National Luna NLDC-25 User manual

Index
Introduction
Safety Information
External features
Preparing for Installation
Fitting the NLDC-25
Universal Mounting Fixture
Typical Installation diagram
Installation steps
Selecting battery type
Ignition over-ride
Temperature compensation
Remote monitor
Remote monitor operation
Remote monitor warning messages
Application examples
Specifications
1
1
2
3
3
4
6
7
7
8
8
9
10
11
12
15

SAFETY INFORMATION :
ŸBefore installation, read the instructions carefully.
ŸBefore installation, disconnect any existing batteries.
ŸThe NLDC-25 is used for charging 12V lead-acid and automotive Lithium batteries only.
ŸDo not use for any purpose other than battery charging.
ŸDo not attempt to power any devices or instruments directly using the output of NLDC-25.
ŸDo not attempt to charge a non-rechargeable or battery other than 12V.
ŸNever attempt to charge a damaged battery or leaking battery.
ŸAvoid open flames in the vicinity of the battery.
ŸBattery acid is highly corrosive. If your skin or eyes come into contact with acid, immediately rinse
the affected area with water and seek medical advice.
ŸDo not alter or disassemble the NLDC-25 under any circumstances.
ŸUnauthorized disassembly, repairs or modifications will void any warranty.
ŸAttempts to use the NLDC-25 for purposes other than indicated in this manual will void the warranty.
ŸEnsure all connections are secure and cables are installed in a safe manner.
ŸUse the correct cabling size and fuses in accordance with the installation instructions.
The NLDC-25 from National Luna is a DC to DC battery charger and isolator for a dual-battery system.
It will charge an auxiliary or service battery from a vehicle alternator or Solar panel up to 25A output current.
Traditional 12V and 24V vehicle alternators as well as variable voltage alternators are supported.
The integrated MPPT solar regulator provides a maximum output power of 375W but can support solar panels higher than this.
Solar panel voltages up to 42V can be connected.
The NLDC-25 features a 6-stage charge algorithm that is suitable for any Lead-Acid battery type as well as automotive Lithium-Ion batteries.
3 safety stages analyse the battery and can detect batteries that are damaged and unable to accept charge.
Temperature compensation is used to optimise the output voltage, ensuring safe and full battery charging under various conditions.
The NLDC-25 supports the connection of a remote monitor that displays information about the system and battery levels to the user on a
high-contrast LCD screen.
The NLDC-25 has a IP67 rating for harsh environments and is protected against reverse-polarity, over-voltage, over-temperature and
over-current conditions.
NLDC-25 Dual Battery Isolator and Charger
1

NLDC-25 External features
1 - NL-DC25 Metal Base
2 - Remote monitor connecting port
3 - Status display
4 - Removable top cover
5 - Temperature compensation input
6 - Ignition over-ride input
7 - Removable terminal block
8 - Terminal block - Auxiliary battery output
9 - Terminal block - Common ground connections
10 - Terminal block - Alternator input
11 - Terminal block - SOLAR panel input
12 - Mounting feet
Status Display
1 - Battery type selection button
2 - Battery type indicator
3 - OK / Fault indicator : Green = OK, Red = Fault
4 - Input source indicator (ALT or SOLAR)
5 - Charge stage indicator
NLDC-25 Features
1
3
2
4
DC-DC Battery Charger
Battery
Float
Li-ion Wet
Ca+ AGM/Gel
Charge
OK /
342 5
2
1
5
6
7
8
9
10
11
12

ŸThe NLDC-25 should be located close to the auxiliary battery for best voltage regulation.
ŸThe NLDC-25 can operate in harsh environments but it is best installed in a location that is cooler with adequate ventilation.
ŸAvoid areas exposed to harsh or corrosive chemicals, excessive dust, extreme heat or mechanical movement.
ŸThe NLDC-25 can be installed vertically or horizontally.
ŸDo not block or obstruct the cooling fins on the NLDC-25.
ŸAllow clearance around the NLDC-25 for cables and ventilation.
ŸIt is normal for the NLDC-25 to get hot during operation, keep any objects that are heat-sensitive away from the NLDC-25.
ŸIf the temperature compensation probe is used, it must be able to reach the auxiliary battery.
2
ŸIt is recommended to use 16mm cables for connections to the main and auxiliary batteries. Smaller gauge cables can be used for short
distances.
ŸIn-line fuses must be fitted in the positive cables close to the respective main and auxiliary batteries.
ŸUse the common ground connections on the terminal block for all negative cable connections.
ŸUse appropriate cable lugs for the cable size used.
Preparing for Installation
Removing the top cover
3
In order to select the battery type and to install the
temperature compensation & ignition over-ride
wires, the top cover will need to be removed.
Loosen the two screws as indicated in order to
release the cover.

