eye contact with the road.
7. Emergency warning devices require high electrical voltages and/or currents. Properly
connect and ground all circuits. Shorting or improper grounding of this device may
caused personal injuring, vehicle damage or both
8. All operators should be properly trained in the operation of this device to ensure
both their and public safety
Unpacking & Pre-Installation Check
D&R Electronics Co. advises that you open and examine all shipments within 48 hours of
receipt. The Power Distribution Unit PDU is shipped pre-assembled and factory tested.
All necessary hardware for standard installation is included. Remove all components from
the shipping carton.
Use this pre-installation check list to verify your unit:
1. Confirm contents with the packing slip
2. Examine unit for damaged in transit (i.e. scratches, broken or bent connectors. etc).
Report any damage to the carrier immediately. Keep all shipping material
3. The unit is factory tested and a pre-installation check is not needed.
Part NO: 212-0024-8S 4 September 24th, 2020
Wiring and Setup Instructions
1. Good wiring practice and thorough knowledge of vehicle power system is required by the
installer of this and any other product.
2. Looms, grommet, cable ties or other installation hardware should be used to anchor and
protect wires
3. All wire should conform to the minimum wire size as specified by the manufacturer.
4. Splices should be minimized and made in a fashion so as to protect from corrosion to re-
duce loss of conductivity.
Warning
Installation and Mounting
1. Any device used inside a vehicle, may cause severe personal injury if not properly mounted
and secured. Objects used in the vehicle may become airborne during a collision or other
sudden changes in vehicle speed or direction, such as braking, acceleration or turns.
2. Be sure to mount unit through the steel of the vehicle. Avoid mounting through plastic or
other non-structural materials.
3. POINT OF INSTALLATION MUST NOT INTERFERE WITH DEPLOYMENT OF
VEHICLE AIR BAGS.
4. D&R Electronics recommends this and any of our other products be installed by quali-
fied professionals.
Warning
Mounting the PDU unit
The PDU-8S may be mounted anywhere inside the vehicle away from heat, moisture or the ele-
ments. NOTE the PDU is not watertight do not mount it in the engine compartment, on the ex-
terior of the vehicle or an area where moisture/dirt/ other contaminants can fall into the ex-
posed areas of the PDU.
Ensure that the mounting location is flat and the device is secured to solid vehicle body parts
To mount the PDU unit proceed as follows:
1. Determine an appropriate mounting location
2. Confirm there is adequate access and clearance for the wiring and its connections.
3. Secure the PDU with 4 self tapping mounting screws (not supplied).
Part NO: 212-0024-8S 5 September 24th, 2020
Note: The exact number of available connections varies by application, refer
to the specifications and typical output fusing combinations to ensure that the
safety and reliability of this product is not compromised.
Figure 1
Left side view of the PDU-8S showing the location of the high power Input and Output connectors.
The wiring to the PDU will be determined by the installers design of the power
distribution and wire routing for the installed equipment.
Fuses and wire for the screw terminal outputs are selected based on equipment
power requirements and their manufacturers recommendations. The maximum
fuse sizes and some possible combinations are shown in a table on the following
page Figure 2.
The fuses are indicated as 20A maximum, the x is no fuse or no connection and
the N/A means that the limit of that area has been reached with the indicated max-
imum fuse values and that spot is not available. Many combinations can be de-
rived based on the PDU specifications and the equipment power requirements.
The table in Figure 2 shows eight of these possible combinations, these can be
used as a starting point to help plan the power distribution for the intended appli-
cation.
NOTE: Interconnect Wire, Mounting Hardware, Fuses and any termination
or additional hardware mentioned in the installation procedure IS NOT
SUPPLIED. These items are industry standard and are provided by the
installer at the time of installation.
Part NO: 212-0024-8S 6 September 24th, 2020
Figure 2
Typical fuse and output combination showing maximum fuse ratings for 10A continuous loads,
the chart is read vertically the six possible combinations shown add to a total draw of 60A (the
maximum PDU Input rating) .
Output Fuse Combinations
TIMER 1x20A 20A 20A 20A
2xx20A 20A 20A
3xxx20A 20A
4xxxx20A
5xxxxN/A
6xxxxN/A
7xxxxN/A
8xxxxN/A
12V BATTERY 120A 20A 20A 20A 15A
220A 20A 20A 20A 15A
320A 20A 20A 20A 15A
420A 20A x15A 15A
5N/A N/A x10A 15A
6N/A N/A xN/A 15A
7N/A N/A xN/A N/A
8N/A N/A xN/A N/A
AND
IGNITION 120A 20A 20A 20A 20A
220A 20A 20A 20A 20A
320A 20A 20A x15A
420A 20A xx15A
5N/A xxx15A
6N/A xxxN/A
7N/A xxxN/A
8N/A xxxN/A
AND
PDU-8S outputs showing some possible fuse combinations
Part NO: 212-0024-8S 7 September 24th, 2020
Figure 3 - Input and High current output wiring diagram
Connecting the Battery Input (+12V IN) to the PDU
Figure 3 shows a typical wiring connection to the battery, both the +12V IN (input) and
GROUND IN (input) are wired directly to the battery terminals. This is the “best” method of
supplying reliable power to the installed equipment. If a good “solid” chassis Ground is availa-
ble then the GROUND IN terminal may be connected to the vehicle chassis close to the in-
stalled PDU. The interconnect wires must be 6 AWG if the installation power distribution will
be at or close to the maximum rating of the PDU (see specifications).
1. Run a 6 AWG wire lead from the Battery via a fusible link or circuit breaker rated at 80A to
the PDU-8S.
