Projecta Intelli-RV PM335C Instruction Manual

1 Product Instructions

The PM335C unit is designed for use in caravans or motor homes. It integrates several functions: battery charger, distribution blocks, MPPT solar charger controller, Voltage Sensitive Relay (VSR), battery low voltage protection, and water pump controller. The PM335C is designed for easy installation and features a user-friendly interface.

1.1 Overview

The 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

• 1 Master Power unit
• 2 Display Screen/Monitor
• 3 Up to 4 water tank probes, based on monitor selection (not included)
• 4 Accessories cables

Display Screen options: Select from P/No: PM4SWLED, PMD-BT3C, PMD-BT4C or PMD-BT7C.

Water Tank Probes: Available in P/No. PMWS200 or PMWS400. Supports up to 4 probes.

Optional Accessories: Outdoor temperature sensor (P/No. PMTS-5M), Battery Sensor (P/No. PMBS-3M).

Figure 1 System Components depicts the main PM335C unit connected to a Starter Battery, Service Battery, and Solar input. It also shows connections for various display screens and optional sensors like the outdoor temperature sensor and battery sensor.

Intelli-RV App

The Intelli-RV phone app provides comprehensive control and monitoring for Intelli-RV users. It allows users to track battery status, monitor power consumption, check water tank levels, and manage caravan loads, including lights, pumps, and hot water systems. Scan the QR code to download the APP.

1.2 Features

The PM335C features:

• 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 (VSR) for DC charge up to 12V 60 Amps continuous with 80 Amp for up to 30 minutes.
• Battery Low Voltage Protection (BLVP).
• 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

The PM335C manages power distribution through various output categories:

• Class A5 (2 units): Relay controlled output with fuse, protected by the main master switch relay. Used for water pumps.
• Class C2 (10 units): Fused outputs, protected by the master switch relay. Used for ventilation fans, etc.
• Class C3 (2 units): Always On Load (LVD protected). Used for fridge, security alarms, etc.
• Class D (1 unit): Constant supply loads (no discharge protection). Used for breakaway systems, Sway Controllers, Radio memory.

The block diagram illustrates inputs like Solar, AC In, House Battery, Vehicle Battery, and outputs categorized into Class A5, C2, C3, and D, all connected through a battery switch and various fuses.

1.4 Water Tank Probe

The PM335C can monitor up to 4 water tank probes. Two probe styles are available:

• PMWS200: Side installation, suitable for water tanks, depth ≥ 200mm.
• PMWS400: Side installation, suitable for water tanks, depth 300-400mm.

Figure 4 PMWS200 and Figure 5 PMWS400 show the physical appearance and installation details of these probes.

2 Key Features and Functions

2.1 Multiple Inputs

The PM335C supports multiple charging sources simultaneously, including AC mains, Solar, and the starter battery (Vehicle). Charging priorities are managed as follows:

2.2 Battery Charging of House/Service Battery

The charger automatically starts when an appropriate power source (grid, generator, or solar) is connected. It employs a multistage charging process (Soft-start, bulk, absorption, float & recycle) using microprocessor-controlled algorithms to quickly charge the service battery. Float and Recycle stages ensure the battery remains in optimal condition even when connected for extended periods. If a new input source is added during the Float stage, the charger will revert to the Bulk stage.

Figure 6 Charging Algorithm illustrates the voltage and current profile over time during the charging stages: Soft Start, Bulk, Absorption, Float, and Recycle.

Battery Temperature Sensor

An optional battery temperature sensor (P/N: PMBS-3m) allows the PM335C to adjust charging in real-time based on battery temperature, with a compensation rate of -4mV±10%/°C/cell. If the sensor is not used, the PM335C defaults to 25°C. A voltage sensor can also compensate for voltage drops caused by cables, ensuring accurate charging voltage delivery.

Adjustable Charging Capacity

Users can set the charging current based on battery capacity, with a default threshold of 10% of battery capacity (I = 0.1C).

Lithium Battery Charging

For Lithium batteries, the PM335C automatically sets the maximum charging current to 30% of battery capacity (Imax=0.3C).

2.3 Vehicle Battery Charger

The PM335C provides a float charge of up to 3A for the starter battery, keeping it topped up via AC mains or Solar. It begins charging the starter battery when its voltage drops below 12.4V (after a 30-minute delay) and stops when it reaches 12.8V.

