NDS POWERSERVICE PLUS 25 User manual

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1
POWERSERVICE
User Manual
ENGLISH
VALID FOR THE FOLLOWING MODELS
PLUS 25
PLUS 30
PLUS 40
PLUS 12-24/20
PLUS 24-24/20
GOLD 25-M
GOLD 30-M
GOLD 40-M
GOLD 12-24-M
GOLD 24-24-M

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INSTRUCTIONS FOR THE PROPER DISPOSAL!
this electronic device is subject to the European
Directive 2012/19/EU. according to the local waste
disposal rules, 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.

INDEX
1. SAFETY INSTRUCTIONS 2
2. MODELS 3
3. DESCRIPTION 4
4. OPERATION 6
5. LED INDICATORS 9
6. CHARGING CURVES 10
7. CONNECTIONS 13
8. INSTALLATION 16
9. WIRING DIAGRAMS 19
10. CHECKING THE SYSTEM’S OPERATION 24
11. MAINTENANCE 26
12. FUSE REPLACEMENT 27
13. TROUBLESHOOTING 29
14. TECHNICAL FEATURES 31
15. F.A.Q. 39
16. WARRANTY 42

1. SAFETY INSTRUCTIONS
• 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.
• 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.
• 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
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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 colour, size
or accessories.
2. MODELS
This manual is Valid for the following models
3
NOTE
It is indispensable, for a correct installation, to be
equipped with suitable measuring instruments:
• Multimeter with DC voltage measurement (20V or
autoscale) and continuity measurement.
• Amperometric clamp with direct current measurement
(40A scale and higher).
INPUT: 12V / OUTPUT: 12V
PRODUCT CODE
PLUS 25
PLUS 26
PLUS 27
GOLD 25-M
GOLD 30-M
GOLD 40-M
INPUT: 24V / OUTPUT: 24V
PRODUCT CODE
PLUS 24-24/20
GOLD 24-24-M
INPUT: 12V / OUTPUT: 24V
PRODUCT CODE
PLUS 12-24/20
GOLD 12-24-M

3. DESCRIPTION
POWERSERVICE is the special line of DC-DC/AC-DC
chargers designed, patented and assembled by NDS,
which ensure an efficient charge to the leisure batteries,
guaranteeing 50% more charge than the alternator only.
POWERSERVICE units safeguard battery life with
specific charge curves for all types of batteries.
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 batteries (with capacities exceeding 75Ah) to
maximum power, making the most of all available
sources of energy on a motorhome or camper-van.
POWERSERVICE includes two advanced models
tailored for modern recreational vehicles needs:
•PLUS: CHARGER DC-DC - charges from alternator and
solar panel.
•GOLD: CHARGER DC-DC | AC-DC - charges from
alternator, solar panel and external mains electricity
supply.
MAIN FEATURES:
• Echarging at Up 40 Amps per Hour of Travel.
• High Efficiency, up to 92%.
• 5 Step Recharging
• Selectable Charging Curve: AGM, Gel, Flooded,
Lithium (LiFePO4)
• AUX Connection for Existing Systems.
• Split-Charge relay separates engine and leisure
batteries.
4

• 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.
The innovative circuitry in the POWERSERVICE unit
guarantees greater efficiency by reducing energy
expenditure. output current is regulated both
according to the needs of leisure 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.
3.1 PROTECTIONS
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POWERSERVICE units are equipped with several
protection systems to ensure a high level of safety and
security:
4. OPERATION
POWERSERVICE chargers provide the right charging
curve to the most common leisure battery technologies
by increasing the voltage coming from the alternator
using a DC-DC converter. the charge curve related to
the leisure 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
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PROTECTION TYPE
REACTION TYPE
Battery over-voltage
Charge is interrupted
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
Reduces the output current and
turns off. automatic reactivation
when the device temperature
returns to an acceptable working
level
Output short-circuit
Protection by fuses
Solar panel over-voltage
Charge is interrupted
Temperature too low
If the lithium curve is selected, then
charge is interrupted

