NDS POWERSERVICE PLUS 25 User manual

!
1
powerservice
Power charger
User manual
NDS ENERGY s.r.l."
Via Pascoli, 169"
65010 Cappelle sul Tavo (Pe) Italy"
Tel.:[phone] | mob./whatsapp: [phone]"
fax: [phone]"
web: www.ndsenergy.it"
email: [e-mail]
Plus 25, plus 30, Plus 40, plus 40/l, plus 12-24/20, plus 24-24/20
Gold 25-M, gold 30-m, gold 40-m, gold 40-m/l, gold 12-24-m,
gold 24-24-m
Gold
plus

2

index
introduction 4
description 6
models 7
protection 9
installation 10
connections 11
operation 19
charging curves 23
led indicators 26
on-off (0-1) switch 29
fuse replacement 31
maintenance 33
technical features 34
warranty 40
3

introduction
powerservice is the special line of DC-DC/AC-dc chargers
designed, patented and assembled by nds, which ensure an
efficient charge to the service batteries, guaranteeing 50% more
charge than the alternator only. Powerservice units
safeguard battery life with specific charge curves for all types
of batteries.
warning
•Child Safety: Keep the device Out of Reach.
•carefully check the integrity of the device and connectors.
•To avoid overheating and possible fires do not install the
device in a sealed environment, Always choose a well
ventilated area.
• Do not place the device on highly flammable surfaces or
environments (eg: paper, cloth, etc.).
•do not cover the cooling slits on the side and the fan on the
top.
•do not install the device near flooded batteries: they
produce flammable, corrosive and explosive gas while
working, and it can damage the product.
•protect the device from sunlight or direct sources of heat.
•To avoid malfunctions, DO NOT install and use the device in
very humid environments, in contact with water splashes,
various liquids, or exposed to rain.
•To avoid risk of electric shock and/or fire, the vehicle's fuel
system must be in good condition.
4
essential equipment for installation
certain measuring instruments are essential for a correct
installation:
•Multimeter with continuous voltage measurement (20V scale
or autoscale) and continuity measurement.
•clamp meter with DC current measurement (40A scale and
above).

•in case of damaged connecting cables or inadequate section,
immediately replace them with suitable cables as specified by
this manual or by a qualified electrician.
•DO NOT use the device with damaged cables and/or
inadequate section.
•in case of anomalies in the conformity of the product do not
use it! it is strictly forbidden to open the device. Repairs may
only be carried out by qualified technical personnel using
original spare parts.
•Keep the instruction manual near the device for easy access
to the essential safety, use and maintenance information.
•The information contained in this manual may be changed
without notice. NDS Energy s.r.l. reserves the right to make
changes and improvements to the product at any time
without notice and without obligation to apply these
changes to the devices previously distributed.
•The images of the products are purely indicative and may
therefore not be fully representative of the characteristics
of the product, differing in color, size or accessories.
5
PWS Plus 25 per batterie 12V
this electronic device is subject to the
European Directive 2012/19/EU. according to the
local waste disposal roules, do not dispose of
old products with normal household waste.
The proper disposal of products that can no
longer be used prevents potential negative
consequences for the environment and for
the population.

description
The powerservice charger line has been designed to guarantee
reliability and maximum charging performance simply and
automatically, responding to the needs of the most demanding
travellers to get maximum energy in the shortest possible time.
powerservice allows you to correctly charge one or more
leisure/service batteries (with capacities exceeding 75Ah) to
maximum power, making the most of all available sources of
energy on a motorhome or campervan.
powerservice includes two advanced models
•plus: charger dc-dc - charges from alternator and solar
panel.
•gold: charger dc-dc | Ac-dc -charges from alternator,
solar panel and external main electricity supply.
main features:
• recharging at up 40 amps per hour of travel.
• high efficiency, up to 92%.
• 5 step recharging
• selectable charging curve: AGM, Gel, flooded, lithium.
• AUX connection for existing systems.
• SPLIT-CHARGE RELAY SEPARATES ENGINE AND SERVICE BATTERIES.
• compatible with Euro 6 systems with Smart Alternator.
• charge management with microprocessor.
• fan speed regulated by temperature and operating power,
for a silent and efficient device.
• protection by internal fuses.
• alternator protection (in case of overload).
• CHARGING PHASE & POWER SOURCE INDICATION BY LEDS.
• power supply function if battery is not present.
• Emergency switch reverts to original charging system in
case of failure.
• quiet, compact and easy to install."
6