2.4 Power Supply Mode

If no battery is connected, the PM335C operates as a 12.8VDC power supply.

2.5 MPPT Solar Charger Controller

The PM335C includes an MPPT solar charger controller with:

• Max input voltage: up to 42VDC
• Max charging current: 30A
• Max supply current: 30A

Note: LiFePO4 BMS over-voltage protection may trigger when charging via solar. In such cases, disconnect the solar charge fuse and discharge the battery.

2.6 Voltage Sensitive Relay (commonly known as VSR)

The PM335C features a built-in VSR that charges the service battery via the alternator when the engine is running or via an external DC-DC charger.

• Lead Acid Battery: The VSR engages to charge the service battery from the alternator when the starter battery reaches 13.4VDC (with a time delay). Charging continues until the starter battery voltage drops below 12.8VDC.
• LiFePO4 Lithium Battery: The VSR engages when the starter battery reaches 14.0VDC (with a time delay). Charging continues until the starter battery charging current drops below 2A (with a time delay).

Note: The PM335C starter battery input does not support 5-stage charging; it utilizes available alternator power. If the vehicle has a smart charging system (Variable Voltage or Temperature Compensating), the VSR may not function correctly. Projecta PMDCS range of DC-DC chargers are recommended in such cases.

2.7 Categorised Outputs

The 15 outputs are categorized as follows:

• Class A5 (2): Relay controlled, fused, protected by master switch relay. Uses: Water pump.
• Class C2 (10): Fused, protected by master switch relay. Uses: Ventilation fan, etc.
• Class C3 (2): Always On Load (LVD protected). Uses: Fridge, security alarm, etc.
• Class D (1): Constant Supply loads (no discharge protection). Uses: Breakaway systems, Sway Controllers, Radio memory.

The PM235C/335C Load Output diagram shows how these loads are connected via fuses and switches.

2.8 Battery Low Voltage Protection (BLVP or commonly known as an LVD)

The PM335C master power unit has a built-in low voltage protection relay that disconnects loads when battery voltage drops below a threshold (default 10.5VDC). This can be manually controlled via the LOAD button on the LCD display. Class C3 loads remain active if the battery switch is ON, and Class D loads are always active.

2.9 Battery Switch

The PM335C provides a convenient way to switch off the service battery output, protecting it from being drained by onboard electronics. It isolates the battery and supports a remote manual battery switch. The manual switch on the unit must be set to “ON” for the remote switch to function. The switch is only effective when the battery is the sole energy resource for the loads.

2.10 Precise Battery Measurement

The PM335C features a microprocessor-controlled battery measurement system that records battery voltage, charge/discharge current, remaining capacity (Ah), and time remaining. It offers accurate readings even for small currents, helping to identify faults, alarms, and installation errors. For accurate SOC% measurement with heavy loads connected directly to the battery, P/NO. PMSHUNT is required.

2.11 Night Mode

In Night Mode, the monitor backlight turns off, and cooling fans operate at a reduced speed. Charge current is halved.

3 Structure and Installation

3.1 PM335C Power Management System

The PM335C unit is shown with its various connection terminals. A table details the numbered components:

• 1 AC Input: IEC Socket
• 2 Solar+: Screw terminal, Solar input Positive
• 3 SBAT+: Starter BATT input Positive
• 4 BAT+: Service BATT input Positive
• 5 Always ON+: 40A Always ON output Positive
• 6 Solar-: Screw terminal, Solar input Negative
• 7 BAT-: Service BATT input Negative
• 8 Load-: WAGO connector, Load negative
• 9 Load+: WAGO connector, Load positive
• 10 Battery Sensor / Dry contact: 20 pin socket, Battery sensor and 6 dry set contact
• 11 Switch Panel / COMM: 16 pin socket, IO COMM for LED panel and 485 COM for Power module and sensors
• 12 LCD Monitor: 12 pin socket, COM for LCD monitor
• 13-16 Water 1-4: 8 pin socket each, for Water Tank probes
• 17 Remote Switch: WAGO connector, Power Management Remote Switch

The diagram shows the physical layout of the PM335C unit with numbered connection points corresponding to the table.

Installation

The PM335C uses fan-forced air cooling for heat dissipation. Ensure adequate installation space with a minimum distance of 50mm on the left and right sides for ventilation. A recommended vent size is 144 x 54mm.