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
I g n i t i o n + o r D + s i g n a l c o n n e c t e d t o t h e
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
leisure 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.
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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 leisure
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.
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5. LED INDICATORS
POWERSERVICE è is equipped with LED indicators to
signal the source of incoming charge and the charge
phase that the device is using. the charging phase in
progress is shown with a corresponding number of
flashes on the relevant LEDs.
9
NOTE
All the led signals are at page 28.
GOLD
solar
panel
grid
230v
ALTERNATOR
PLUS
SOLAR
panel
ALTERNATOR

6. CHARGING CURVES
POWERSERVICE units support battery charging for
AGM, Gel and flooded lead-acid batteries. There is a
special curve for Euro 6 systems with “smart”
alternators and LiFePO4lithium batteries . The charge
curves are selectable using two jumpers.
A Curve: AGM
B Curve: GEL
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YES
NO
MODEL
12V
24V
Max voltage
14,8V
29,6V
Float voltage
13,8V
27,6V
Max desulfation voltage
15,8V
31,6V
YES
YES
MODEL
12V
24V
Max voltage
14,3V
28,6V
Float voltage
13,6V
27,2V
Max desulfation voltage
15,8V
31,6V

C CURVE: GENERIC CURVE (FLOODED, LiFePO4)
D CURVE: GENERIC CURVE FOR SMART
ALTERNATOR, EURO 6 (LiFePO4)
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NO
YES
MODEL
12V
24V
Max voltage
14,5V
29V
Float voltage
13,5V
27V
Max desulfation voltage
not allowed
MODEL
12V
24V
Max voltage
14,6V
29,2v
Float voltage
13,7V
27,4V
Max desulfation voltage
not allowed
NO
NO
CAUTION
The D curve is specific for euro 6 engines with smart
alternators and entails a delay of several seconds for the
activation of the system, wait until the end of the
procedure.

A, B CURVE (AGM, GEL)
C, D CURVE (FLOODED, LiFePO4)
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Vmax
Imax
Imax/2
1 2 3 4
15,8V max
V
I
5 t
maximum
current
maximum
voltage
desulfa
tion
maintenance
Vmax
Imax
Imax/2
1 2 3
V
I
5 t
maximum
current
maximum
voltage
maintenance
NOTE
During charging, the device’s led indicators will emit
flashes corresponding to the charging phase being used at
the time. the various phases are indicated at the base of
the above graphs.

7. CONNECTIONS
The device has a seven (7) terminal block for power
connections for cables up to 16mm2.
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GOLD
Z
9
1
2
3
4
5
6
7
8
PLUS
1
2
3
4
5
6
7
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1. - (negative) connection from the starter battery.
2. - (negative) connection of the leisure 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 leisure 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).
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, Sargen, 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
auxiliary input (5).
14
NOTE
The negative pins n°1 and 2 are internally connected to
each

A relay with Normally Closed contact is active On
POWERSERVICE 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 leisure 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 leisure 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 leisure battery in case of
malfunctions, taking power directly from the alternator.
15
NOTE
To take advantage of direct charging from the alternator,
the POWERSERVICE switch must be moved to position 0.
The normal position is 1.

8. 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 leisure 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
r ea c h v e r y h i g h t e m p e ra t u r e s ( e g . e n g i n e
compartment).
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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 leisure battery
to Pin No. 2 of the POWERSERVICE.
7. Disconnect all the cables on the positive pole of the
leisure 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 leisure 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).
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CAUTION
POWERSERVICE GOLD version integrates a 230VAC
battery charger, therefore: pre-existing chargers, external
chargers, integrated in the control unit chargers, must be
uninstalled!

To avoid interferences in audio / video systems:
• Use high quality (and in good condition) cables for
TV antennas and other transceivers.
• make sure that the POWERSERVICE’S power
cables (input and output) are far from transceivers
cables, sensitive devices power cables and AC
current cables.
• Place sensitive equipment as far as possible from
the POWERSERVICE.
18
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 10mm2 for:
connections between engine battery and Power
Service, and in the output towards the leisure 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.