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Redarc PowerDock PPSDOCK User manual

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PowerDock
Dock for the GoBlock
Portable Dual Battery System
MODEL:
 PPSDOCK
PowerDock™
Dock for the GoBlock
Portable Dual Battery System
When installed correctly, the PowerDock provides
a secure way to transport the GoBlock in a vehicle,
and serves as an interface between the vehicle
and the GoBlock's functions.
The PowerDock allows you to get the most out
of your GoBlock portable power system. This
permanent installation allows you to securely
mount your system and rapidly charge your
GoBlock from both the vehicle and connected
solar inputs.
CONTENTS
WARNINGS & SAFETY INFORMATION �����������������������������4
KIT CONTENTS ���������������������������������������������������������������������6
PARTS OF THE PowerDock �������������������������������������������������7
MOUNTING THE PowerDock�����������������������������������������������8
Mounting Surface Requirements�������������������������������������������� 8
Mounting Clearances ������������������������������������������������������������ 9
Mounting Parts�������������������������������������������������������������������� 10
Sourcing Your Own Mounting Hardware ������������������������������ 10
Mounting Steps������������������������������������������������������������������� 11
WIRING ������������������������������������������������������������������������������� 13
Wiring Parts ������������������������������������������������������������������������ 13
Sourcing Your Own Parts ���������������������������������������������������� 15
Cable Sizing������������������������������������������������������������������������ 15
Wiring the PowerDock Terminal Assembly ��������������������������� 17
Wiring to the Vehicle������������������������������������������������������������ 21
OPERATION ������������������������������������������������������������������������ 22
Dock the GoBlock��������������������������������������������������������������� 22
Undock the GoBlock ����������������������������������������������������������� 23
Safe Vehicle Transportation�������������������������������������������������� 24
Padlock Attachment������������������������������������������������������������ 24
CARE AND MAINTENANCE ��������������������������������������������� 25
Care and Maintenance Advice ��������������������������������������������� 25
Spare Parts������������������������������������������������������������������������� 26
TROUBLESHOOTING ��������������������������������������������������������� 27
General Troubleshooting������������������������������������������������������ 27
Frequently Asked Questions ������������������������������������������������ 27
TECHNICAL SPECIFICATIONS������������������������������������������ 28
WARRANTY������������������������������������������������������������������������ 29
ADDITIONAL INFORMATION�������������������������������������������� 30
Checking the Product Serial Number����������������������������������� 30
4 | Warnings & Safety Information
WARNINGS & SAFETY INFORMATION
Save these instructions — this manual contains important safety instructions. Do not operate
the system unless you have read and understood this manual. REDARC recommends that the
PowerDock be installed by a suitably qualified person.
Disclaimer: REDARC accepts no liability for any injury, loss or property damage which may occur
from the improper or unsafe installation or use of its products.
WARNING
An unsecured GoBlock can become dangerous in an accident or sudden stop. The GoBlock
must be securely locked into the PowerDock during transport — make sure the Handle is
fully closed and latched prior to travel.
The PowerDock must be installed behind (not in front) of the vehicle seats. Do not install the
PowerDock in the vehicle interior area shared by occupants.
Do not mount the PowerDock to non-permanent/moveable floor panels in your vehicle.
The Dock must be permanently mounted to a fixed structural part of the vehicle, or to a
surface that is rated to hold a minimum of 500 kg (1102 lb).
Incorrect handling or disassembly/reassembly may result in a risk of electric shock or fire.
Any attempt to disassemble/reassemble the PowerDock, or make unapproved repairs or
modifications will void the warranty and the user’s authority to operate the PowerDock.
Do not insert foreign objects or fingers into the PowerDock Terminals.
Do not expose the PowerDock to temperatures beyond the published limits.
Do not operate the PowerDock beyond the published ratings. Doing so may result in damage
to the PowerDock, fire, explosion and burns/personal injury. For this reason, it is of utmost
importance that you follow the instructions when installing and operating the PowerDock.
If any mechanism or part of the PowerDock becomes broken or damaged, it may affect it's
ability to safely restrain the GoBlock. Discontinue use of the PowerDock immediately.
Use suitable Personal Protective Equipment (PPE) when operating power tools.
Warnings & Safety Information | 5
CAUTION
Terminals are high powered and have a risk of arcing – keep flammable substances away
from the terminals.
The PowerDock should not be used by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they are supervised
or have been instructed on how to use the appliance by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the PowerDock.
Cable and fuse sizes are specified by various codes and standards which depend on the type
of vehicle the PowerDock is installed into. Selecting the wrong cable or fuse size could result
in harm to the installer or user and/or damage to the battery or other equipment installed in
the system. The installer is responsible for ensuring that the correct cable and fuse sizes are
used when installing the PowerDock.
Risk of Pinch Points! Take care when docking/undocking the GoBlock from the PowerDock
and keep fingers clear of the Handle when closing it. Keep fingers clear of the PowerDock
Terminals.
When the GoBlock is Docked in the PowerDock and is charging/discharging, parts of the
system may become hot. Do not place flammable items nearby to the PowerDock when it is
in use.
Do not use the PowerDock to store or transport objects other than the GoBlock.
Keep metal objects and liquids away from the Terminal Contacts in the PowerDock Tray.
Accidental arcing may occur, causing fuses to blow.
NOTICE
REDARC recommends only using genuine Anderson™ connectors for the PowerDock
installation. Counterfeit or generic connectors may result in a poor quality connection.