Fitting the NLDC-25
4
The NLDC-25 has 4 mounting feet, use these to attach the NLDC-25 to a secure,
flat surface.
Use appropriate screws or bolts to attach the NLDC-25 securely, M4 machine bolts
are recommended.
DO NOT drill into or modify the NLDC-25 housing.
Allow enough clearance for power cables to connect to the terminal block.
50mm or more is recommended.
It is recommended to secure cables together and prevent excessive movement
in the final application.
If the remote monitor is fitted, allow clearance for the plug and cable.
The NLDC-25 is supplied with a universal mounting fixture
and fasteners that can be used to aid installation in a variety of
applications.
This fixture allows the NLDC-25 to be attached in several ways
depending on the application requirements.
Use the supplied screws and washers to secure the NLDC-25 to the
plate in the chosen orientation.
Secure the fixture in the final application with appropriate fasteners.
Universal mounting fixture
M4x20 screws
Spring washer
Flat washer
Cable Clearance

5
The supplied step-plates can be used to raise the NLDC-25
above obstructions such as pipes or cables if necessary.
Use the supplied screws and washers to assemble the fixture
as shown in the diagram.
Use appropriate fasteners to secure the assembled plate
to the application.
The NLDC-25 can be rotated on the plate by 90° to suite the
application.
Vertical or horizontal installation is supported.
Step plates
M4x20 screws
Spring washer
Flat washer

Typical Installation
FUSE FUSE
SOLAR PANELS
+
-
+
-
AUX
BATTERY
MAIN
BATTERY
6
+
-

Installation Steps
Selecting Battery Type
The NLDC-25 will optimise charge voltage based on the selected battery
type.
Remove the NLDC-25 top cover to access the battery select button.
The battery type can be selected by pressing the “Battery” button on the
NLDC-25 control panel. The chosen battery type is displayed.
ŸDisconnect the main battery before starting installation.
ŸInstall the NLDC-25 using the mounting feet. (Described on page 4).
ŸInstall positive and negative cables from the Auxiliary battery to the NLDC-25. Connect to the AUX and GND terminals respectively.
ŸInstall one in-line fuse on the positive cable near to the Auxiliary battery. Do not connect the battery yet.
ŸInstall positive and negative cables from the NLDC-25 to the Main battery. Connect to the ALT and GND terminals respectively.
ŸInstall one in-line fuse on the positive cable near to the Main battery.
ŸIf a solar panel is used, connect the positive and negative cables from the solar panel to the SOLAR and GND terminals respectively.
ŸConnect the temperature compensation probe and IGN over-ride cable if used. (See page 8).
ŸInstall the remote monitor (if used) and run its cable to the remote monitor port on the NLDC-25. (See page 9).
ŸDouble check all cables and connections for correct installation.
ŸRe-connect the Main battery. The NLDC-25 should now be powered and will show status on the status display.
ŸSelect the Auxiliary battery type. See “Selecting Battery Type” below.
ŸConnect the Auxiliary battery.
ŸIf the remote monitor is installed, the voltages of the Main and Auxiliary batteries will now be displayed.
ŸThe system is now ready.
Wet
AGM / Gel
Ca+
Li-ion Used for automotive Lithium-ion or LiFe
batteries.
Used for regular automotive starting
and flooded high-cycle batteries.
Used for flooded deep-cycle, calcium and
maintenance - free batteries.
Used for all types of AGM and Gel
batteries.
For safety reasons, the battery type cannot be changed if the
AUX battery is already connected.
7

The ignition (IGN) over-ride input can be used in vehicles that have
variable alternator output.
This is common with “Smart” alternators.
Connect the IGN terminal using a small gauge wire to a 12V
ignition lead or source in the vehicle.
This source must be switched to a positive voltage when the
vehicle is started and switched off when the vehicle is turned off.
If the IGN feature is used, the Turn-ON and Turn-OFF voltages of
the NLDC-25 are adjusted (See specifications on page 15).
IGN over-ride Temperature sensor
The NLDC-25 is supplied with a temperature compensation probe.
For best performance, connect the probe end to one of the AUX
battery terminals or to the battery casing.
Connect the smaller ring on the sensor cable to the “sensor” terminal
on the NLDC-25. Connect the larger ring to one of the GND terminals.
With the probe fitted, the NLDC-25 will optimise final charge voltage
based on the measured temperature. This prevents over-charge at
higher temperatures and increases charge performance at lower
temperatures.
For safety, charge is stopped if the battery temperature increases
above 50°C.
Fitting the temperature probe in a location other than on the
AUX battery can increase the risk of battery over or
under-charging.
CAUTION - DO NOT connect the IGN over-ride permanently
to a non-switched positive source.
Doing so may result in excessive drain on the Main battery.
8
+
-
AUX
BATTERY
+
-
MAIN
BATTERY
Temperature sensor
Ignition