Projecta PMDC-30 DC-DC Charger with Intelli-Jay Integration
Model Number: PMDC-30 (P/No. PMDC-30 (C4975F))
Contact Projecta for technical help: 1800 294 294
1. General & Safety Information
This section provides important safety and operation instructions. Please read and retain this manual for future reference.
The PMDC-30 should be installed by a qualified Auto Electrician familiar with caravan electrical systems. The following recommendations are to be conducted prior to installation:
- The unit MUST NOT be disassembled for Safety and Warranty reasons.
- PMDC-30 is designed for internal installation ONLY.
- Recommended cable size for input and output connections is a minimum of 6mm².
- Output charging current of the PMDC-30 charge booster depends on the wire size of the auxiliary circuits in the Charging Vehicle and Caravan.
- Verify the input voltage is within the unit's specifications (refer to Specification table).
- Confirm that the circuit connections to the Alternator or Vehicle battery and input to the Intelli-Jay transformer have correct polarities.
- Use the shortest possible cable lengths to connect the Input and Output circuits to the unit.
- Ensure sufficient ventilation around the unit's heatsink.
2. Introduction
2.1 General Introduction
The PMDC-30 is a 30 Amp output DC to DC charger, designed for integration with the Intelli-Jay battery management system. It comes with stripped, tinned, and labelled input and output wiring for ease of installation.
Features:
- 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.
- Plug and Play for easy installation.
- 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, and battery over temperature.
- Adjustable current outputs (15A/20A/25A Default/30A) via Dip Switches 1 & 2.
- Selectable Battery Type via Dip Switches 3 & 4.
2.2 Block Diagram
Figure 2-1: Block Diagram of PMDC-30
The diagram shows an Alternator and Motor battery connected to a DC/DC Converter. The DC/DC Converter outputs 30A to an Intelli-Jay Transformer. Voltage and temperature sensors are connected to a Microcontroller Unit (MCU), which also interfaces with a DIP Switch, LED, and COM port. The MCU receives voltage and temperature detection signals.
The charging efficiency of the PMDC-30 is up to 96%.
PMDC-30 also supports communication via RS485.
Note: PMDC-30 will treat a Euro 6 engine as a conventional engine.
| Alternator type | Alternator input voltage | Working state |
|---|---|---|
| Conventional alternator | 12.8V | ON |
| 12.0V | OFF |
2.3 Multi Stage Charging Algorithm
The PMDC-30 charges the house battery through the Intelli-Jay transformer quickly and fully. It uses a microprocessor-controlled charging algorithm with a variable absorption charging timer to ensure optimal charging for batteries in different discharged states.
Figure 2-2: Charging Algorithm
The graph illustrates the charging process over time. It shows Battery Voltage and Charging Current. The stages are Soft Start, Bulk, Absorption, Float, and Recycle. Battery voltage rises through these stages, starting from a lower level (e.g., 11.5V) and increasing towards a higher level. Charging current is high during Bulk, reduces during Absorption and Float, and may cycle during Recycle. Timeframes indicated are 10 days, 1 hour, and 5 minutes.
2.4 Battery Temperature Compensation
Battery temperature is crucial for correct charging. The charging formula is automatically adjusted in real-time based on the actual battery temperature to ensure batteries are fully charged without overcharging or undercharging. Recommended charging voltages from battery manufacturers are typically applied at 20°C – 25°C.
The BTS (Battery Temperature Sensor) connected to the PMDC-30 measures battery temperature and makes real-time adjustments. The default compensation rate is -3mV/°C/cell. If the BTS is not present or connected, the PMDC-30 uses 25°C as the default setting.
Figure 2-3: Battery Temperature Sensor (BTS)
A textual description of the BTS would be here if it were an image. It typically consists of a sensor probe connected via a cable to the charger.
2.5 De-Rate Curve Against Temperature Increase
The PMDC-30 monitors its internal temperature to determine output power. It will reduce its output power as the temperature increases. The following curve illustrates this relationship.