The innovative circuitry in the powerservice unit guarantees
greater efficiency by reducing energy expenditure. output
current is regulated both according to the needs of service
batteries and to the quantity of input energy. while travelling
the device gradually reduces the output current in the event
that the alternator is in overload conditions (eg: at night with
lights on, air conditioner on, engine idling and engine fan on, etc
…). The cooling fan is activated only if necessary and the
rotation speed is electronically controlled according to the
temperature inside the device keeping fan noise to minimum.
models
here are the two powerservice models:
powerservice plus:
• charges from alternator.
• charges from solar panel (integrated pwm solar regulator)
"
7
12V
code
max output
current with 12V
alternator
maximum power with
solar panel
maximum voltage
open circuit with
solar panel
plus 25
25A
250w
28v
plus 30
30A
250w
28v
plus 40
40A
250w
28v
24V
plus 12-24/20
20A
N/d
N/d
plus 24-24/20
20A
N/d
N/d

powerservice gold:
•charges from alternator
•charges from solar panel (integrated pwm solar regulator)
•charges from external mains electricity supply
8
12V
code
max output
current with 12V
alternator
maximum
power
with
panel
maximum
voltage open
circuit with
solar panel
maximum
current from
GRID
90vac-250vac
gold 25-M
25A
250w
28v
20a
gold 30-M
30A
250w
28v
20a
gold 40-m
40A
250w
28v
20a
24V
gold 12-24-M
20A
N/d
N/d
10a
gold 24-24-M
20A
N/d
N/d
10a

protection
powerservice units are equipped with several protection
systems to ensure a high level of safety and security:
• Start-up without sudden changes in current and voltage
(Soft Start)
• Alternator overload protection
• Battery overvoltage alarm
• Output fuse failure alarm
• solar panel overvoltage alarm
• Under and Over-temperature protection"
9
Battery overvoltage
alarm
the internal acoustic buzzer is activated by a
battery voltage above 17V, the charge is
interrupted
Protection for
Alternator Overload
Power Service automatically shuts off if the
input voltage from the alternator and / or the
engine battery falls below 12.8V
Over-temperature
protection
reduces the output current in relation to the
system overheating and turns off, reactivating
automatically when the temperature of the
device returns to an acceptable level
Alarm for output fuse
failure
the internal acoustic buzzer warns with an
alarm if there is a sudden failure of the output
fuses
Solar panel
overvoltage alarm
The acoustic buzzer warns If the photovoltaic
panel connected to the device has an
incorrect operating voltage, higher than 28V
temperature too low
alarm
the leds indicates that the external
temperature is -2°C

installation
powerservice can be installed easily and securely thanks to
the external flanges (aluminum feet).
The ideal mounting position is smooth, well ventilated and not
subject to overheating; avoid surfaces covered with fabric or
carpet. Install the device as close as possible to the service
batteries.
powerservice can work in any position; if installed on a
vertical wall, it is recommended to keep the short side parallel
to the floor, with connections downwards. Do not install the
device close to sources of heat or in a place that is not
adequately ventilated and that could reach very high
temperatures (eg.engine compartment).
10

connections
The device has a seven (7) terminal block for power connections
for cables up to 16mm2.
1. - (negative) connection from the starter battery
2. - (negative) connection of the service battery
3. + (positive) connection from the starter battery
4. d+ Signal from the alternator or ignition+ signal line
5. AUX: connection of the existing control unit (sargent, schaudt, etc.)
6. output of the charger (connects to the positive terminal of the
service battery)
7. solar panel direct connection 12V nominal (maximum voltage with open
circuit lower than 28V).
8. debug and update connection (nds internal use).
9. IEC socket for the connection of the mains power supply (Only for
GOLD series)
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NOTE: The negative pins n°1 and 2 are internally connected to each other.
plus
8
1
2
3
4
5
6
7
1
2
3
4
5
6
7
gold
9
8