2. Cut the wire to length and strip 1/2” length of insulation from the end of the wire, insert the
bare wire into a suitable ring terminal (these are not provided the ring hole must clear a 1/4”
bolt), crimp or solder..
3. Connect as shown in Figure 3.
Connecting ground input to the PDU
1. Run a 6 AWG wire lead to the chassis of the vehicle, if necessary run this wire directly to
the battery negative terminal if a good low resistance chassis connection is not available
2. Prepare the 6 AWG Ground wire for connection to the PDU using the same procedure as
the battery input wire.
3. Connect as shown in Figure 3.
+12V IN
via 80A
circuit
breaker
VEHICLE
BATTERY
High Current +12V output
i.e. light & siren control
system
Battery voltage sense input connected directly to battery
terminals, this is necessary for proper PDU operation.
1A Fuse
Battery Sense Lines
Part NO: 212-0024-8S 8 September 24th, 2020
SPECIAL NOTES:
1. Making a good solid ground connection to the chassis requires the removal of the paint
right down to the shiny bare metal at the point of securing the ground wire to the chassis.
2. All ground returns for equipment connected to the PDU should terminate at the PDU using
the GROUND terminal block. To minimize wire bunching and exceeding the current capac-
ity of each screw terminal on the output block (15A max per screw connection) distribute
these return wires evenly across the whole GROUND block.
Connecting the Battery Voltage Monitor from the PDU
We recommend using 18 AWG stranded wire for this connection. The color for the wires
should be RED and BLACK, however if this is not available then two distinct colors should be
used. It is very important to maintain the correct polarity from the battery to the PDU sense in-
puts.
WARNING: Any wire connected directly to the battery should be fused, and located as
close as possible to the POSITIVE battery terminal. We recommend a 1A fuse inside an
inline weather resistant fuse-holder be used.
Connecting high Current (AMP) power outputs from the PDU
The PDU supplies two high current (+12V OUT) outputs which may be used to power high
current devices such as a lightbar or siren and light control system; this output uses the same
style of power connector as the input wire from the battery (Figure 1). Connection to these out-
puts are via 8 AWG power wires terminated with a ring terminal. These outputs are rated at
50A VDC continuous current and fused by a 70A MAXI fuse (MAX70 or AMT70 are the part
numbers for this fuse).
1. Leave the fuse out until the attached equipment is properly wired and secured.
2. If a single connection (one power and one ground) is to carry the full current then the wires
must be 8AWG in size. Otherwise the wire supplied by the manufacturer for the equipment
will be used to connect to these output power clips.
3. Run the wire from device (i.e. light and siren controller) to the PDU mounting location. Us-
ing the same process for the Battery input wire (steps 2 and 3).
Part NO: 212-0024-8S 9 September 24th, 2020
Connecting the ground outputs (GND) from the PDU
These outputs for ground connection is the return path for the device/equipment connected to
the two +12V OUT from the PDU.
1. Run the ground wire from device (i.e. light and siren controller) to the PDU mounting loca-
tion.
2. Prepare the wire in the same manner as the “+12V OUT” and insert the wire.
Connecting the Ignition Control to the PDU
To activate the ignition control and timed outputs feature, the PDU must receive a control sig-
nal from the vehicle.
1. The installer must locate the ignition output from the vehicles wiring harness and run an 18
AWG wire from this point to the ignition input (IGN IN) on the PDU.
Care must be taken to connect the correct ignition control wire from the vehicle wiring har-
ness, some of the newer vehicles have more than one type of ignition control wires. The in-
staller must consult the factory specifications and wiring diagrams for the vehicle that is
being retrofitted with the equipment and this PDU.
Part NO: 212-0024-8S 10 September 24th,
Connecting the power output from the PDU
Determine the type of power required by the connecting equipment (i.e. ignition controlled,
constant/battery or timed) and start connecting the vehicle equipment according to the system
design requirements.
1. All power connections will terminate at the PDU, bring the POWER and GROUND
(return) wires for the equipment to be connected directly to the PDU.
2. Connect the power wire from the equipment to the appropriate output on the PDU (i.e. ig-
nition controlled, constant/battery or timed).
3. Connect the return wire from the equipment to one of the terminals screws on the
GROUND terminal block or any chassis GROUND.
As you install the equipment distribute the many ground return wires to be connected
to terminal block evenly over the entire group of 7 terminal screws.
It is highly recommended that connecting wires to the screw terminals on the
GROUND terminal block be terminated with spade/fork terminals to make neat relia-
ble connections.
1. Once all the wire connections to and from the PDU are completed the output fuses can be
installed according to the required rating of the connected equipment.
The PDU accepts a standard Automotive Blade ATO/ATC Type fuses, each fuse location has
an LED indicator to show that the fuse is in place and working. The LED indicator will glow
RED if the fuse is “GOOD” otherwise it will be off.
Setting The Time Delay on Timed Outputs
The time delay for the timed outputs is user selectable and is set by a 4 position miniature
switch that is accessible through the cover at the back of the PDU. The delay time can range
from 2 minutes to 13 hours, this function is triggered by turning the vehicle ignition “OFF”
and only if the battery voltage is lower than 14V.
When the selected time has elapsed power to all timed outputs will be shut “OFF”. If during
the timing cycle the ignition is turned back on the timer will reset and the time cycle will re-
start when the ignition is turned off again.
The PDU has a built in Voltage Monitoring circuit, this will automatically shut down any timed
outputs if the battery voltage is reaching a “CRITICAL LOW” point (11.5 VDC). Similarly
this Voltage monitor circuit will cut off power to the timed outputs if the battery voltage ex-
ceeds 18V DC.
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