National Luna DC25 Distribution Box User manual

DC25 Distribution Box

1
Index
2
2
3
5
4
6
4
7
8
8
12
8
9
15
13
10
Connecting remote temperature sensor
Preparing for Installation
Safety Information
Wiring Diagram
Features
Introduction
Connecting Auxiliary battery
Connecting Solar Panels
Connecting External Battery Chargers
Ignition Over-ride
System Operation
Remote Monitor
Remote Monitor Status Messages
Specifications
Warranty
Selecting Battery Type

Introduction
2
ŸAvoid open flames in the vicinity of the battery.
ŸEnsure the DC25 Distribution Box is secured in mobile applications.
ŸDo not alter or modify the DC25 Distribution Box under any circumstances.
ŸDo not use for any purpose other than indicated in this manual.
ŸUnauthorized disassembly, repairs or modifications will void any 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.
ŸDo not attempt to charge a non-rechargeable or battery other than 12V.
ŸInstall the supplied in-line fuses as indicated in the installation instructions.
SAFETY INFORMATION :
ŸBefore installation, read the instructions carefully.
ŸThe DC25 Distribution Box is used for charging 12V lead-acid and Lithium batteries only.
ŸNever attempt to charge a damaged or leaking battery.
ŸAttempts to use the DC25 Distribution Box for purposes other than indicated in this manual will void
the warranty.
The DC25 Distribution Box supports 12V lead-acid (wet, calcium, Gel, AGM) as well as lithium batteries.
The primary charge input supports 12V and 24V vehicle systems and will provide up to 25A of current to
the auxiliary battery using an optimized 6-stage charge algorithm.
to fridges and other small appliances. These connectors can also be used with external battery chargers
as an alternative to the built-in dedicated charge port.
Heavy-duty connectors can be used for connecting a variety of accessories from inverters (600W max)
The introduction of two dual-port USB modules with fast charge allows several smart devices such as
smart-phones, tablets, GPS, cameras and other USB-devices to be powered up to 18W on each port.
A built-in 25A MPPT solar regulator circuit supports solar panels up to 42V and provides up to 25A (375W)
charge current to the battery.
The National Luna DC25 Distribution Box is ideally suited to fixed installations such as trailers,
caravans and campers where the auxiliary batteries are separated from the charge system.
The DC25 Distribution Box features a high-performance 25A DC-DC charge system that offers charging
from the vehicle alternator as well as from Solar panels. Multiple outputs offer USB charging and fused
DC sockets for connecting 12V devices.
ŸThe battery charge profile takes into account battery temperature for safe charging when the
remote temperature sensor is connected.
Supported battery types (set to AGM by default) :
ŸLead-acid (Calcium, Flooded, AGM, Gel, VRLA)
Temperature Compensation & battery protection :
ŸLithium-ion, LiFePO4

Features
3
USB Charge Modules
Battery Gauge
Main Switch
50A Heavy-duty
IN/OUT connectors
SOLAR PANEL input
Remote Monitor port
IGNITION sense port
MAIN BATT input
External Charger input
Charger input fuse
Hella-type DC Socket
12V DC Sockets
Fuses
Control Panel
Mounting Base
Cable entry ports

4
Wiring diagram - Typical Installation
Preparing for Installation
The DC25 Distribution Box should be mounted securely on a flat surface using the mounting frame.
Locate the DC25 Distribution Box such that the cables are not restricted or under strain.
(Fig 1).
Allow a 50mm gap along the bottom of the DC25 Distribution Box for ventilation.
Open the cable entry holes and attach grommets before mounting the DC25 Distribution Box.
2
Use 16mm cables for the input from the vehicle main battery and cables to the auxiliary battery.
Install a 40A in-line fuse close to the main battery on the positive cable (Fig 2).
Install a second 40A fuse close to the auxiliary battery on the positive cable.
Make sure all connections are secure and terminated correctly with appropriate tools.
The input cables must be terminated with a RED 50A coupler matching the input on the DC Distribution
Box marked "MAIN BATT".
If solar panels are used, they can be connected to the input marked "SOLAR PANEL" and must have a
maximum voltage below 42V.
Install the fuse on the positive cable
close to the main battery.
Ensure terminals are crimped securely.
a flat surface using the holes in the
mounting frame
Secure the DC25 Distribution Box onto
To vehicle
MAIN battery
Fuse
SOLAR Panels
SOLAR
MAIN
BATT
40A
+
-
Fig 2
Fuse
40A
+
-
Auxiliary
Battery
Fig 1

Connecting Auxiliary battery cables
Cables to the auxiliary must be connected internally. It is necessary to remove the main cover for
this.
With the cover open, the remote temperature probe can be connected and battery type selected.
3
5 6
4
Unplug the main wire harness from the circuit.
The cover can now be completely removed. cable-entry holes.
Use a screw-driver or flat tool to open the desired
2
Open the cover slightly and unplug the remote
monitor feed cable.
Fit standard cable grommets into the open holes. Feed the auxiliary battery cables through the
grommets.
5
1
Remove the screws holding the cover on the left and
right-hand sides of the enclosure.
Remove the final two screws from the bottom.

