National Luna DC40 User manual

Power Pack DC40

1
Index
3
3
4
5
6
7
8
9
9
10
10
11
12
14
17
15
Changing Battery Type
Connecting External Battery Chargers
Introduction
Connecting DC power sources
Ignition Over-ride
Safety Information
Features
Wiring Diagram
Preparing for Installation
Installing Battery
Connecting Solar Panels
Remote Monitor
Remote Monitor Status Messages
Specifications
Warranty
System Operation

2

Introduction
3
ŸEnsure the Power Pack DC40 is secured in mobile applications.
ŸDo not alter or modify the Power Pack DC40 under any circumstances.
ŸDo not attempt to charge a non-rechargeable or battery other than 12V.
ŸUnauthorized disassembly, repairs or modifications will void any warranty.
ŸNever attempt to charge a damaged or leaking battery.
ŸThe Power Pack DC40 is used for charging 12V lead-acid and automotive Lithium batteries only.
ŸDo not use for any purpose other than indicated in this manual.
ŸDisconnect any existing batteries.
ŸEnsure all connections are secure and cables are installed in a safe manner.
ŸAvoid open flames in the vicinity of the battery.
ŸInstall the supplied in-line fuse as indicated in the installation instructions.
ŸAttempts to use the Power Pack DC40 for purposes other than indicated in this manual will void the
warranty.
ŸBefore installation, read the instructions carefully.
ŸUse the correct cabling size and fuses in accordance with the installation instructions.
This combination results in a self-contained split-charge system that is at-home in the vehicle or in camp
and can be used to power fridges, lights, pumps and other 12V appliances.
The Power Pack DC40 can be charged from a vehicle alternator, solar panels or external chargers making
it versatile for a variety of applications.
The Power Pack DC40 supports 12V lead-acid (wet, calcium, Gel, AGM) as well as lithium batteries.
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.
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.
The National Luna Power Pack DC40 blends the convenience of a portable battery system and the
performance of a DC-DC battery charger with MPPT solar regulator.
The primary charge input supports 12V and 24V vehicle systems and will provide up to 40A of current to
the auxiliary battery using an optimized 6-stage charge algorithm.
Heavy-duty connectors can be used for connecting a variety of accessories from inverters (600W max)
A built-in 40A MPPT solar regulator circuit supports solar panels up to 42V and provides up to 40A (600W)
charge current to the battery.
Supported battery types (set to AGM by default) :
ŸLithium-ion, LiFePO4
Temperature Compensation & battery protection :
ŸLead-acid (Calcium, Flooded, AGM, Gel, VRLA)
ŸThe battery charge profile takes into account battery temperature with a sensor (located inside the
battery compartment) for safe charging under various conditions.
Max battery size :
Ÿ330mm x 180mm x 280mm (L x W x H)
SAFETY INFORMATION :

Features
4
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
Direct DC Input
12V DC Sockets
Fuses
Control Panel
Sliding Lid
Battery Compartment

5
Wiring diagram - Typical Installation
NOTICE - Importance of correct cable type and connection quality.
To vehicle
MAIN battery
DC source
11V - 32V
Fuse
Fuse
SOLAR Panels
SOLAR
MAIN
BATT
DC IN
50A
+
+
-
-
The Power Pack DC40 input current can be expected to reach 50A under normal conditions.
Poor connections result in high voltage loss, lowering system performance.
Follow these guidelines during installation :
Special care must be taken to ensure that the cable, connectors and power source are rated for this
current.
- If more than one system is installed, avoid the use of shared cabling.
2
- A cable thickness of 16mm (5 AWG) is recommended.
- Ensure all cable terminals are crimped with appropriate tools.
- Use the correct size of terminal and ensure they are clean and free of corrosion.
- Always use the supplied fuses or replace with the same type and value of fuse.

MAIN
BATT
SOLAR
PANEL
INPUT
If a standard solar panel is used, it can be connected to the input marked "SOLAR PANEL".
Before installing a battery into the Power Pack DC40, select the correct battery type.
(Instructions on page 7)
Make sure all connections are secure and terminated correctly with appropriate tools.
For applications where the Power Pack DC40 is installed in a vehicle, locate the Power Pack such that
the input cables are not restricted or under strain. The Power Pack should also be secured to prevent
movement.
The input cables must be terminated with a RED 50A coupler matching the input on the Power Pack
DC40 marked "MAIN BATT".
Once the battery type is selected, a battery can be installed into the Power Pack DC40 and the RED
input cable connected (Fig 2).
2
Use 16mm cables for the input from the vehicle main battery and install the supplied 50A in-line fuse
close to the main battery on the positive cable (Fig 1).
Connect the supply from the main
battery (alternator) to the RED input
on the Power Pack DC40.
Ensure terminals are crimped securely.
Install the fuse on the positive cable
close to the main battery.
Fig 1 Fig 2
6
Preparing for Installation

Changing battery type
7
This is best done before the battery is inserted into the Power Pack DC40.
For safety, the battery type cannot be changed if the auxiliary battery is already connected.
The battery type should be chosen before the auxiliary battery is installed.
A power source can be connected to the MAIN BATT, SOLAR PANEL or DC INPUT to power the system
and change the battery type.
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.
Left side Right side
1
34
2
The cover can now hinge open.
Remove screws from the left, right and bottom as indicated.
The cover can now be opened fully to expose the
internal DC-DC system.
With the cover slightly open, unplug the remote
monitor cable.
Connect power to the MAIN BATT or SOLAR input.
The DC-DC system will now activate and show the
current battery selection.
Remove the cover of the internal DC-DC system by
loosening two screws on top.
- The auxiliary battery can now be installed.
Once the preferred battery type is selected, disconnect
the power source.
- Replace the cover of the DC-DC system.
- Re-connect the remote monitor plug and close the cover.
- Re-install the screws that were removed earlier.
Battery Types
5
6
The AGM battery type
is the default factory
setting.
To change this, press
the "Battery" button
until the desired type is
highlighted.
DC-DC Battery Charger
Battery
Float
Li-ion Wet
Ca+ AGM/Gel
Charge
OK /

8
Installing Battery
It is best to lay the Power Pack on its side or end to do this.
To hold a battery securely in the Power Pack, install the U-bolt and hold-down bracket.
Note : Select the battery type before installing the auxiliary battery. See page 7.
Return the Power Pack to the
upright position.
Insert the U-bolt through the holes
drilled into the bottom of the
Power Pack.
Remove the Power Pack sliding lid
and insert the auxiliary battery into
the battery compartment.
Attach the hold-down bracket,
washers and wing-nuts.
Connect the positive (RED) and
negative (BLACK) cables to the
battery terminals.
Make sure the connections are
clean and tight
Take care not to over-tighten the
screws.
1
2
3

9
Connecting Solar Panels
Connecting additional DC power sources
Fuses for DC power sources
The Power Pack supports the direct connection of
solar panels up to 42V through the heavy-duty connector
marked "SOLAR PANEL".
Note that if the solar panels have internal or in-line
regulators, connect them to one of the AUXILIARY
IN/OUT connectors instead.
To utilise the full 40A output capability of the Power Pack
DC40, the DC source should have a rating of 600W or
more with a voltage between 11V and 32V.
* Do not connect battery chargers to this input.
The DC input on the Power Pack DC40 is designed as
an alternative input that can be used with DC power
sources such as AC-DC power supplies, wind turbines,
hydro-electric and generators with DC output.
The fuse current rating should be more than the maximum expected source current but not more than
50A.
When using an external DC power source, install a fuse close to the power source on the positive cable.
DC Power Supply
11V - 32V +
-
FUSE
DC IN
DC INPUT