Projecta Intelli-RV PM200 12V Power Management System

Important Safety Information

Please read this manual thoroughly before use and store it in a safe place for future reference.

Warnings

• Explosive gases: Prevent flames and sparks. Provide adequate ventilation during charging.
• Read instructions before charging.
• For indoor use only. Do not expose to rain.
• 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.
• Disconnect the 240V mains supply before making or breaking connections to the battery.
• The battery charger must be plugged into an earthed socket outlet.
• Connection to supply mains must be in accordance with National wiring rules.
• Do not attempt to charge non-rechargeable batteries.
• Never charge a frozen battery.
• If the AC cord is damaged, do not attempt to use it. It must be replaced or repaired by a qualified person.
• Corrosive substances may escape from the battery during charging and damage delicate surfaces. Store and charge in a suitable area.
• Where possible, ensure all vehicle accessories (lights, heaters, appliances, etc.) are turned off prior to charging.
• 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.
• Young children should be supervised to ensure they do not play with the appliance.
• If the recreational vehicle is to be put into storage without power, turn off the BATTERY MASTER SWITCH. If the recreational vehicle is to be put into long-term storage without power, disconnect ALL cabling from the battery.

System Introduction - PM200

The PM200 is designed for use in caravans or motorhomes. It integrates functions such as a battery charger, distribution blocks, PWM solar charger controller, charging relay, battery low voltage protector, water pump controller, water tank indicator, and an LED display.

The PM200 is designed for easy installation and a user-friendly interface.

System Components:

• PM235 Master power unit
• PMSWLED LED Display
• PMWS200 or PMWS400 Water tank sensor (Not supplied)
• Cables (Refer to Chapter 4.1 for the cable list)

A system schematic diagram shows the PMSWLED display connected to the PM235 Master Power Unit. The PM235 has connections for PV (Solar), AC In, Service Battery, and Starter Battery. The display unit connects to the PM235 via a communication port. Water tank probes connect to the PM235 unit, and these probes are designed for side installation in water tanks of varying depths.

Key Features and Functions

2.1 Multiple Inputs

The PM200 can accept power from multiple sources simultaneously: AC mains, solar panels, and the starter battery (auxiliary). The system prioritizes these sources in the following order: AC Mains, then Solar, then Auxiliary. The dominating source provides power at any given time.

2.2 Battery Charger of Stationery/Service Battery

The charger automatically activates when a qualified power source (grid, generator, or solar) is connected. It employs a multi-stage charging algorithm (soft start, bulk, absorption, float, recycle) for efficient and complete battery charging. The microprocessor-controlled algorithm ensures optimal charging for batteries in various states. Float and recycle charging programs maintain battery condition during extended connection periods.

• Battery temperature compensation charging: Utilizes the supplied Battery Temperature Sensor (BTS PM30) to adjust charging in real-time based on battery temperature (compensation rate of -4mV ±10% /°C /cell). If the BTS is not present, a default of 25°C is used.
• Voltage compensation charging: With a voltage sensor (PM30), the PM200 can automatically adjust its output to compensate for voltage drops in cables, ensuring the correct voltage is delivered for optimal charging.
• Adjustable charging capacity: Users can set the charging current by specifying the battery capacity. The default charging current is set at 10% of the battery capacity (I=0.1C).
• Lithium battery charging: The PM200 can be configured for Lithium batteries, automatically setting the maximum charging current to 30% of the battery capacity (Imax = 0.3C).

The charging algorithm is illustrated with a graph showing voltage and current stages over time: Soft Start (increases battery life), Bulk (maximum charge to set voltage), Absorption (full charge without overcharging), Float (maintains battery at 100% charge), and Recycle (recharges battery if voltage drops).

2.3 Vehicle Battery Charger

In addition to charging the service battery, the PM200 provides a float charge of up to 3A to maintain the starter battery when connected to AC mains or PV. Charging begins after a 30-minute delay if the starter battery voltage drops below 12.4V and stops when it reaches 12.8V.

2.4 Power Supply Mode

If no battery is connected, the PM200 operates as a power supply with a 12.8VDC output.