specific aux connection (pin no. 5) for the following
models: Plus 25, plus 30, Plus 40, plus 24-24 / 20, Gold 25-m,
gold 30-m, gold 40-m, gold 24-24-m.
powerservice has an auxiliary terminal: (terminal n°5) dedicated
to the original control unit output (eg CBE, SARGENT, Schaudt,
nord elettronica) or to the split-charge relay. THIS TERMINAL IS
USED TO CONNECT APPLIANCES SUCH AS THE FRIDGE, LIGHTS, PUMP, ETC.
ALL THE CABLES THAT WERE ORIGINALLY CONNECTED TO THE LEISURE
BATTERY'S POSITIVE TERMINAL SHOULD BE CONNECTED TO THIS AUXILARY
INPUT (5).
a relay with Normally Closed contact is active On Pin N°5 (AUX)
and internally connected to Pin N°6 (Exit Pin). the Normally open
contact is connected to input B+ (Pin N°3), so if the ignition+ signal
line is not active (engine off) the appliance will be powered by
the service battery. When the engine is running the internal
relay will switch on the AUX and the loads will be powered
directly by the alternator, input B+. The service battery will be
free of loads, allowing the powerservice to further
accelerate the charge while driving.
In case of vehicles without a control unit (self-build vehicles
for example), and/or a vehicle with the electrical system BEING
INSTALLED FOR THE FIRST TIME,, the AUX input (Pin n°5) will have the
same operation indicated above. It is always advisable to install
an external "split-charge relay", since it guarantees the
recharging of the service battery in case of malfunctions,
TAKING POWER DIRECTLY FROM THE ALTERNATOR."
!
Note: to take advantage of direct charging from the
alternator, the powerservice switch must be moved to
POSITION O. THE NORMAL POSITION IS 1.
12

installation
Power Service Gold version integrates a 230VAC battery
charger, therefore other pre-existing chargers, both external
or integrated into the control unit must not to be used.
1. Set the power switch to 0.
2. Connect the negative pole of the STARTer BATTERY to
powerservice Pin N°1.
3. Connect the fuse holder to the positive pole of the STARTer
BATTERY.
4. Connect the other end of the fuse holder to Pin N°3 of the
powerservice.
5. Insert a 70A fuse into the fuse holder.
6. Connect the negative terminal of the service battery to Pin
No. 2 of the powerservice.
7. Disconnect all the cables on the positive pole of the service
battery and connect them to pin N°5 of the powerservice
(Not valid for models plus 12-24 and gold 12-24)
8. Connect the service battery positive pole to Pin N°6 of the
powerservice
9. connect the D+ OR IGNITION+ SIGNAL WIRE to the powerservice
Pin n°4.
10. only for Gold models: connect the 230VAc mains supply to the
input iec connector. link the connection after the general
system safety switch (rcd switch)."
13
NOTe
• the data connector (placed on the right of the power
connector) is for technical use.it is strictly forbidden to
connect any device in this socket, any tampering could
irreparably damage the appliance.
• use cables with a cross-section of at least 10mm2for:
connections between engine battery and Power Service, and
in the output towards the service battery. if the distance
between the motor battery and the device exceeds 2 meters,
it’s RECOMMENDED to increase the cable section, to reduce
voltage drop and power losses.

14
For cables longer than 2 meters use 16mm2cables
installation in vehicle with existing charging
system using control unit/parallel relay
for the control unit we mean the unit of control and
distribution of energy on the HABITATION PART of the vehicle (Eg.:
CBE ds300, Schaudt EBL163, nord elettronica ne287, SARGENT, BCA,
ETC.).
1 2 3 4 5 6 7
+-+-
+-
alternator
d+
x
starting battery
input
ac
leisure battery
solar
panel
aC/DC
control
unit
fridge
12V appliance
e.g. light,
water, pump
+
+
+
+
1
4
345
10
1mm2
10 mm2
10 mm2
10 mm2
10 mm210 mm2
9
11
2
6
7
70A
50A

15
For cables longer than 2 meters use 16mm2cables
installation with split charge relay only
the parallel relay refers to the pre-existing relay which, when
the vehicle engine is switched on, makes the connection
between the service battery and the engine battery.
1 2 3 4 5 6 7
+-+-
+-
alternator
d+
starting battery leisure battery
solar
panel
split-charge
relay
fridge 12V appliance
e.g. light, water
+
+
+
+
1
4
4
1mm2
10 mm2
10 mm2
10 mm2
10 mm210 mm2
3
10
9
11
5
2
6
7
70A 50A

