NDS POWERSERVICE PLUS 25 User manual

!
1
powerservice
user manual
Gold
plus
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

!
2
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.
instructions for the proper disposal

index
1. safety instructions 4
2. models 5
3. description 6
3. 1 protections 7
4. operation 8
5. led indicators 10
6. charging curves 11
7. connections 14
8. installation 16
9. wiring diagrams 18
10.Checking the system’s operation 23
11. MAintenance 25
12.fuse replacement 26
13. troubleshooting 28
14.technical features 30
15.FAQ 38
16.warranty 41
3

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 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.
4

2. models
this manual is Valid for the following models
5
PWS Plus 25 per batterie
Input: 12V / output: 12V
product code
PLUS 25
PLUS 26
PLUS 27
gold 25-M
gold 30-M
gold 40-M
Note
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).
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 service 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/service 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:
• 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.
6

• 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 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.
3. 1 protections
powerservice units are equipped with several protection
systems to ensure a high level of safety and security:
"
7
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

4. 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.
8
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.
9

5. led indicators
powerservice 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.
10
plus
gold
Note
all the led signals are at page 28.
alterna
tor
solar
panel
grid
230v
solar
panel
alterna
tor

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 LiFePO4 lithium batteries .
The charge curves are selectable using two jumpers.
11
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
a curve: AGM
b curve: gel

12
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.
Model
12V
24V
max voltage
14,5V
29V
float voltage
13,5V
27V
max desulfation voltage
not allowed
C curve: generic curve (flooded, LiFePO4)
d curve: generic curve for smart alternator,
euro 6 (LiFePO4)
Model
12V
24V
max voltage
14,6V
29,2v
float voltage
13,7V
27,4V
max desulfation voltage
not allowed
no
yes
no
no

13
A, B curve (agm, gel)
C, D curve (flooded, LiFePO4)
Vmax
Imax
Imax/2
1 2 3 4
15,8V max
V
I
5 t
maximum
current
maximum
voltage
desulfa
tion
mainte
nance
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.
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)
14
plus
gold
NOTe
The negative pins n°1 and 2 are internally connected to each
9
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
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.
15
Note
to take advantage of direct charging from the
alternator, the powerservice switch must be moved to
POSITION O. 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 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).
1. Set the power switch to 0.
2. Connect the negative pole of the STARTer BATTERY to
powerservice Pin N°1.
16
caution
powerservice Gold version integrates a 230VAC battery
charger, therefore: pre-existing chargers, external chargers,
integrated in the control unit chargers, must be uninstalled!

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).
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.
17
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.

9. wiring diagrams
18
For cables longer than 2 meters use 16mm2cables
installation in vehicle with no control unit
and / 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.

19
installation in vehicle with existing using
control unit (charging system)
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.).
For cables longer than 2 meters use 16mm2cables

20
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.