Figure 2-4: De-rate curve against temperature increase
The graph shows 'Output power percentage' on the Y-axis and 'Ambient temperature' on the X-axis. At 25°C, output power is 100%. As temperature increases, output power decreases. At 60°C, output power is reduced to 50%. At 75°C, output power is further reduced or potentially off.
3. Structure and Dimension
3.1 Exterior and Dimension
Figure 3-1: PMDC-30 front view
The front view shows the Projecta logo, the Intelli-Jay branding, and the PMDC-30 unit itself. It displays connection terminals labelled "Alternator", "AUX BAT", and "Vehicle Batt", along with status LEDs and dip switches.
Figure 3-2: PMDC-30 dimensions
The dimensions are provided in millimeters: Length 181mm (or 170mm for the main body), Height 148mm (or 100mm for the main body), and Depth 52mm. The heatsink extends beyond the main body, with a total width of 161.5mm.
3.2 Connectors and Terminals
Figure 3-3: Connectors and terminals
The diagram labels seven connection points on the PMDC-30 unit. These are numbered 1 through 7.
| No. | PMDC-30 | Remarks | Circuit colours and labelling | |
|---|---|---|---|---|
| 1 | Alternator | Connects to positive of Alternator | Or connects to positive of motor battery | Red + Label "Aux+" |
| BAT- | Connects to negative of Alternator | Or connects to positive of motor battery | Black - Label "Aux-" | |
| 2 | AUX BAT | Connects to positive of auxiliary battery | Connect to IntelliJay | Red + Label "Vehicle Batt+" |
| BAT- | Connects to negative and negative of auxiliary battery | Connect to IntelliJay | Black - Label "Vehicle Batt-" | |
| 3 | COM | For communication of RS485 | Not Connected | |
| 4 | 1, 2 | Dip switch for output current setting | Details of setting can be found as Chapter 4.6 | |
| 3, 4 | Dip switch for battery type setting | |||
| 5 | 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 |
| No. | Specification | Colour | Quantity | Protection for | |
|---|---|---|---|---|---|
| 6 | Alternator | 30A/32VDC for PMDC-30 | Amber | 2 | Input from alternator |
| 7 | AUX BAT | 20A/32VDC | Yellow | 2 | Output to charge auxiliary battery |
3.3 Status Indicators
| No. | Colour | Status | Description | |
|---|---|---|---|---|
| 1 | Power | Green | ON | Working normal |
| OFF | No working or Low Power Mode | |||
| 3 | Alternator | Green | ON | Motor battery voltage in the range |
| Flashing | Motor battery voltage high | |||
| OFF | Motor battery voltage low | |||
| 4 | Charge | Green | ON | Charging battery at bulk or absorption stage |
| Flashing | Charging battery at float stage | |||
| OFF | No charging to auxiliary battery | |||
| 5 | Fault | Red | ON | 1. PMDC-30 over temperature 2. Motor battery voltage high 3. Output to auxiliary battery short circuit |
| Flashing | 1. Auxiliary battery over temperature or under temperature | |||
| OFF | No fault |
4. Installation
4.1 Material Checking
Before installation, check that the product is in good physical condition. ✔️ Please check the item with the list attached in the box.
4.3 Proper Installation Location
- PMDC-30 is designed with IP20 rating and for internal installation ONLY.
- The temperature at the casing and heat sink of PMDC-30 can reach as high as 60°C during operation.
- Ensure PMDC-30 is installed away from flammables and explosives.
- Please ensure the installation is away from inflammable and explosive goods.
- Ensure PMDC-30 is installed out of reach of children.
- Ensure the mounting surface is flat and rigid.
- Never install PMDC-30 in a sealed enclosure with battery.
4.4 Installation Space
For adequate ventilation, it is important to leave space around the PMDC-30 installation area. See recommended spacing dimensions below.