2.5 PWM Solar Charger Controller

The PM200 includes a built-in PWM charger for the service battery with a maximum input voltage of 25VDC and a maximum charging/supply current of 30A.

2.6 Voltage Charging Relay (VCR)

The PM200 features a built-in Voltage Charging Relay (VCR) that allows the service battery to be charged by the alternator when the engine is running.

• Lead Acid Battery: The VCR activates 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 VCR activates when the starter battery reaches 14.0VDC (with a time delay). Charging continues until the starter battery voltage drops below 13.5VDC with less than 2A charge to the service battery.

Note: When charging from the starter battery, the PM200 does not provide 5-stage charging; it utilizes available power from the alternator. If the vehicle has a smart charging system (variable voltage or temperature compensating), the VCR may not function correctly, and a DC-DC charging system is recommended.

2.7 Categorised Outputs

The PM200 provides 14 categorized outputs for various loads:

• Class A1 (1 output): Relay-controlled output with fuse, protected by the main master switch relay. Suitable for water pumps.
• Class B (10 outputs): Fused outputs, protected by the master switch relay. Suitable for ventilation fans, etc.
• Class C (2 outputs): Live load outputs. Suitable for fridges, security alarms, etc.
• Class D (1 output): Permanent on load. Suitable for auto steps.

2.8 Battery Low Voltage Protection (BLVP)

A built-in low voltage protection relay disconnects the load when the battery voltage drops below a set threshold. The default setting is 10.5VDC for lead-acid batteries and 11.2VDC for LiFePO4 batteries.

2.9 Manual Battery Switch

The PM200 includes a manual battery switch to disconnect the service battery output, protecting it from being drained by onboard electronics. It also supports an external remote battery switch. The local switch is disabled when the 'switch selector' is set to 'Remote'. The switch is only effective when the battery is the sole energy source for the load.

2.10 Silent Mode

In Silent Mode, the backlight of the LED Display and the fan speed are reduced or turned off for quieter operation.

Structure and Installation

3.1 PM200 Master Power Unit

The PM235 Master Power Unit has various connection ports and indicators on its front and rear panels. These include AC input, switch panel communication, battery sensor input, PV input, starter and service battery connections, and multiple load outputs (L1 to L14). It also features a main battery switch and dip switches for configuration.

Installation: The PM235 can be installed on a horizontal surface or vertically on a wall. Ensure adequate clearance (5cm on each side) on both sides of the unit for proper ventilation.

3.2 L.E.D Display

The PMSWLED display panel features controls and indicators for water pump, night mode, general loads, and water tank levels (fresh, tap, waste). It also displays starter and service battery voltages.

Installation: The PMSWLED is designed for panel mounting, with dimensions and hole size specifications provided.

3.3 Water Tank Probe

The PM200 supports up to three water tank probes (PMWS200 or PMWS400). These probes are for side installation in water tanks and come in different depths (PMWS200 for depths >200mm, PMWS400 for depths 300-400mm).

Installation: Instructions and dimensions for installing the water tank probes are provided, including the required hole size for the tank wall.

Wiring

4.1 Material

Recommended minimum cable sizes are provided based on current ratings to ensure safe and efficient operation.

Cables passing through panels or walls should be protected from sharp edges using cable glands.

4.3 Preparation

The PM200 system is designed for easy installation. A screwdriver and DC cables are required. Follow the recommended minimum wiring sizes.

4.4 Connection

The PM200 unit uses spring and screw terminals for connections. Terminal Type 1 (ERTB10-10.16) is suitable for cable gauges from 0.5 mm² to 10 mm², and Terminal Type 2 (WAGO 804-114) is suitable for 0.25 mm² to 2.5 mm².

Illustrations show the connection process for both terminal types.