Connecting remote temperature sensor
6
The remote temperature sensor provides feedback to the system about the battery temperature.
This is used to ensure safe and full charge under a variety of ambient conditions.
The sensor should be placed onto the auxiliary battery for best results.
78
1
Remove the cover of the internal DC-DC system by
loosening two screws on top.
Connecting battery cables ... cont.
Make sure the terminal screw is tight.
Feed the positive battery cable through the grommet
and connect it to the top terminal of the main switch.
Tighten the cable grommets when done.
2
Connect the larger ring to the GND terminal.
Connect the smaller ring of the sensor to the terminal
marked "Sense".
Feed the remote temperature sensor wire together with the positive
or negative battery cables.
Tip :
Feed the negative cable to the terminal indicated.
Loosen the screw and insert the battery cable on top
of the existing cable.
Make sure the terminal is re-tightened.
Tighten the cable grommets when done.

Changing battery type
7
- Replace the cover of the DC-DC system.
- Re-connect the remote monitor plug and close the cover.
- Re-install and tighten the screws that were removed earlier.
Once the preferred battery type is selected, disconnect the power source.
- Re-connect the wire harness and any other wires removed earlier.
- The auxiliary battery can now be connected.
Wet
AGM / Gel
Ca+
Li-ion Used for automotive Lithium-ion or
LiFePO4 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.
Battery Types
DC-DC Battery Charger
Battery
Float
Li-ion Wet
Ca+ AGM/Gel
Charge
OK /
To change this, press
the "Battery" button
until the desired type is
selected.
The AGM battery type
is the default factory
setting.
Ensure the main breaker switch is in the OFF position then connect a 12V power source to the MAIN
BATTERY or SOLAR inputs. The system will indicate the current battery type.
With the cover still removed, the auxiliary battery type can be selected.
Press the "Battery" button to select the desired battery type.
Reassembly

8
Connecting external Battery Chargers
Connecting Solar Panels
Ignition over-ride (optional accessory)
CAUTION
solar panels up to 42V through the heavy-duty connector
marked "SOLAR PANEL".
The Distribution Box supports the direct connection of
This will bypass the Power Pack solar MPPT system.
Note that if the solar panels have internal regulators,
connect them to one of the AUXILIARY IN/OUT
connectors instead.
The Distribution Box has a charge port specifically for
use with National Luna Intelligent Battery Chargers.
This port can support up to 10A charge current.
In order to connect other brands of chargers to this input,
a quick-connector cable is available separately.
Charge currents exceeding 10A can then be connected.
Other charger brands can be connected to one of the
grey heavy-duty AUXILIARY IN/OUT connectors.
Insert the charger quick-connector into the charge port
labeled "NL5 CHARGER" until it clicks securely.
IGNITION SENSE port.
This may be the case in some vehicles with "Smart
Alternators".
The IGNITION SENSE port increases support for vehicles
where the charge voltage drops very low or is very erratic.
Plug the small end of the over-ride cable (optional) into the
Plug the larger end into a socket that provides a positive
voltage only when the ignition of the vehicle is ON.
Only use the IGNITION SENSE feature if the vehicle alternator voltage is below 13.2V under normal
conditions.
Connecting the IGNITION over-ride to a permanent 12V source may result in excessive discharge of
the MAIN battery.
IGNITION
SENSE
NL5 CHARGER

System operation
9
In order to charge or supply power to accessories connected to any
of the plugs & sockets, the main switch on the Distribution Box must
be in the ON position.
When not in use then it is best to turn the switch OFF.
This will isolate the auxiliary battery from all loads.
Each of the modules and sockets are grouped
with a fuse for safety.
If any of the fuses need replacement, be sure to
replace it with the correct value :
Top group
Middle group
Bottom group
Charger fuse
Fuses
Main Switch
If the IGNITION SENSE input is used, charge will begin with input voltage above 12.0V and stop when
voltage drops below 11.5V.
If solar panels are connected and exposed to sunlight, the Distribution Box will seek the maximum power
possible from the panels under the present conditions. Voltage from the panel must be between 9V and
42V.
Charge to the auxiliary battery will start once voltage on the MAIN BATT input exceeds 13.2V. It will stop
charge once voltage drops below 12.6V after a short delay.
If both MAIN BATT and SOLAR are connected simultaneously. Priority will be given to the MAIN BATT
source and will switch to the SOLAR source automatically when voltage on the MAIN BATT
input drops below 12.6V (11.5V if IGNITION SENSE is used).
Top group
(5A)
Middle group
(15A)
Bottom group
(15A)
Charger fuse
(10A)
POWER PACK
DC 25
REMOTE MONITOR
IGNITION
SENSE
AUXILIARY
IN / OUT
NL5 CHARGER
MAIN
BATT
SOLAR
PANEL
INPUT
15A
5A
15A
10A
:
:
:
:

