Expion360 EX-PC45 Operating instructions

Installation and Operation Guide
EX-PC45 45 A Voyager Converter Charger

NOTES
•Horizontal mounting of the power converter is recommended although it can be mounted in any position
that provides unobstructed ventilation to the fan and vent holes.
•The OEM should test the power converter under full load conditions in its intended mounting location. This
will ensure there is sufficient ventilation to the converter allowing it to operate at its maximum rated output.
Failure to provide adequate ventilation to the converter will cause the converter output to be reduced as it
responds to ambient conditions.
•The INTELI-POWER converters are not designed for zero clearance compartments.
•Use a 5/32” hex driver to tighten the output screws. Do not exceed 50 in-lb torque on the output terminals.
•The INTELI-POWER converters are not weather-tight or designed for wet mounting locations. They must be
protected from direct contact with water.
•Avoid the introduction of foreign materials into the case as this could damage or cause a malfunction of the
converter.
INSTALLATION
1. Secure the converter firmly to the mounting surface.
2. Connect chassis ground lug (found on unit base) to chassis. Ground wire to be 10 AWG copper wire
minimum (follow all applicable codes when sizing conductor).
3. Disconnect the battery from both positive (+) and ground (-) cables.
4. Connect battery ground (-) to converter NEG (-) lug. Conductor to be minimum 8AWG copper with minimum
75 ⁰C jacket rating (follow all applicable codes when sizing conductor).
5. Disconnect any optional accessories or modules.
6. Plug the converter into the appropriate outlet.
7. Using a DC voltmeter, verify the converter output. If no output is measured, refer to the troubleshooting
guide in this manual or on the Expion360 website.
8. Disconnect power to the converter.
9. Connect battery POS (+) to converter POS (+) lug. Conductor to be minimum 8AWG copper with a minimum
75 ⁰C jacket rating (follow all applicable codes when sizing conductor). Note: When connecting the battery to
converter POS (+), a spark may occur. This is normal.
10. Reconnect cables.
11. Reconnect any optional accessories or modules.
12. Reconnect power to the converter.
Torque Data
DC Lugs: 30 to 50 in-lb
Chassis Ground Lug:
25 to 35 in-lb
DO NOT REMOVE TERMINAL BLOCK SCREWS
CAUTION RISK OF FIRE
The chassis bonding wire must be a separate wire connected
directly from the grounding lug provided on the converter.
DO NOT connect output negative to chassis using the same wire.

FEATURES
MULTIPLE BATTERY CHARGING: INTELI-POWER converters have the capability of charging multiple batteries
at the same time.
GFCI PROTECTION: INTELI-POWER converters have the LOWEST ground fault leakage. The user can
confidently utilize the RV’s AC outlets without concern of ground fault interruption of the shore power source.
REVERSE POLARITY PROTECTION prevents damage if battery leads are connected in reverse. If the battery
leads are connected in reverse, the converter protection fuse will blow and damage to the converter will be
avoided. Connecting the battery leads in reverse is the only event that will blow this fuse. Replacement blade
fuses are available at any automotive store.
GENERAL OPERATION
INTELI-POWER converters will supply “clean” power from input voltages ranging from 105 – 130 Vac.
INTELI-POWER converters are designed for use with a battery; however, filtered DC voltage can power
sensitive electronics without the need for a battery or other filtering.
At normal input voltages, the full-load rated capacity is available. At input voltages, less than 105 Vac the
converter may not supply full-rated output capacity.
The full-rated output is available for load, battery charging, or both. When charging the battery, the converter
has a nominal voltage output of 14.4 Vdc.
CAUTION
The EX-PC45 45 A Voyager Converter Charger is designed to charge lithium iron phosphate batteries. DO NOT
USE THIS MODEL TO CHARGE LEAD-ACID BATTERIES!
When storing the vehicle for extended periods of time, disconnect the batteries. Follow the steps in the
installation section before reconnecting the converter charger.
CAUTION
IF THE REVERSE POLARITY PROTECTION FUSES ARE BLOWN DURING INSTALLATION, CHECK TO SEE THAT
THE BATTERY HAS BEEN CONNECTED PROPERLY BEFORE REPLACING THE FUSES. REPLACE THE FUSES
ONLY WITH THE SAME TYPE AND RATING AS THE ORIGINAL FUSES. USING OTHER FUSES MAY RESULT IN
CONVERTER DAMAGE, INJURY, OR OTHER CONSEQUENCES. (SEE WARRANTY)
WARNING
THIS EQUIPMENT IS NOT IGNITION PROTECTED AND MAY PRODUCE ARCS OR SPARKS. TO PREVENT FIRE
OR EXPLOSION, DO NOT INSTALL IN COMPARTMENTS CONTAINING FLAMMABLE GASES OR MATERIALS.

PRODUCT SPECIFICATIONS
EX-PC45
Input: 105 – 130 Vac, 60 Hz, 725 Watts
Output: 14.4 Vdc, 45 Adc
Dimensions (W x L x H): 7.25 in x 8.25 in x 4.5 in
Weight: 4.5 lb
TROUBLESHOOTING GUIDE
Problem
Possible
Causes
Action
1. No output
Proper AC power not connected
Connect power supply
Check AC distribution panel for
proper operation
External fuses blown
Check for reverse polarity
Replace fuses with the same type
and rating
Short circuit
Trace circuits for possible fault
Overheating
Check the airflow
Allow unit to cool
Overvoltage condition
(See also Item 4)
(No overvoltage protection for 230 V units)
Check input voltage
The converter will shut down if the
input voltage exceeds 132 Vdc
Correct the input voltage
2. External fuses blown
Reverse polarity connection
Correct connections and replace
fuses with the same type and
rating
3. Low output
Excessive load for converter
Reduce load requirements or
install a larger converter
Input voltage not between 105 – 130 Vac
Correct the input supply voltage
Mild overheating
Check the airflow
Allow unit to cool
4. Intermittent or no
output when connected
to a generator, works on
shore power
The unit has shut down due to overvoltage
Add another load to the generator,
this may reduce the spikes to an
acceptable level
Some generators produce excessive voltage
spikes in the AC power output. This may
cause the overvoltage protection to shut the
unit down
Contact the generator
manufacturer for a possible defect
in the generator