Display

5.1 PM235 Master Power Unit

The PM235 unit features several LEDs that indicate the system status:

• Mains (Green): ON (AC input OK), OFF (AC disconnected), Quick flashing (AC input abnormal).
• Str Bat (Green): ON (Starter Battery charging), Slow flashing (Auxiliary input normal, charging by AC), Quick flashing (Starter Battery input error), OFF (Starter Battery disconnected).
• PV (Green): ON (PV charging battery), Slow flashing (PV input normal, charging by AC or Starter Battery), Quick flashing (PV input error), OFF (PV disconnected).
• CHG (Green): ON (Battery charged), Flashing (Battery charging), Slow flashing (Battery discharge), OFF (Battery disconnect).
• FAULT (Red): ON (Short circuit), Flashing codes indicate various faults like low/high service battery voltage, over-temperature, charge timeouts, VCR anomaly, or ambient over-temperature.

5.2 L.E.D Display

The PMSWLED display provides detailed information:

• Water Pump (Control): On/off control for the water pump.
• Night Mode (Scene Mode): Activates a low-power mode.
• Load (Control): On/off control for general DC loads.
• Fresh, Tap, Waste Water Tank (Sensors): Indicate the water levels in the respective tanks.
• Starter Battery & Service Battery (Voltage): Display the voltage of both batteries.

LED indications on the PMSWLED for Mains, PV, and Fault are similar to those on the PM235 unit.

Operation

6.1 Configuration on PM200

The battery type and capacity can be configured using the dip switches on the PM235 master power unit.

6.1.1 Battery Capacity and Battery Type

Dip switches (DS1-DS4) are used to set the charging current and battery type (AGM, GEL, LiFePO4, WET). Tables provide the specific settings for charging current based on battery capacity and type, as well as absorption and float voltages for different battery types.

The factory default setting is all dip switches OFF.

6.1.2 Select Battery Switch Local/Remote

A dip switch allows selection between the local battery switch on the PM235 unit and a remote battery switch. When set to 'Remote', the local switch is disabled.

6.2 Daily Maintenance

• Ensure the Battery Switch is ON when charging from the AC grid.
• Check that the nominal battery voltage is 12VDC.
• Ensure adequate ventilation space (10 cm on each side) around the PM235 unit.
• When replacing a battery, fully charge the new battery using the grid for the first time to calibrate the State of Charge (SOC).
• It is recommended to switch off the local or remote Battery Switch to cut off service battery consumption when not in use or during storage.

Trouble Shooting

A table lists common LED error indicators on the PM235 unit and their corresponding descriptions:

• Mains LED Quick Flashing: AC input abnormal.
• Str Bat LED Quick Flashing: Starter Battery voltage is too low (below 13.4V) or too high (above 16.0V) while AC power is connected.
• PV LED Quick Flashing: Solar input voltage error (Solar input > 25Vdc).
• Fuse LED OFF: Fuse blown, indicating a need to check the load and replace the fuse.
• FAULT LED ON/Flashing: Indicates various faults including short circuit, low/high service battery voltage, over-temperature (heat sink or ambient), bulk charge timeout, or VCR anomaly.

Specification

Detailed specifications for the PM235 unit are provided, including:

• Electrical Specifications: Grid input voltage, power factor, input current, battery voltage ranges (starter and service), PV charger type and ratings, charging relay specifications, charger modes (algorithms, battery types, voltages, currents), power supply mode output, efficiency, and working temperature range.
• Others: Battery disconnect (LVD) settings, current draw on battery in different states, fused outputs (number and rating), protection features (short circuit, reverse polarity, overload, over-temperature, over-voltage), physical dimensions, weight, enclosure material, connector types, cooling method, and protection category.
• Approvals: Electrical (AS/NZS 60335-2-29) and EMC (CISPR14).

Warranty Statement

This warranty statement is applicable only to products sold in Australia by Brown & Watson International Pty Ltd. It covers defects in material and workmanship for a period of one (1) year from the date of original purchase, provided the product is used under normal conditions. The warranty excludes ordinary wear and tear, abuse, alterations, or consumer-caused damage. To make a warranty claim, the consumer must return the product to the place of purchase with the original invoice and a written explanation of the claim. Brown & Watson International reserves the right to repair or replace the product at its discretion for 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 rights under Australian Consumer Law.

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. They are also entitled to have goods 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
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