Projecta PMDCS30 Bedienungsanleitung

DC-DC CHARGER

INTELLI-GRID 12V

P/No. PMDCS30, PMDCS60, PMDCS30-20

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1. GENERAL & SAFETY INFORMATION

This section contains important safety and operation instructions. Please read and

retain this manual for future reference.

The DC-DC charger should be installed by a qualified Auto Electrician with

knowledge of automotive electrical systems. The following recommendations are to

be conducted prior to installation:

• The unit MUST not be disassembled for Safety and Warranty reasons.

• The DC-DC charger is designed for internal installation ONLY.

• Recommended cable size for input and output connections to unit need to be

followed. Output charging current of the DC-DC charger will depend on wire size of

the auxiliary circuits in the Charging Vehicle.

• 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-GRID / INTELLI-RV (if connected) and the polarity is correct.

• Use the shortest possible cable lengths to connect the Input and Output circuits to

the unit.

• Ensure there is sufficient ventilation around the heatsink of the unit.

2. INTRODUCTION

2.1 GENERAL INTRODUCTION

PMDCS DC-DC chargers are designed to integrate with INTELLI-RV or INTELLI-GRID

battery/power management systems, but they can also function as standalone dual

battery chargers. They come with stripped and tinned, labelled input and output

wiring for ease of installation.

FEATURES

• Adaptive charge – adapts to smaller cables or excessive runs by adjusting the charge

rate to avoid overloading wiring.

• Non-isolation design with maximum efficiency of 96%.

• Euro-6 engine (smart alternator) compatible.

• Built-in multi-stage charging algorithm.

• Built-in automatic temperature and voltage compensated charging.

• 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.

• Adjust current outputs and select battery type via dip switches.

2.2 BLOCK DIAGRAM

Figure 2-1: Block Diagram of DC-DC setup

DC/DC

Converter

MCU

Motor

battery Transformer

D+ LED COM

Voltage detect Temperature detect

Voltage detect

Alternator

DIP

Switch

Battery Voltage

Charging Current

Soft Start Bulk Absorption Float Recycle

Icc

11.5V

10 days 1h 5

mins

½ Icc

The charging efficiency of the PMDCS is up to 96%.

PMDCS units also support communication of RS485.

Alternator type Alternator input voltage Working state

Conventional alternator 13.2V with 10 second delay on ON

12.8V with 60 second delay off OFF

D+ wired 11.7V ON

11.7V OFF

Note: If D+ is used and you want to switch to conventional alternator mode, disconnect

D+ and disconnect the PMDCS from the house/auxiliary battery and reconnect. This will

reset the system.

2.3 MULTI STAGE CHARGING ALGORITHM

The charging algorithm is microprocessor-controlled with a variable absorption charging

timer to ensure optimal charging for batteries with varying degrees of discharge.

Figure 2-2: Charging Algorithm

PMDCS will treat it as conventional engine rather

than Euro 6 engine.

2.4 BATTERY TEMPERATURE COMPENSATION

Correct charging of the battery is affected by its temperature, so the charging

formula must be adjusted automatically and in real-time based on the actual

battery temperature to ensure that the battery is fully charged but not overcharged

or undercharged. All charging voltages recommended by battery manufacture are

applied at 20°C – 25°C.

The BTS (Battery Temperature Sensor), terminated to the PMDCS, measures the

temperature of the battery and automatically makes adjustments at real-time to

properly charge the batteries at the default compensation rate of -3mV/°C/cell.

If the BTS is not present or connected, the PMDCS will use 25°C as the default

temperature setting.

Figure 2-3: Battery Temperature Sensor (BTS)

100%

50%

Output power percentage

25°C 60°C

Ambient temperature

75°C

2.5 DE-RATE CURVE AGAINST TEMPERATURE INCREASE

The PMDCS charger will monitor internal temperature to decide output power.

It will de-rate its output power against temperature increasing. The following

curve shows how the output power changes with an increase in temperature.

Figure 2-4: De-rate curve against temperature increase

Wire Input

Red V-Sen

White Temp

Black BAT-

3. STRUCTURE AND DIMENSION

3.1 EXTERIOR AND DIMENSION

Figure 3-1: PMDCS front view

Figure 3-2: PMDCS dimensions

3.2 CONNECTORS AND TERMINALS

Figure 3-3: Connectors and terminals

Table 3-1: Connectors and terminals guide

No. Print PMDCS Remarks Circuit colours

and labelling

Alternator Connects to positive of Alternator Connects to positive

battery post

Red + Label

“Aux+”

BAT- Connects to negative of Alternator Connects to negative

battery post

Black – Label

“Aux-”

AUX BAT Connects to positive of auxiliary

battery

Red + Label

“Vehicle Batt+”

BAT- Connects to negative and

negative of auxiliary battery

Black – Label

“Vehicle Batt-”

