PROJECTA PM335C Power Management System Instruction Manual

For charging lead acid and LiFePO4 batteries ONLY (of the size & voltage specified in the specifications table)
Always charge the battery on the correct voltage setting. Never set the charger to a higher voltage than the battery specifications state

Disconnect the 240V mains supply before making or breaking the connections to the battery
Connect the positive battery terminals before making any ground connections. The ground connection to the chassis should be made away from the battery and any fuel line. Only connect mains after the battery is connected.

The battery charger must be plugged into an earthed socket outlet
Connection to supply mains is to be in accordance with national wiring rules

Do not attempt to charge non-rechargeable batteries
Never charge a frozen battery

If AC cord is damaged, do not attempt to use. Replace with a compatible earthed IEC cable immediately.
Corrosive substances may escape from the battery during charging and damage delicate surfaces. Store and charge in a suitable area This charger is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning the use of the appliance by a person responsible for their safety

Children being supervised not to play with the appliance
If the recreational vehicle is to be put into storage without power, please turn off the BATTERY MASTER SWITCH. If the recreational vehicle is to be stored for 3 months or longer, it’s advisable to disconnect all fuses from the battery. A full charge should be run every 3 months.

1 Product Instructions

1.1 Overview
PM335C unit is designed for use in caravans or motor homes. It has the following functions integrated into the unit: battery charger, distribution blocks, MPPT solar charger controller, VSR, battery low voltage protection, water pump controller. PM335C is designed for easy installation and has a user-friendly interface.

SYSTEM COMPONENTS

Master Power unit

Display Screen/Monitor
Up to 4 water tank probes, based on monitor selection (not included)

Accessories cables

Figure 1 System Components

1.2 Features
PM335C has the following feature

Smart battery charger 12V 30 Amp (35 Amp total supply for loads + charge)
– Multistage adaptive charging algorithm
– Active Power Factor Correction (PFC) charging
– Temperature compensation charging
Float charge for starter battery
Solar charge controller (MPPT), 30A
15 built in fused outputs
Built-in voltage sensing relay
– for DC charge of up to 12V 60 Amps continuous with 80 Amp for up to 30 minutes
Battery Low Voltage Protection
Built-in battery switch to isolate the battery when in storage
Built-in shunt for precise battery measurement
Support for 4 water tank sensors
Built-in RF for wireless switches
Water tank probe connectors and input screw terminals
RS485 & CAN compatible

1.3 Block diagram

1.4 Water Tank Probe
PM335C can monitor a maximum of 4 water tank probes.
Note: Always check the probe required for the water Tank before purchase. There are 2 Probe styles.

PMWS200:

Side installation
Suitable for water tank

Depth > 200mm

PMWS400:

Side installation
Suitable for water tank
Depth 300-400mm

2 Key Feature and Functions

2.1 Multiple Inputs
PM335C can support multiple charging sources at any one time. These sources include AC mains, Solar and starter battery (Vehicle). Charging priorities are listed within the table to the right.

2.2 Battery Charging of House/Service Battery
The charger automatically starts when the appropriate power is connected, either from grid, generator or solar.
With multiple charging stages (Soft-start, bulk, absorption, float & recycle), the PM335C is designed to fully charge the service battery quickly. PM335C features Microprocessor-controlled charging algorithms. The Float and Recycle charging programs ensure that the battery condition does not change despite being connected for a long period.
When the Charger is at Float Stage, if a new input source is added (AC Mains or Solar), the charger will return to the Bulk stage.

Battery Temperature Sensor
The optional battery temperature sensor (P/N: PMBS-3m) can be used with the PM335C to measure the temperature of the battery, allowing the PM335C to to adjust, in real time, the charge to the battery, at a compensation rate of -4mv±10%/ºc/cell. In installations where the BTS is not present, the PM335C will use 25ºC as a default setting. The voltage sensor can automatically adjust its output to compensate the voltage drop caused by a cable. This assures the right voltage is being delivered for optimal charging.