SAFETY MESSAGE CONVENTIONS
Safety messages in this manual include a signal word to indicate the level of the hazard as follows:
WARNING A potentially hazardous situation which, if not avoided, could result in
death or serious injury to the operator or to bystanders.
CAUTION A potentially hazardous situation which, if not avoided, may result in
moderate or minor injury to the operator or to bystanders.
NOTICE A situation that will not cause personal injury but may cause
equipment damage.
6 | Kit Contents
KIT CONTENTS
1
2
9
10
3
45
11
6
8
7
Ref. Part Description QTY
1PowerDock 1
2PowerDock Terminal Assembly (also available separately: PPSDOCKKIT-002) 1
3 PowerDock Terminals 1
4 Terminals Cover (Insulator) 1
5 M5 Nyloc Nuts 4
6 Washers (M3) 2
7 Screw, K30 × 10 mm Pan-head 2
8PowerDock Mounting Hardware (also available separately: PPSDOCKKIT-001) 1
9 M8 Nyloc Nuts 6
10 M8 Washers 12
11 M8 Bolts 6
The PowerDock Terminal Assembly Kit (PPSDOCKKIT-002) is a servicable part that requires
periodic replacement. For more information, see 'PowerDock Terminal Assembly Kit
(PPSDOCKKIT-002)'(page26).
Parts of the PowerDock | 7
PARTS OF THE PowerDock
1. PowerDock Body
2. PowerDock Terminal Assembly
The electrical interface between the PowerDock
and GoBlock. See 'Wiring the PowerDock
Terminal Assembly'(page17).
Handle Assembly
3. Handle
Restrains the GoBlock when fully closed and
latched.
4. Latch Hook
Hooks into the Anchor Point on the top of
the GoBlock, locking the GoBlock for safe
transportation.
5. Quick Release Button
Press to release the latched Handle when
Undocking the GoBlock (page23).
6. Hinge
7. Padlock Attachment Points
Attach a padlock to the left or right Padlock
Attachment Point as an anti-theft measure.
See 'Padlock Attachment'(page24).
8. Mounting Holes (×14)
Mounting holes for securely bolting the
PowerDock Body to your vehicle.
See 'Mounting the PowerDock'(page8).
9. Cable Channel
A channel for running cables underneath the
PowerDock from front-to-back.
10. Cable Exit Point
Route cables from the PowerDock Terminal
Assembly to the vehicle via the Cable Exit Points
located at the front and back of the Dock.
11. Anti-Vibration Bushes
Absorb vibration during transport. Different
types are located throughout the assembly.
See 'Anti-Vibration Bushes, Pivots and
Feet'(page26).
1
10
710
5 6
7
2
11
3 4
9
8 (×14)
8 | Mounting the PowerDock
MOUNTING THE PowerDock
Mounting Surface Requirements
WARNING
Do not mount the PowerDock to non-permanent/moveable floor panels in your vehicle.
The Dock must be permanently mounted to a fixed structural part of the vehicle, or to a surface
that is rated to hold a minimum of 500 kg (1102 lb).
Before you begin mounting the PowerDock, ensure that the following mounting surface
requirements will be met:
Inspect the mounting surfaces to make sure they are flat and safe to drill. Check the reverse
side of the mounting surface before drilling any holes in order to avoid drilling into any object
accidentally.
The mounting surface for the PowerDock should comprise a single layer rather than multiple
layers (such as a steel tray with plastic tub liner).
Sheet metal mounting surface must have a minimum thickness of 1 mm (3/64").
Large sections of unsupported or non-structural mounting surfaces will require additional
c-section or similar underside support/reinforcement. This includes surfaces such as sheet metal
that is thin or has nearby folds, welds etc., composite boards, plywood, or timber.
Mounting the PowerDock | 9
Mounting Clearances
Choose a position in your vehicle where the PowerDock can be safely and comfortably accessed
when docking and undocking the GoBlock. We recommend that the Handle open away from you
for ease of access when docking and undocking the GoBlock.
Check that there is room for the Protective Covers on the GoBlock to open so you can access the
input/output sockets.
If you intend to use the Padlock Attachment Points (page24), consider leaving enough clearance
on either side of the Dock to access and operate a padlock.
Mount in a location that has adequate clearance
607 mm / 23.9"
Vertical clearance
for access
Clearance to fully
open the Handle
Clearance for
padlock access
(only one side
required, Optional)
230 mm / 9.1"
346 mm /
13.6"
10 | Mounting the PowerDock
Mounting Parts
YOU WILL NEED:
1 × PowerDock (PPSDOCK)
Fasteners (if supplying your own mounting hardware, see note)
Note: The PowerDock (PPSDOCK) includes mounting fasteners suitable for mounting to a substrate
≤ 21 mm (0.85"). If your mounting substrate exceeds this thickness, you will need to source longer
mounting bolts.
POWERDOCK MOUNTING KITS
Using a REDARC PowerDock Mounting Kit is recommended. REDARC kits contain suitably rated
fasteners for safely mounting the PowerDock. Visit the REDARC website for Mounting Kits available
for the PowerDock.
Sourcing Your Own Mounting Hardware
If you choose to source your own mounting hardware/fasteners, ensure they are suitable for use
with your chosen mounting surface. See 'Mounting Surface Requirements'(page8).
Sourced hardware must meet or exceed the below minimum requirements.
6 × Bolts (M8×1.25, Grade 8.8 minimum) Select length to suit the mounting substrate thickness.
6 × M8 Nyloc (or equivalent) self-locking nuts
12 × Flat Washers (M8 × 25 mm)
× 12× 6× 6