Remote Monitor - (Optional accessory)
Connecting the Remote Monitor
In addition to the selectable screen modes, the user is
able to increase or decrease the screen brightness and
choose to turn the display on or off.
The screen will turn off automatically when the system
is idle. It will turn on automatically when the next charge
cycle starts.
Information such as Main and Auxiliary battery voltages,
charge mode, charge current, battery type, battery
temperature and error conditions are displayed in a
choice of 3 user-selectable display modes.
The Remote Monitor provides status about the system
on a high-contrast LCD screen.
Lift the dirt cover on the Remote Monitor port.
Connect the square end of the monitor data cable
Press the plug until it clicks securely.
to the remote port as indicated (fig 1).
It can fit in one direction only.
Connect the flat end of the data cable to the Remote
Monitor. (fig 2).
This connector can fit both ways.
Locate the Remote Monitor in a convenient location
using the supplied mounting fixture.
Fig 2
Power
Screen mode
Brightness UP
Brightness DOWN
Fig 1
REMOTE MONITOR
10

Remote monitor operation
11
Display mode 1 - This mode focuses on the auxiliary battery with the
majority of the screen used to show the auxiliary battery voltage and
The input source (ALT or SOLAR) as well as charge current is displayed
during a charge cycle.
battery temperature.
If there are no active charge cycles, “STBY” is displayed.
If SOLAR is the active charge source, the solar panel voltage is displayed.
The display will turn off automatically after a short delay if there is no active charge cycle.
The remote monitor can be turned ON or OFF by pressing the POWER button.
The display brightness can be increased or decreased by pressing the UP or DOWN buttons.
Display mode 2 - In this mode, the status of the main and auxiliary
batteries are represented as graphical bar-graphs.
The actual voltages are shown for the respective batteries.
During a charge cycle, the input source (ALT or SOLAR) is displayed with
the actual charge current.
If there is no active charge cycle, “STANDBY” is displayed.
The AUX graph is animated during charge and represents the battery state
of charge.
If there are no active charge cycles, “STBY” is displayed.
Display mode 3 - This mode shows voltages of the respective main and
auxiliary batteries as well as charger mode, charge current, battery type
and battery temperature.
The remote monitor has 3 display modes that represent the status of the charging system in different
ways.
Press the MODE button to cycle through the different display options.

Remote monitor STATUS messages
12
The remote monitor will respond and indicate various error conditions that may occur under normal
operation. These warnings should be investigated to prevent damage to the batteries or the Power Pack.
The following symbols or messages may appear on any of the 3 display modes :
The remote monitor will show the charge status during an active charge cycle.
During the Float stage, “FLOAT” is shown.
During the normal bulk and absorption charge stage, the charge current will be shown as well as the
input source.
During the Analysis stage, “TEST” will be shown. This stage helps to detect a defective battery.
Warning Messages
LOW BATTERY or NO BATTERY - This symbol is displayed when either the Main or Auxiliary battery
voltage is lower than 11.4V or there is no connection to one of the batteries.
Check fuses and connections to both batteries. Ensure the main switch is ON when in use.
If this symbol and voltage display are flashing, the battery is not holding charge and should be
tested.
OVER VOLTAGE PROTECTION - The voltage applied to the SOLAR or ALT inputs is too high.
Ensure the applied voltages are within specification. Refer to specifications on page 13.
Charge will stop until the system temperature recovers to a safe level.
This error will also be displayed if the Power Pack internal circuit temperature is above 115°C.
OVER CURRENT PROTECTION - The detected charge current is higher than specification.
Inspect the installation for cable faults or short-circuits.
OVER TEMPERATURE PROTECTION - The detected auxiliary battery temperature is above 60°C.
Charging is stopped to prevent damage to the battery.
REVERSE POLARITY - The connections to the auxiliary battery have been reversed.
Check the battery connections.
BAD BATTERY - The Power Pack has detected that the AUX battery is not able to be charged safely.
Test the battery and replace if necessary.
OVP -
OTP -
OCP -
REV -
BAD -
Please check cable The plug to the remote monitor may not be inserted correctly. Ensure it is fully inserted.