Diagrams show the unit's dimensions (76.3mm height, 296mm width, 338.9mm depth) and recommended mounting clearances.

3.2 Water Tank Probe

Details on the PMWS400 and PMWS200 water tank probes are provided, including their dimensions and installation methods. Both are side-installation probes suitable for water tanks, with the PMWS200 for depths ≥ 200mm and the PMWS400 for depths 300-400mm.

Installation diagrams show how the probes are mounted through the tank wall with seals and washers.

4 Wiring

4.1 System Components

A table lists the system components, their model/length, quantity, and P/No. on drawing:

• 1 Battery Management System: PM335C, QTY 1, P/NO. 1
• 2 Display Screen: PM4SWLED/PMD-BT3C/PMD-BT4C/PMD-BT7C, QTY 1, P/NO. 2
• 3 Water Tank Level Sensor: PMWS200/PMWS400, QTY 4, P/NO. 3
• 4 AC Power Cable: 0.3M, QTY 1, P/NO. PMACR
• 5 Display Screen Cable: 5M/10M, QTY 1, Refer to Display Manual and diagram on page 22-25
• 6 Battery Sensor Cable (Optional): 3M/10M, QTY 1, PMBS-3M/PMBS-10M

4.2 System Schematic

The system schematic illustrates the connections between the PM335C unit, display screen, sensors (battery temperature, water tank), AC input, starter battery, service battery, and solar input. It also shows the various output classes (C2, A5, C3, D) and their connections.

The diagram also includes a table for output categories (Class A5, C2, C3, D) with their quantity, description, and possible uses.

5 Wiring

5.1 PM335C Master unit

This section details the status and description of the LEDs on the PM335C Master unit:

• Mains (Green): ON (AC input OK), OFF (AC disconnected), Quick flashing (AC input abnormal).
• AUX (Green): ON (Starter battery charging), Slow flashing (Input of Aux is normal but battery is charged by AC Mains), Quick flashing (Starter Battery input error), OFF (Starter Battery disconnected).
• Solar (Green): ON (Solar charging the battery), Slow flashing (Input voltage of PV is normal but Battery is charged by AC Mains), Quick flashing (Solar input abnormal), OFF (Solar disconnected).
• CHG (Green): ON (Battery charging - Float Stage), Slow flashing (Battery charging - BULK, ABS Stage or VSR), Quick flashing (Battery discharging), OFF (Battery disconnected).
• FAULT (Red): 1 flash (Short circuit), 2 flashes (Service battery undervoltage), 3 flashes (Service battery overvoltage), 4 flashes (Over temperature - heat sink), 5 flashes (Bulk charge time-out), 8 flashes (VSR abnormal), 9 flashes (Over temperature - Unit or PCB/Load circuit).

6 Operation

6.1 Manual switch

An ON/OFF switch on the side of the unit controls power. When powered by battery alone, it switches the entire machine on/off. When powered by mains, it puts the machine into sleep mode. The switch must be “ON” for the Remote Switch to operate.

6.2 Remote Switch (Optional)

Remote switch terminals are located near the positive 14 terminal. An external switch can be used here, functioning identically to the manual battery switch. The manual battery switch must be “ON” for the remote switch line to function. If not used, both terminals must be bridged.

6.3 Dip switch

A 5-pin dip switch is used for adjusting charging current and battery type. Switch 5 is not used and should be in the “OFF” position. These settings are not adjustable if a digital screen is used.

Pin 1-2 Definition (AC/Solar Charge)

Pin 3-4 Definition (Type, Absorption, Float)

6.4 Maintenance

Battery Monitor Maintenance

To ensure accurate readings from the PM335C's battery measurement software:

• 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 during storage, unless required sooner. Charge until the “CHG” LED is ON or “Float” is shown on the monitor.

Daily Maintenance

• Confirm the Power switch is ON when charging with AC grid.
• Check the nominal battery is 12VDC.
• Ensure 50mm clearance on each side of the PM335C unit for ventilation.
• When replacing a battery, fully charge it via AC grid to Float Stage to ensure SOC% calibration.

Note: If the house battery is allowed to drain significantly, it must be charged to float mode via AC mains to recalibrate internal/external shunts. Failure to do so results in inaccurate SOC% readings, potentially causing premature shutdown.

Important Note: Only energy consumption of loads connected to the PM335C is measured unless a shunt (Projecta p/n PMSHUNT) is fitted.

