Redarc PowerDock PPSDOCK User manual
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)'(page26).
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'(page17).
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 (page23).
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'(page24).
8. Mounting Holes (×14)
Mounting holes for securely bolting the
PowerDock Body to your vehicle.
See 'Mounting the PowerDock'(page8).
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'(page26).
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 (page24), 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'(page8).
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
Mounting the PowerDock | 11
Mounting Steps
WARNING Use suitable Personal Protective Equipment
(PPE) when operating power tools.
1. Confirm that the clearances around the Dock are adequate; see 'Mounting
Clearances'(page9). Check that there is enough clearance above the Dock by fully opening
the Handle.
2. Position the Dock in its final location and mark the centre of each mounting hole. At least 1
hole at each of the 6 mounting hole locations must be used, for a total of 6 bolts.
3. Drill the holes — check first that the reverse side of the mounting surface is clear before drilling
any holes to avoid drilling into any object accidentally.
De-burr the drilled holes and clear away swarf. To prevent rust, touch up any exposed bare
metal surfaces with a rust inhibitor (e.g. primer).
Mounting Hole locations in the PowerDock base. One hole from each location must be used.
1
2
3
4
5
6
12 | Mounting the PowerDock
4. Position the PowerDock over the drilled holes and fasten using the mounting hardware. Torque
each bolt to 20 – 25 Nm (14.6 – 18.4 lbf-ft).
NOTE: The combined height of the mounting bolt head and top washer must not exceed
9 mm (0.35"), to allow clearance between the bolt head and the GoBlock.
If hardware exceeds the stated dimensions, it may cause damage to the GoBlock and prevent
the GoBlock from docking safely.
Using a REDARC Mounting Kit is recommended.
Maximum
9 mm (0.35")
PowerDock Base
Sheet Metal
M8 Bolt Head
M8 Washer
Wiring | 13
WIRING
Wiring Parts
YOU WILL NEED:
1 × PowerDock (PPSDOCK)
PowerDock Complete Wiring Kit (PPSDOCKWK-002 recommended)
POWERDOCK WIRING KITS
Using a REDARC PowerDock Wiring Kit is recommended. A range of kits are available to suit
different mounting configurations — Visit the REDARC website for the full range of Wiring Kits
available for the PowerDock.
POWERDOCK BASIC WIRING KIT (PPSDOCKWK-001)
For wiring the PowerDock Terminal Assembly only.
Item Part Quantity
11 m (3' 3") Black Cable, spliced (10 mm²) 1
21 m (3' 3") Yellow Cable (10 mm²) 1
31 m (3' 3") Red Cable (10 mm²) 1
48.5 m (27' 11") Blue Cable (0.5 mm², with 2 A blade fuse) 1
54-Pole Terminal Block 1
6M5 Nyloc Nut 4
7M5 Washer 4
8M5×25 Bolts 4
1.5 m (4' 11") 8 m (26' 3") 0.5 m (1' 8")
1 m (3' 3") 1 m (3' 3") 1 m (3' 3")
8.5 m (27' 11")
31
2
4
5
8
7
6
14 | Wiring
1.5 m (4' 11") 8 m (26' 3") 0.5 m (1' 8")
1 m (3' 3") 1 m (3' 3") 1 m (3' 3")
8.5 m (27' 11")
POWERDOCK COMPLETE WIRING KIT (PPSDOCKWK-002)
For complete wiring installation to your vehicle.
Ref. Part Description QTY
11 m (3' 3") Black Cable, spliced (10 mm²) 1
21 m (3' 3") Yellow Cable (10 mm²) 1
31 m (3' 3") Red Cable (10 mm²) 1
48.5 m (27' 11") Blue Cable (0.5 mm², with 2 A blade fuse) 1
54-Pole Terminal Block 1
6M5 Nyloc Nut 4
7M5 Washer 4
8M5×25 Bolts 4
98 m (26' 3") Red Cable (4 AWG) 1
10 0.5 m (1' 8") Black Cable (6 AWG) 1
11 1.5 m (4' 11") Anderson Solar Cable (6 AWG) 1
12 60 A Midi fuse 1
13 Midi Fuse Holder 1
14 100 mm (3.9") Red Cable, (short length) 1
15 Cable ties (bundle) 1
31
10911
15
13
14
12
2
4
5
8
7
6
Wiring | 15
Sourcing Your Own Parts
CAUTION
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.
If supplying your own cable, refer to 'Cable Sizing'.