3COM For communication of RS485 Not Connected

1Only used on PMDCS30-20

Details of setting can be

found as Chapter 4.6

2Set on for 30Amp, off for 15Amps

3Used to set battery chemistry

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

Table 3-2: Fuse specification

No. Print PMDCS30 PMDCS30-20 PMDCS60 Protection for

6 Alternator 30A/32VDC 40A Internal Input from alternator

7AUX BAT 20A/32VDC 20A Internal Output to charge auxiliary battery

N/A Fridge N/A 15A N/A Fridge output

3.3 STATUS INDICATORS

Table 3-3: LED codes

No. Print Power Fridge/Load Alternator Charge Fault

4-2 Alternator Present Green Light

Green Light

Off

Green Light

Off

Green Light

Off

4-3 Charger faulty Green Light

Green Light

Off

Green Light

Off

Green Light

Off

Red Light

4-5 Alternator over voltage Green Light

Green Light

Off

Green

Light Flash

Green Light

Off

Red Light

Flash

4-6 Fridge/Load Short

Circuit*

Green Light

Flash

Green Light

Off

Red Light

4-7 Fridge/Load Output

Overload*

Green Light

Flash

Green Light

Off

Red Light

4-9 Bulk Time out Green Light

Green Light

Off

Green Light

Flash

Red Light

Flash

4-12 Output Overvoltage Green Light

Green Light

Off

Green Light

Off

Green Light

Flash

Red Light

Flash

4-13 Fridge/Load output Green Light

Green Light

Red Light

Off

4-14 Softstart Charging Green Light

Green Light

Green

Light Flash

Green Light

Flash

Red Light

Off

4-15 Bulk charging Green Light

Green Light

Off

Green Light

Flash

Red Light

Off

4-16 Absorption charging Green Light

Green Light

Off

Green

Light Flash

Green Light

Red Light

Off

4-17 Float charging

(charged)

Green Light

Off

Green Light

Red Light

Off

4-18 Recycle Mode Green Light

Green Light

Off

Green

Light Flash

Green Light

Flash

Red Light

Off

4. INSTALLATION

4.1 CHECK YOUR PRODUCT

Before installation, check that the product is in good physical condition.

4.3 PROPER INSTALLATION LOCATION

• The DC-DC charger is designed with IP20 and for internal installation ONLY.

• The temperature at the casing and heat sink of the DC-DC charger can be as high as 60°C

during operation.

• Ensure the DC-DC charger is installed away from flammables and explosives.

• Ensure the DC-DC charger is installed out of reach of children.

• Ensure mounting surface is flat and rigid.

Please check the item with the list attached in the box.

Never install the DC-DC charger in a sealed enclosure with battery.

4.4 INSTALLATION SPACE

For adequate ventilation, it is important to leave space around where the DC-DC

charger 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

≥ 50mm

≥ 50mm ≥ 100mm

≥ 50mm

4.6 DIP SWITCH SETTING

Table 4-1: Dip switch setting for fridge operation for PMDCS30-20

Pin 1 Operation

OFF Constant Load Relay On (Switches between car when running and battery when car not running)

Ideal for Compressor fridges

ON Load Relay On with Ignition Input (Vehicle Charging) Ideal for 3 way fridges

Table 4-2: Dip switch setting for output current

Output Current settings

Pin 2 PMDCS30 &

PMDCS30-20

PMDCS60

OFF 15A 45A

ON 30A (Default) 60A (Default)

Table 4-3: Dip switch setting for battery type

Dip switch for battery type setting Battery type Absorption

charging voltage

Float charging

voltage

Pin 3 Pin 4

OFF OFF AGM (Default setting) 14.4V 13.5V

OFF ON GEL 14.1V 13.5V

ON OFF LFP 14.2V 13.5V

ON ON WET 14.7V 13.5V

Do not connect the DC-DC charger to AC Mains

Please ensure the connections are tight and have correct polarity.

Damages caused by improper installation may void warranty.

Dip Switches

Set output current and battery type

UP = OFF DOWN = ON

4.5 WIRING DIAGRAM

Starter

battery

Fuse

Alternator

BAT -

PMDCS

Fridge

Aux Bat

BAT -

D+

BAT -

Temp

V-sen

+ -

Fridge

Auxiliary

battery

+ -

Fuse

BLACK

START

IGN

LOCK

WHITE

RED

PMDCS30 Recommended cables:

– Alternator positive/negative cable:

8 B&S, 8mm2up to 9m, Fuse 80A

– Auxiliary positive/negative cable:

8 B&S, 8mm2 up to 9m

– D+ signal: >0.64mm2, Fuse 5A

PMDCS30-20 Recommended cables:

– Alternator positive/negative cable:

6 B&S, 14mm2up to 9m, Fuse 125A

– Auxiliary positive/negative cable:

8 B&S, 8mm2 up to 9m

– Load cables: 8 B&S, 8mm2, Fuse 80A

– D+ signal: >0.64mm2, Fuse 5A

PMDCS60 Recommended cables:

– Alternator positive/negative cable:

4 B&S, 20mm2up to 9m, Fuse 175A

– Auxiliary positive/negative cable:

6 B&S, 14mm2 up to 9m, Fuse 125A

– D+ signal: >0.64mm2, Fuse 5A

5. FRIDGE BYPASS MODE (PMDCS30-20 ONLY)

5.1 CONTINUOUS POWER MODE

5.2 NON CONTINUOUS POWER MODE

House

Battery

30Amp

CAR ON PMDCS30-20

3 Way

Fridge

House

Battery

CAR OFF PMDCS30-20

House

Battery

30Amp

CAR ON PMDCS30-20 3 Way

Fridge

2 Way

Fridge

2 Way

Fridge

House

Battery

CAR OFF PMDCS30-20

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