16
For cables longer than 2 meters use 16mm2cables
installation in vehicle with no control unit
or split charge relay
in this case, for ordinary vehicles to be transformed to RV or
vehicles that need an auxiliary battery, the powerservice can
be used to manage the charge and the distribution of energy.
+
+
+
+
1 2 3 4 5 6 7
+-+-
+-
alternator
d+
starter battery leisure battery
solar
panel
fridge & 12V
appliances
1
4
5
1mm2
10 mm210 mm2
10 mm210 mm2
3
2
6
7
70A 50A

17
Plus and Gold 12-24-m installation in vehicle
with 12V alternator and 24V service/Leisure
batteries
For cables longer than 2 meters use 16mm2cables
+
+
+
+
1 2 3 4 5 6 7
+-+- +-
alternator
d+
starting battery leisure battery
pack 24v
1
4
1mm2
10 mm210 mm2
10 mm2
10 mm2
10 mm2
3
2
8
6
70A 30A

18
For cables longer than 2 meters use 16mm2cables
installation with i-manager in systems with
two leisure batteries
the powerservice output must be connected to the common
positive of the i-manager, in order to supply the two service
batteries.
-+
+-+-
-
alternator
d+
Starter battery leisure battery 1 leisure battery 2
imanager
display
1 2 3 4 5 6 7
solar
panel
aC/DC +
+
+
+
+
control
unit
fridge
12v
appliances
(light, pump,
ecc..)
1
8
1mm2
10 mm2
10 mm2
10 mm2
10 mm2
10 mm2
10 mm2
10 mm2
3
4
4
9
10
11
13
12
20A 70A
120A
120A
14
15
6
5
7
2
2
11 12 13 614
10 mm2

operation
powerservice chargers provide the right charging curve to
the most common service battery technologies by increasing the
voltage coming from the alternator using a DC-DC converter.
the charge curve related to the service battery technology in
use (wet lead-acid, gel, Agm, lithium), must be selected using
internal jumper switches. The 5 charging phases operate
independently from the input energy source, and for each phase
the voltage and current supplied are continuously monitored,
so as to quickly charge the battery as efficiently as possible.
Charging from the alternator
After the engine has started (and the alternator), the Ignition+
or D+ signal connected to the powerservice input will be active
and the device will monitor the voltage of the engine battery to
check its charge.
with a voltage higher than 13.3V (26.6V for 24-24 versions), the
powerservice will start charging the service batteries.
During charging, the voltage of the starter battery will be
constantly monitored to check any problems of supply or
overload by the alternator, intervening promptly, if necessary,
reducing the output current or stopping the charge completely.
the output current is limited if the powerservice detects an
active signal d+ (or ignition+) and starter battery voltage below
13V.
the device switches off completely if it detects a voltage of
12.8V at the starter battery, or if the signal d+ or Ignition+ (ie
engine shutdown) is no longer detected.
19
Caution: when selecting the intelligent alternator
(euro6) charging curve, the activation and deactivation
thresholds of the device are as follows: activation >12V
and deactivation <11.8V. in the latter case, the activation
TIMES WILL ALSO BE DELAYED.
If you choose the ignition+ signal instead of the d+, don’t leave
the power on for more than 30 seconds.

Power supply from solar panel
If the following situations occur:
•IGNITION+ or D + signal not active,
•solar panel illuminated by sunlight with AN OPEN-CIRCUIT
voltage higher than 16V,
the powerservice starts charging using the integrated solar
regulator with PWM technology; charging phases are the same
as those provided by the alternator and by an external mains
supply.
the device stops charging using the solar controller when the
panel voltage becomes lower than the service battery (there is
not enough light to sustain a charging current).
POWER SUPPLY FROM 230V MAINS CONNECTION (GOLD series
only)
If the ignition+ or D+ signal is not active, and the power supply is
connected and active, the powerservice gold GIVES PRIORITY TO
THE MAINS POWER SUPPLY AND STOPS USING THE SOLAR PANEL.
the power source is selected by power priority, as below:
1. Alternator.
2. MAINS POWER SUPPLY (GOLD only).
3. Solar Panel.
The charging source used will be displayed by the relevant LED.
20