Adjustable Charging capacity
Users can adjust the charging current by specifying the battery capacity. The charging current is set at threshold rate of 10% the of the battery capacity (I = 0.1C) by default

Lithium Battery Charging
The PM335C can be configured to charge Lithium batteries. With Lithium batteries, the max charging current will automatically be set at 30% of battery capacity (Imax=0.3C)

2.3 Vehicle Battery Charger
Along with a powerful charger for the service battery, PM335C offers a float charge of up to 3A to keep the starter battery topped up, whether connected to AC mains or PV (Solar). When the starter battery is less than 12.4V, the PM335C starts charging after a 30 minute delay, and stops charging when the voltage reaches 12.8V

2.4 Power Supply Mode
If no battery is attached to PM335C Unit, it will automatically work as a power supply with a 12.8VDC output.

2.5 MPPT Solar Charger Controller
PM335C has a built-in MPPT charger for the service battery with:

Max input voltage up to 50VDC
Max charging current 30A
Max supply current 30A
* PM335C may cause LiFePO4 BMS over-voltage protecting to trigger when charging through Solar. In this case, disconnect the solar charge fuse and discharge the battery.

2.6 Voltage charging relay (commonly known as VSR)
PM335C has a built-in voltage charging relay (also known as a VSR), which offers a convenient source to charge the service battery via the alternator whilst the engine is running or via an external DC-DC charger.

LEAD ACID BATTERY – When the starter battery reaches 13.4VDC with threshold time delay, the VSR will charge the service battery from the alternator. The VSR will continue the charging until the starter battery voltage drops under 12.8VDC.

LiFePO4 LITHIUM BATTERY – When the starter battery reaches 14.0VDC with threshold time delay, the VSR will charge the service battery from the alternator. The VSR will continue charging until the starter battery charging current less than 2A charge to the service battery with threshold time delay.

NOTE: The PM335C starter battery input does not provide 5-stage charging.
It takes whatever power is available from the alternator to charge.
It simply takes whatever power and charging is available from the alternator
NOTE: PM335C If your vehicle is fitted with a smart charging system (Variable Voltage or Temperature Compensating), the VSR charge system may not function correctly and the Projecta PMDCS range of DC-DC chargers are recommended.
Please consult your local dealer or installer for further information.

2.7 Categorised Outputs
The 15 outputs are categorised into groups and controls as per below:

2.8 Battery Low voltage protection (BLVP or commonly known as an LVD)
PM335C master power unit has a built-in low voltage protection relay. It will disconnect the load once the battery voltage drops below the threshold voltage. The default setting is 10.5VDC. This can be manually turned On/Off via the LOAD button on the LCD display.
NOTE: Class C3 will remain active as long as the battery switch is left on and Class D loads remain active all the time.

2.9 Battery switch
The PM335C unit offers a convenient way to switch off the output of the service battery on-board. It protects the service battery from being drained by electronics on board, completely isolating the battery. PM335C unit also supports a remote manual battery switch. Before using the remote switch, ensure the manual battery switch at the unit is set as “ON”.
The switch is only effective when the system has no other energy resource for the load except the battery.

2.10 Precise Battery Measurement
PM335C unit has a battery measurement system controlled by microprocessor. It measures battery voltage, charge/discharge current, remaining battery capacity (in amp hours) and time remaining.
Compared to conventional indicating meters, even small currents can be measured and read accurately with this device. This feature highlights faults, alarms and installation errors.
NOTE: If you have loads connected directly on the battery instead of PM335C Power Management System, the measurement will not be accurate.
NOTE: P/No. PMSHUNT will be required for heavy loads designed to be connected direct to battery to ensure SOC% accuracy.

2.11 Night Mode
In Night Mode, the backlight of the monitor will turn off and the cooling fans will operate at a decreased speed. Charge current will be reduced to half rated selection when night mode is active.