Specifications
13
Baery Temperature Compensaon
High temperature
Low Temperature
Baery over-temperature protecon
Device Protecon
Reverse Polarity
Over Voltage
Over Current
Bad Baery Detect
-17mV per °C above 30°C
+17mV per °C below 21°C
60°C
Over Temperature
Charge Algorithm
Voltage
Diagnosis Recovery Bulk Absorption Analysis Float
Current
Step 1 2 3 4 5 6
Voltage Range
MAIN BATT input
SOLAR PANEL input
Solar Regulator
Type
Output Current
Output Power
12V Alternator Input
Turn ON
Turn OFF
Over-Voltage
24V Alternator Input
Turn ON
Turn OFF
Over-Voltage
Ignion Over-ride (12V / 24V)
Turn ON
Turn OFF
Over-Voltage
Baery charge output
Voltage
Max Current
Max Power
Operang Temperature
Standby Current (switch ON)
Dimensions
Remote Display
USB charge output (each port)
Baery Gauge display range
Baery Types Bulk Voltage Float Voltage
AGM / Gel 14.4V 13.6V
Standard Wet 14.6V 13.6V
Calcium 14.8V 13.6V
Lithium Ion 14.4V 13.6V
9V - 42V
11V - 32V
13.2V
12.6V
MPPT
375W
25A
14.8V - 16V
-20°C to 85°C
11.5V 23V
15.5V - 16V 31V - 32V
3V -14.8V
25A
375W
26.4V
23.2V
29.6V - 31V
12.0V 24.0V
257mm x 261mm x 120mm
Oponal
10.7V - 14.7V
5V-3A, 9V-2A, 12V-1.5A
< 35mA

14
261 mm
257 mm
20 mm
120 mm
201 mm
171 mm
239 mm
Mounting hole locations

15
10. National Luna shall not be held responsible for any injuries to persons caused by the incorrect or negligent usage of
11. Repair work to be done in terms of this warranty must be referred to National Luna for written authorisation before
this appliance.
12. National Luna reserves the right to refuse repair or service under warranty if the original proof of purchase cannot be
6. National Luna shall not be responsible for any damages of any kind resulting from incorrect voltages or faults with
regards to power supply which fall outside of the appliance operating specifications.
any work is performed.
chemicals, use of corrosive substances, fire, flood, civil-disturbances, lightning or any other natural phenomenon.
9. National Luna will not accept any responsibility for the consequential loss or damage caused by, or due to the
malfunctioning of this appliance.
7. National Luna shall not be responsible for damage to the product caused by negligent use, storage of hazardous
produced.
8. Warranty returns to the factory for repairs - in the event where the unit has been shipped to the factory for repairs,
undesirable or hazardous operation or may be the cause of the malfunction of this product.
transport costs will be for the owners account.
13. Removal of serial numbers may render the warranty void.
replace or repair without cost to the owner, through an authorised service agent, any part found to be defective by
3. This warranty does not apply to accessories or items where the length of life depends on the amount of use and care
National Luna warrants this product to be free from defects in materials and / or workmanship under normal use and service to the original
purchaser subject to the following :
National Luna.
2. Where parts are replaced by an authorised service agent, the labour costs for the work done will be for the owner’s
given.
4. This warranty is valid within the borders of South Africa only.
5. National Luna may consider a warranty void if modifications have been made to this product which may cause
account.
This National Luna Warranty supersedes any other advertised Guarantee or Warranty provided with this appliance by any wholesaler or
retailer.
1. At any time within THREE YEARS from the date of purchase by the original purchaser, National Luna will at its discretion
National Luna Limited Warranty - South Africa
National Luna Limited Warranty - International
1. National Luna has a world wide distributor network. These distributors import products and carry the warranty
2. Cross-border customs and duties apply. A National Luna manufactured product that is returned to the factory in South
Africa will have the South African warranty applied. However, all transport costs incurred will be for the purchaser's
3. It is important to note that a private purchase of this product in South Africa and exported will not carry a warranty.
The standard National Luna Warranty in South Africa cannot be applied outside the borders of South Africa.
Any labour and parts required for repairs would incur costs in foreign currency and be for the owner’s account.
account.
4. In the event of a National Luna product being fitted as standard equipment in caravans and trailers and subsequently
being exported from South Africa, the warranty must be carried by the persons responsible for the importing into a
country other than South Africa.
(at their cost) in line with the various countries’ conditions of sale.
5. It is recommended that National Luna products be purchased from the authorised importer in a particular country who
carries the applicable warranty and back-up service.

16
Replaceable Modules
The Distribution Box is designed to allow some of the plugs
& sockets to be replaced with other compatible modules
within the 29mm range.
The lower group can accommodate the following 29mm
modules :
Dual USB charger
(Engel plug compatible)
Screw-in DC socket
Hella-type socket
(factory fitted)
Cigarette-lighter socket
(factory fitted)
12V DC socket

Remote Monitor
NL5 Intelligent Battery Charger
Ignition Sense cable
Charge Port adapter cable (1m)
Optional Accessories

BMS-20300 DEC 2020
www.nationalluna.com
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