Figure 4-1: The required dimensions for ventilation
Minimum clearances are required: 50mm on the left, right, and top sides, and 100mm on the bottom side for ventilation.
4.5 Mounting Holes
Find an appropriate mounting surface that is flat and rigid. Drill mounting holes per the dimensions below.
Figure 4-2: Drill holes for mounting
The diagram shows the unit's dimensions (181mm width, 148mm height, 52mm depth) and indicates four mounting holes, each with a diameter of Ø5.5mm, positioned appropriately on the unit's face.
4.6 DIP Switch Setting
The unit features dip switches to set output current and battery type. UP position is OFF, DOWN position is ON.
| Pin 1 | Pin 2 | Charge current (Max Amps) |
|---|---|---|
| OFF | OFF | 30 |
| OFF | ON | 25 (Default) |
| ON | OFF | 20 |
| ON | ON | 15 |
| Dip switch for battery type setting | Battery type | Absorption charging voltage | Float charging voltage | |
|---|---|---|---|---|
| Pin 3 | Pin 4 | |||
| OFF | OFF | AGM | 14.6V | 13.5V |
| OFF | ON | GEL | 14.2V | 13.8V |
| ON | OFF | LFP | 14.4V | 13.5V |
| ON | ON | WET (Default setting) | 14.8V | 13.8V |
Important Notes:
- Do not connect PMDC-30 to AC Mains.
- Please ensure the connections are tight and have correct polarity.
- Damages caused by improper installation may void warranty.
6. Specification
| Attribute | Value |
|---|---|
| Model Number | PMDC-30 |
| Electrical | |
| Alternator input voltage range (Intelligent type) | 12~16VDC |
| Automatic activation D+ | Yes |
| Absorption charge voltage | Default Setting: 14.8VDC |
| Float charge voltage | Default Setting: 13.8VDC |
| Charge current | 30A |
| Total current of load and charging | 30A |
| Maximum charging efficiency | 96% |
| Temperature compensation | Default Setting: -3mV/°C/cell |
| Voltage compensation | Yes |
| Charge algorithm | Premium II multi stage |
| Protection |
|
| Communication | RS485, RJ45 connector |
| Storage temperature | -40°C ~ 70°C |
| Operating temperature | -40°C ~ 70°C |
| Enclosure | |
| Battery Connection | Cable with connector |
| Protection category | IP20 |
| Weight | 1.0kg |
| Dimensions (h*w*d) | 181*148*52mm |
| Standards | |
| Emission | ECE 10R-06, EN61000-6-1, EN61000-6-3 |
Warranty Statement
Brown & Watson International Pty. Ltd. (“BWI”) warrants that its products will, under normal use and service, be free of failures in material and workmanship for a period of three (3) years from the date of original purchase. This warranty does not cover ordinary wear and tear, abuse, alteration, or damage caused by the purchaser.
To make a warranty claim, the consumer must deliver the product at their cost to the original place of purchase or a nominated alternative. The original invoice and a written explanation of the claim must also be provided.
BWI reserves the right to repair or replace minor failures. For major failures, the consumer is entitled to a replacement or refund, plus compensation for foreseeable loss or damage.
This warranty is in addition to other rights and remedies available under State or Federal legislation.
Important Note: Goods come with guarantees that cannot be excluded under the Australian Consumer Law. Consumers are entitled to a replacement or refund for a major failure and compensation for other reasonably foreseeable loss or damage. Goods also have to be repaired or replaced if they 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
Phone: (03) 9730 6000
Fax: (03) 9730 6050
National Toll Free: 1800 113 443
NEW ZEALAND OFFICE
Griffiths Equipment Ltd.
19 Bell Avenue,
Mount Wellington, Auckland 1060, New Zealand
Phone: (09) 525 4575
Fax: (09) 579 1192
Document Issue: IS494, Issue 2, 7.10.2021
