PROJECTA PM235C Power Management System

IMPORTANT SAFETY INFORMATION

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

WARNINGS

• Explosive gases. Prevent flames and sparks. Provide adequate ventilation during charging
• Before charging, read the instructions
• For indoor use ONLY.
• 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 the 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 are 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.

Product Instructions

Overview
PM235C is designed for use in caravans or motor homes. It has the following functions integrated into the unit: battery charger, distribution blocks, PWM solar charger controller, VSR charging, battery low voltage protection, water pump controller.
PM235C 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

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 (PWM), 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. Voltage is dependent of vehicle input (12V systems only).
• 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

Block diagram

Water Tank Probe
PM235C 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

Key Features and Functions

Multiple Inputs
PM235C 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.

Table 3 Source priority

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 PM235C is designed to fully charge the service battery quickly. The PM235C 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.

1. SOFT START
   Increases battery life by gently starting to charge the battery 5% of bulk
2. BULK
   Reduces charging time by delivering maximum charge to set voltage life by gently starting to charge the battery 25% of bulk
3. ABSORPTION
   Ensures a full charge to the battery without overcharging
4. FLOAT
   Float charge maintains the battery at 100% charge
5. RECYCLE

Battery Temperature & Voltage Sensor
The optional battery temperature sensor (P/N: PMBS-3m) can be used with the PM235C to measure the temperature of the battery, allowing the PM235C 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 PM235C 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 PM235C 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)

Vehicle Battery Charger
Along with a powerful charger for the service battery, PM235C 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 PM235C starts charging after a 30 minute delay, and stops charging when the voltage reaches 12.8V

Power Supply Mode
If no battery is attached to PM235C Unit, it will automatically work as a power supply with a 12.8VDC output.

PWM Solar Charger Controller
PM235C has a built-in PWM charger for the service battery with:

• Max input voltage 30VDC
• Max charging current 30A
• Max supply current 30A
• PM235C 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.

Voltage charging relay (commonly known as VSR)
PM235C 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 is less than 2A charge to the service battery with threshold time delay.

NOTE: The PM235C starter battery input does not provide 5-stage charging. It takes whatever power is available from the alternator to charge.

NOTE: 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.

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

Battery Low voltage protection (BLVP or commonly known as an LVD)
PM235C 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.

Battery switch
The PM235C unit offers a convenient way to switch off the output of the service battery onboard. It protects the service battery from being drained by electronics on board, completely isolating the battery. The PM235C 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.

Precise Battery Measurement
PM235C has a battery measurement system controlled by a 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 the PM235C Power Management System, the measurement will not be accurate. NOTE: P/No. PMSHUNT will be required for heavy loads designed to be connected directly to the battery to ensure SOC% accuracy.

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.

STRUCTURE AND INSTALLATION

PM235C Power Management System

Installation:
PM235C 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

Water Tank Probe

PMWS400 WATER TANK PROBE

PMWS200 WATER TANK PROBE

Wiring

System Components

System Schematic

Preparation
PM235C 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.

Connection
PM235C 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.

TYPE 1 (SCREW TERMINALS)

TYPE 2 & 3 (SPRING TERMINALS)

PM235C Master unit

Operation

Manual switch

There is an ON/OFF switch on the side of the machine, which is used to control the whole machine to switch on/off when it is powered by battery alone, and to control the whole machine to enter into sleep mode when it is powered by mains power. This switch must be be “ON” in order for the Remote Switch to operate.

Remote switch (optional)

The remote switch terminals are located next to the positive 14 terminal. This requires the use of an external switch and functions the same way as the manual On/Off Battery Switch on the side of the charger. The Battery switch must be “ON” in order to use the Remote Switch line. When not used both terminals must be bridged together.

Dip switch

There is 5 pin dip switch on the unit which is used for adjusting charging current and battery type. At this time, switch 5 is not used and should be in the “OFF” position

Note: These do not not to be adjusted if a digital screen is used

Pin 1-2 Definition

Pin 3-4 Definition

Maintenance

BATTERY MONITOR MAINTENANCE
PM235C systems feature built-in battery measurement software. To ensure accurate readings, maintain the system with the following instructions:

1. Fully charge the battery from AC input instead of solar every 2 weeks.
2. Fully charge the battery from mains at least once every 3 months, even in storage, unless required to earlier.

DAILY MAINTENANCE

• Confirm the Power switch is turned ON when you want to charge the battery from the AC grid
• Check the nominal battery is 12VDC
• Ensure the Space (50mm each side) beside the PM235C unit for the appropriate ventilation
• When replacing an existing battery, fully charge via AC grid to Float Stage to ensure SOC% is accurately calibrated.
  • Only the energy consumption of the loads connected to the PM235C 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.

SPECIFICATION

ADD-ON ACCESSORIES

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, pages 22-25).

SC520/SC540 5-Stage MPPT SOLAR CHARGER CONTROLLER WITH 100V INPUT
Get the most out of your solar array using these Maximum Power Point Tracking (MPPT) Solar controllers increasing the charging output by up to 30% (compared to PWM Solar controllers).

PMDCS30/PMDCS60 DC-DC 12V CHARGER
Smart DC to DC chargers are specifically designed for Intelli-RV and Intelli-Grid.

PMDCS30-20 DC-DC 12V CHARGER
Smart DC to DC chargers specifically designed for Intelli-RV and Intelli-Grid where a 3-way fridge or compressor fridge is used.

Note: If using load as a ‘CONSTANT’ connection (set via display or APP), the output of DCDC charger MUST be connected directly to LB-HD or PMSHUNT.

PMTPMS TYRE PRESSURE MONITORING SYSTEM MODULE
The Tyre Pressure Monitoring System (TPMS) monitors the RV’s tyre pressure before and during the journey.

PMLVL LEVELLING SENSOR
Level the RV with the levelling sensor which can be monitored via the phone app.

Calibration
To calibrate the level sensor, the RV needs to be level in both forward and back and side to side. Once level, go to the Setting Page, select Level Sensor and press Calibrate. This will zero the sensor.

LB200-HD 12V HIGH DISCHARGE 200AH LITHIUM BATTERY
LB200-HD boast impressive capabilities and are ideal for 4WDs and caravans with high power demands

LB400-HD 12V HIGH DISCHARGE 400AH LITHIUM BATTERY
The LB400-HD boasts an astonishing 400Ah capacity and a market leading 300A discharge capability making it ideal to partner with high current drawing appliances such as 3000W inverters.

Connection

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 onthe 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 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
• 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

FAQs

Q: What is the maximum number of water tank probes that the PM235C can monitor?
A: The PM235C can monitor a maximum of 4 water tank probes.

Q: What are the possible uses of the different classes in the block diagram?
A: Class A5 can be used for water pumps, Class C2 for ventilation fans, Class C3 for fridges, security alarms, etc., and Class D for breakaway systems, sway controllers, and radio memory.

Documents / Resources

PROJECTA PM235C Power Management System [pdf] Instruction Manual PM235C Power Management System, PM235C, Power Management System, Management System

References

• User Manual