For storage: It is recommended to switch off the Manual Battery Switch on the unit or the Remote Switch (if installed) to cut power from the service battery. Note that some loads (Class D) may continue to draw power.

7 Specifications

8 Add-On Accessories

8.1 Projecta Accessory Range

The PM235C, PM335C, and PM435C support additional Projecta accessories. Connection details can be found in the connection diagrams (Figures 25, pages 22-25).

SC520/SC540 5 Stage MPPT Solar Charger Controller with 100V Input

This controller maximizes solar array output by up to 30% using MPPT technology. Specifications include:

• PART No: SC520 (20 AMP), SC540 (60 AMP)
• Battery Voltage: 12/24/48V
• Maximum Solar Voltage: 100V
• Standby Current: 1mA (12V), 3mA (24V), 5mA (48V)
• Charge Type: 5 Stage
• Input: 100V
• Output: 20A (SC520), 40A (SC540)
• Control Type: MPPT
• Batteries Supported: GEL, AGM, Wet, Lithium
• Temperature Compensation: -18mV/12V
• Communication: RS485, Bluetooth
• Storage Temperature: -40-70°C
• Humidity: 5-95%
• IP Rating: IP31
• Weight: 1.4Kg
• Cooling: Convection

PMDCS30/PMDCS60 DC-DC 12V Charger

Smart DC to DC chargers designed for Intelli-RV and Intelli-Grid.

• PART No: PMDCS30 (30 AMP), PMDCS60 (60 AMP)
• Charge Type: 5 Stage
• Alternator Input Voltage: 12V, <30A (PMDCS30), 12V, <60A (PMDCS60)
• Output: 12V, <30A (PMDCS30), 12V, <60A (PMDCS60)
• Batteries Supported: GEL, AGM, Wet, Lithium
• Alternator Type: Smart & Conventional
• Storage Temperature: -40-70°C
• Operating Temperature: -40-70°C
• Temperature Compensation: -3mV/°C/Cell
• IP Rating: IP20
• Dimensions: 181 x 148 x 52mm
• Weight: 1.0kg
• Cooling: Convection
• Smart Alternator: Turn on 12.2V, Turn off 11.6V
• Conventional: Turn on 13.2V, Turn off 12.8V

PMDCS30-20 DC-DC 12V Charger

Smart DC to DC chargers for Intelli-RV and Intelli-Grid, suitable for 3-way fridge or compressor fridge applications.

• PART No: PMDCS30-20
• Charge Type: 5 Stage
• Alternator Input Voltage: 12-16V
• Output: 12V, <30A
• Batteries Supported: GEL, AGM, Wet, Lithium
• Alternator Type: Smart & Conventional
• Storage Temperature: -40-70°C
• Operating Temperature: -40-70°C
• Temperature Compensation: -3mV/°C/Cell
• IP Rating: IP20
• Dimensions: 181 x 148 x 52mm
• Weight: 1.0kg
• Cooling: Convection
• Smart Alternator: Turn on 12.2V, Turn off 11.6V
• Conventional: Turn on 13.2V, Turn off 12.8V

Note: If using a load as 'CONSTANT' connection, the output of the DC-DC charger MUST be connected directly to LB-HD or PMSHUNT.

Warranty Statement

This warranty statement is applicable only to products sold in Australia.

Brown & Watson International Pty Ltd (BWI) warrants products against failures in material and workmanship for one (1) year from the date of original purchase, provided they are used under normal use and service conditions. This warranty excludes ordinary wear and tear, abuse, alteration, 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 an alternative nominated location, along with the original invoice and a written explanation of the claim. For minor failures, BWI may repair or replace the product at its discretion. For major failures, the consumer is entitled to a replacement, refund, and compensation for foreseeable loss or damage. This warranty is in addition to other consumer rights and remedies.

Important Note

Australian Consumer Law guarantees apply, entitling consumers to replacement or refund for major failures and compensation for other foreseeable loss or damage. Goods failing to be of acceptable quality also entitle the consumer to repair or replacement.

Distributed by:

• AUSTRALIA: Brown & Watson International Pty Ltd, Knoxfield, Victoria. Contact details provided.
• NEW ZEALAND: Narva New Zealand Ltd, Auckland. Contact details provided.

Document reference: IS598, Issue 3 30/7/25.