3 STRUCTURE AND INSTALLATION

3.1 PM335C Power Management System

Installation:
PM335C adopts fan-forced air cooling for heat dissipation. In order to ensure good heat dissipation, it is necessary to ensure that there is enough installation space. The installation space needs to keep a minimum distance of 50mm on the left and right of the unit to keep the vents clear. It is also recommended that the installation space has adequate ventilation to ensure effective airflow.
Recommended vent size: 144 x 54mm

3.2 Water Tank Probe

4 Wiring

4.1 System Components

4.2 System Schematic

4.3 Preparation
PM335C system is designed with ease of installation in mind. To complete the easy installation, a screwdriver and DC cables are required. Follow Table 5 recommendation for minimum wiring sizes.

When running cables, if they pass through panels or wall, ensure the cables are protected from damage by sharp edges. In such cases, it is recommended to use cable glands.

4.4 Connection
PM335C is designed with both spring and screw terminals. Please refer to following illustration below.
Each type of terminal is designed to fit a different range of cables.

5 Wiring

5.1 PM335C Master unit

6 Operation

6.4 Maintenance

BATTERY MONITOR MAINTENANCE
PM335C systems feature built-in battery measurement software. To ensure accurate readings, maintain the system with the following instructions:

Fully charge the battery from AC input instead of solar every 2 weeks.
Fully charge the battery from mains at least once every 3 months, even in storage, unless required to earlier.
•Charge the battery with AC grid until the “CHG” LED on PM335C unit or “Float” shows on the monitor.

DAILY MAINTENANCE

Confirm the Power switch is turned ON when you want to charge the battery with AC grid
Check the nominal battery is 12VDC

Ensure the Space (50mm each side) beside the PM335C unit for the appropriate ventilation
When replacing and existing battery, fully charge via AC grid to Float Stage to ensure SOC% is accurately calibrated.

Only the energy consumption of the loads connected on the PM335C is measured and calculated in the data on the Monitor. Unless a shunt is fitted. Projecta p/n PMSHUNT
For storage it is recommended to switch off the the Manual Battery Switch on the unit or the Remote Switch (if installed) to cut off power to the system from the service battery.

NOTE:There may be some loads connected to the battery or constant output line(class D) that can continue to draw power.

7 SPECIFICATION

8 ADD-ON ACCESSORIES

8.1 Projecta Accessory Range
The PM235C, PM335C and PM435C support a range of additional Projecta accessories as listed below: For details on how to connect these, refer to the connection diagram (Figure 25, page 22-25).

WARRANTY STATEMENT

Applicable only to product sold in Australia
Brown & Watson International Pty Ltd of 1500 Ferntree Gully Road, Knoxfield, Vic.,telephone (03) 9730 6000, fax (03) 9730 6050, warrants that all products described in its current catalogue (save and except for all bulbs and lenses whether made of glass or some other substance) will under normal use and service be free of failures in material and workmanship for a period of one (1) year (unless this period has been extended as indicated elsewhere) from the date of the original purchase by the consumer as marked on the invoice. This warranty does not cover ordinary wear and tear, abuse, alteration of products or damage caused by the consumer.

To make a warranty claim the consumer must deliver the product at their cost to the original place of purchase or to any other place which may be nominated by either BWI or the retailer from where the product was bought in order that a warranty assessment may be performed. The consumer must also deliver the original invoice evidencing the date and place of purchase together with an explanation in writing as to the nature of the claim.

In the event that the claim is determined to be for a minor failure of the product then BWI reserves the right to repair or replace it at its discretion. In the event that a major failure isdetermined the consumer will be entitled to a replacement or a refund as well as compensation for any other reasonably foreseeable loss or damage. This warranty is in addition to any other rights or remedies that the consumer may have under State or Federal legislation.

IMPORTANT NOTE
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

Distributed by
AUSTRALIA
Brown & Watson International Pty Ltd
Knoxfield, Victoria 3180
Telephone (03) 9730 6000
Facsimile (03) 9730 6050
National Toll Free 1800 113 443

NEW ZEALAND
Narva New Zealand Ltd
22–24 Olive Road
PO Box 12556 Penrose
Auckland, New Zealand
Telephone (09) 525 4575
Facsimile (09) 579 1192

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Documents / Resources

PROJECTA PM335C Power Management System [pdf] Instruction Manual
PM335C, PM335C Power Management System, PM335C, Power Management System, Management System

References

User Manual