PROJECTA INTELLI Jay

1. GENERAL & SAFETY INFORMATION

This section contains 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 with knowledge of 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 to unit is minimum 6mm². Output charging current of the PMDC-30 charge booster will depend on wire size of the auxiliary circuits in the Charging Vehicle and Caravan.
• 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-Jay transformer polarities are correct.
• Use the shortest possible cable lengths to connect the Input and Output circuits to the unit.
• Ensure there's sufficient ventilation around the heatsink of the unit.

2. INTRODUCTION

2.1 GENERAL INTRODUCTION

The PMDC-30 is a 30 Amp output DC to DC charger, designed to be integrated with the Intelli-Jay battery management system. It comes with stripped & tinned, labelled input and output wiring, for ease of installation.

FEATURES

• Non-isolation design with max efficiency 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, 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

The PMDC-30 DC-DC Converter is depicted as a central unit. It receives input from an Alternator and Motor battery (30A) and outputs to an Intelli-Jay Transformer (30A). Control signals include Voltage detect, Temperature detect, D+ input, LED status, DIP Switch, and COM port, managed by an MCU.

The charging efficiency of the PMDC-30 is up to 96%. PMDC-30 also supports communication of RS485.

Note: PMDC-30 will treat it as a conventional engine rather than a Euro 6 engine.

2.3 MULTI STAGE CHARGING ALGORITHM

The PMDC-30 is able to charge 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 guarantee optimal charging for batteries of different discharged states.

The charging algorithm graph illustrates the relationship between Battery Voltage and Charging Current over different stages. Starting from Soft Start, the current rises to 1/2 Icc during Bulk charging. In Absorption, current gradually decreases. Float stage maintains a low current, followed by a Recycle stage. Time scales shown are 10 days, 1 hour, and 5 minutes.

2.4 BATTERY TEMPERATURE COMPENSATION

Battery temperature is a key factor in correct charging. The charging formula must be adjusted (automatically and in real time) according to the actual battery temperature to ensure that batteries are fully charged but not overcharged or undercharged. All charging voltages recommended by battery manufacturers are typically applied at 20°C – 25°C.

The BTS (Battery Temperature Sensor) connected to the PMDC-30 measures the battery temperature and automatically makes adjustments in real time to properly charge your batteries at the default compensation rate of -3mV/°C/cell. If the BTS is not present/connected, the PMDC-30 will use 25°C as the default setting.

A Battery Temperature Sensor (BTS) is depicted as a small circular sensor attached to a wire, designed to connect to the PMDC-30.

2.5 DE-RATE CURVE AGAINST TEMPERATURE INCREASE

The PMDC-30 monitors internal temperature to decide output power. It will de-rate its output power against temperature increasing. The following curve reflects the change of output power with temperature increase.

The de-rate curve graph shows Output Power Percentage versus Ambient Temperature. From 25°C to 60°C, output power remains at 100%. Above 60°C, power output decreases linearly, reaching 50% at 75°C.

3. STRUCTURE AND DIMENSION

3.1 EXTERIOR AND DIMENSION

The front view of the PMDC-30 shows status LEDs on the left, and input/output terminals (AUX+, AUX-, Vehicle Batt+, Vehicle Batt-) on the right, along with DIP switches and a COM port. The unit is designed for internal installation ONLY.

The PMDC-30 unit has a main body width of 181mm and height of 148mm. The heatsink extends to 161.5mm in width. The depth of the unit is 49mm, with connectors extending to 52mm. Mounting holes are positioned 170mm apart horizontally and 100mm apart vertically.

3.2 CONNECTORS AND TERMINALS

The PMDC-30 unit is shown with numbered connectors and terminals from 1 to 7.

3.3 STATUS INDICATORS

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 and for internal installation ONLY.
• The temperature at the casing and heat sink of PMDC-30 can be as high as 60°C during operation.
• Ensure PMDC-30 is installed away from flammables and explosives.
• Please have the installation away from inflammable and explosive goods.
• Ensure PMDC-30 is installed out of reach of children.
• Ensure 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 where the PMDC-30 is installed. See recommended spacing dimensions below.

Diagram shows required ventilation spacing around the PMDC-30: minimum 50mm space is required on the top, left, and right sides of the unit, and a minimum of 100mm space is required at the rear.

4.5 MOUNTING HOLES

Find an appropriate mounting surface, flat and rigid. Drill mounting holes per the dimensions below.

The mounting template indicates four holes, each 5.5mm in diameter, arranged in a rectangular pattern. The horizontal spacing between hole centers is 170mm, and the vertical spacing is 100mm.

4.6 DIP SWITCH SETTING

Dip Switches: Set output current and battery type. UP = OFF, DOWN = ON.

⚠️ 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

WARRANTY STATEMENT

Brown & Watson International Pty. Ltd. ("BWI") of 1500 Ferntree Gully Road, Knoxfield, Vic., telephone 1800 294 294, warrants that all products described in its current catalogue will under normal use and service be free of failures in material and workmanship for a period of three (3) year from the date of the original purchase by the customer as marked on the invoice (see elsewhere for specific warranty period). This warranty does not cover ordinary wear and tear, abuse, alteration of products 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 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.

If 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. If a major failure is determined 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
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

Issue 2 7.10.2021