SOURCING LUGS/RING TERMINALS
Lugs must not exceed the given dimensions in
order to fit through the cable entry holes in the
PowerDock Terminal housing. Lugs can be lightly
modified (e.g. filed) to fit if there is only minor
interference.
Lugs must be suitable for 50 A continuous current
for alternator, solar and ground connections.
Max. 13 mm (0.51")
Max.
⌀
9.5 mm (0.34")
Max.
25 mm
(0.98")
Min. 5.1 mm (0.2")
Max. 6 mm (0.24")
Cable Sizing
Using a REDARC PowerDock Wiring Kit is recommended, however specific cable length and gauge
can be purchased to suit your individual installation if preferred.
The PowerDock Terminal requires a minimum 8 AWG (or preferably 10 mm²) cable for Solar,
Alternator and Ground connections. Larger cables and lugs will not fit within the PowerDock
Terminal housing, therefore cable runs longer than 1 m (3') will need a thicker cable to be spliced in
(as close as possible to the PowerDock) to ensure a safe and efficient installation.
'Cable Install Length' refers to the total cable length of the install (i.e. the total length of the cables
from the vehicle battery positive terminal to the PowerDock grounding point). Always choose a
cable cross sectional area equal-to or greater-than the size specified in the table. The selected cable
must be capable of carrying a minimum of 60A.
Cable Install Length Recommended Cable
Cross Section
Closest Equivalent
(BAE, B&S, AWG)
0–1m 0'– 3' ≥8.37mm² 8
1–5m 3'–16' ≥13.56mm² 6
5–9m 16'–30' ≥20.28mm² 4
16 | Wiring
Wiring Diagram
The PowerDock wiring diagram shows a typical configuration for PowerDock installed at the back of
the utility vehicle (Ute) tray. Cabling needs to extend the full length of the vehicle and then return to
the PowerDock Terminals.
PPSDOCK Wiring Diagram
VEHICLE
BATTERY
Anderson
Connector
TO SOLAR
6 AWG / 16 mm (0.5 m / 1' 8")
4 AWG / 25 mm
(8 m / 26' 3")
6 AWG / 16 mm
(1.5 m / 4' 11")
8 AWG / 10 mm (1 m / 3' 3")
20 AWG / 0.5mm (8.5 m / 27' 11")
60A
Fuse
4-Pole
Teminal Block
Battery Earth
Connection Point
POWERDOCK
TERMINALS
POWERDOCK
TO IGNITION
Fuse at point of
connection
8 AWG /
10mm
≤100 mm / 3.9"
recommended
2A Fuse
Wiring | 17
Wiring the PowerDock Terminal Assembly
1. If using your own cables, terminate one end of each cable with the appropriate sized/rated lug.
See 'Sourcing Lugs/Ring Terminals'(page15) for more information.
2. Remove the 4 × Nyloc nuts from the screw threads on the Terminals.
3. Route the cables through the cable entry holes at the bottom of the Terminals housing. Slide the
lugs over the threaded studs in the order shown in the Wiring View.
IGN SolarALT GND
4321
4. Replace the 4 × Nyloc nuts and tighten to 4 ± 0.5 Nm (2.95 ± 0.37 lbf-ft) — use a 4 mm (5/32")
Allen key on the reverse side of the terminals to hold the bolt still as it is tightened.
18 | Wiring
5. From the inside of the PowerDock body, clip the Terminals Shield onto the rectangular slots at
the front of the Dock.
6. Run the loose ends of the cables along the Cable Channel from front-to-back, then through the
Cable Exit Point at the back of the PowerDock Body. Continue to pull them through until the
Terminals Housing is near the Interface on the PowerDock Body.
Note: If your installation configuration requires it, feed the cables through the Cable Exit Point at
the front of the PowerDock Body instead of running them underneath.
Wiring | 19
7. Align the top two top mounting points on the Terminals Housing with the holes in the
PowerDock and Terminals Shield. Using a Torx Plus 10 IP driver (or T10 Torx driver) fasten with
the supplied M3 washers and M3 screws.
Torque the screws to 0.7 – 0.9 Nm (0.5 – 0.7 lbf-ft). When installed correctly, the washers should
be tight against the plastic screw bosses.
NOTICE
The PowerDock Terminal Assembly should be able to move slightly without resistance when
properly fixed to the PowerDock. Take care not to over-tighten the screws as this may damage
the plastic housing.
