Redarc DPS1225 User manual

In-vehicle DC Power Supply
DPS1225, DPS1240,
DPS2410 & DPS2420

1
THE DPS1225, DPS1240, DPS2410 & DPS2420
The DPS series In-vehicle DC Power Supplies feature technology designed to supply 12V
or 24V (model dependant) electrical loads such as lamps, radios, small motors, computer
and communications equipment, fridges, pumps and TVs from a 12V or 24V automotive
power system.
WARNING & SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS - This manual contains IMPORTANT SAFETY
INSTRUCTIONS for the DPS1225/DPS1240/DPS2410/DPS2420 DC Power
Supplies.
DO NOT OPERATE THE POWER SUPPLY UNLESS YOU HAVE READ AND
UNDERSTOOD THIS MANUAL AND THE POWER SUPPLY IS INSTALLED AS PER
THESE INSTALLATION INSTRUCTIONS.
DO NOT USE THE DPS1225/DPS1240/DPS2410/DPS2420 TO CHARGE BATTERIES.
DOING SO MAY RESULT IN HARM TO THE USER AND/OR DAMAGE TO THE DPS1225/
DPS1240/DPS2410/DPS2420.
1. This appliance is not intended for use 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 appliance.
2. Do NOT alter or disassemble the Power Supply under any circumstances. All faulty
units must be returned to REDARC for repair. Incorrect handling or reassembly may
result in a risk of electric shock or fire and may void the unit warranty.
3. Check the manufacturers data for your equipment/loads and ensure the maximum
voltage of the DPS1225/DPS1240/DPS2410/DPS2420 does not exceed the
manufacturers recommended maximum operating voltage.
4. The DPS1225/DPS1240/DPS2410/DPS2420 will achieve best results when proper
load and vehicle maintenance is regularly performed.
SAL.FOR.Instruction Manual.DPS - DOC1090 – Version 2

2
CONTENTS
TABLE OF CONTENTS PAGE
Warnings and Safety Instructions 01
Contents 02
Specifications 03
Fusing 03
1. Product Function 04
1.1 Display Panel 04
1.2 Unit Performance Characteristics 05
1.3 Error Codes 06
2. Installation 06
2.1 Red Wire 06
2.2 Blue Wire 07
2.3 Orange Wire 07
2.4 Brown Wire 08
2.5 Black Wire 08
2.6 Green Wire 08
2.7 Earth Isolation 08
2.8 Cable Sizing 09
2.9 Wiring 09
2.10 Connecting in Parallel 11
3. Troubleshooting 12

3
SPECIFICATIONS
Part Number DPS1225 DPS1240 DPS2410 DPS2420
Input Voltage Range 9-32V
Recommended Input Fuse*1 40A
REDARC FK40
recommended
60A
REDARC FK60
recommended
40A
REDARC FK40
recommended
60A
REDARC FK60
recommended
Nominal Output Current Rating 25A 40A 10A 20A
Surge Current Rating 50A 80A 20A 40A
Recommended Output Fuse*1 40A
REDARC FK40
recommended
60A
REDARC FK60
recommended
40A
REDARC FK40
recommended
40A
REDARC FK40
recommended
No Load Current <100mA <200mA
Standby Current <5mA
Output Voltage (selected with Orange wire)
No Connection 12.0v 24.0v
Earth 13.7v 27.4v
Positive supply 14.5v 29.0v
Line & Load Regulation ±1%
Conversion Efficency >94%
Operating Temperature -50 to +50°C
Weight 680g
Dimensions (mm) 150 x 120 x 37
Standards CE, C-Tick, AS/NZS CISPR1 1:2004
Warranty 2 Years
*1. Please refer to FUSING below.
FUSING
REDARC recommend using MIDI style bolt down fuses as they
ensure a low resistance connection. The REDARC FK40 and FK60
fuse kits are recommended.
Blade type fuses are not recommended as they can result in a
high resistance connection which causes excess heat and may
damage the fuse holder and/or the wiring. Self-resetting circuit
breakers are not recommended as they may trip prematurely and
continue to cycle until failure, due to the heat generated by the
current flowing through the wires.
A single fuse and holder
setup from the Fuse Kits
available from REDARC.
Part number FK40 (40A)
or FK60 (60A).

4
1 PRODUCT FUNCTION
The DPS1225/DPS1240/DPS2410/DPS2420 is a DC-DC power supply designed to run
electrical loads. The input voltage of the DPS can be above, below or equal to the output
voltage making it ideal for running equipment where specific load voltages or extreme
voltage drop are an issue.
The DPS is also designed to isolate the main battery from the load when the vehicle is
turned off to avoid flattening the vehicle’s starter battery.
1.1 Display Panel
The front panel features 4 LEDs to display the voltage level and output status.
LED State ‘Voltage Level’ LEDs ‘Output Status’ LED
Off Unit has no Power Output is off
Blinking Unit is in Standby Unit is supplying power
On Unit is on and can supply power
When blinking, the flash duty-cycle of the ‘Output Status’ LED will increase to
reflect the amount of current being supplied - If the LED is ON solid, the unit is
supplying full power (e.g. 25A for a DPS1225).
Figure 1.1.1 - The DPS Series Front Panels

5
1 PRODUCT FUNCTION
1.2 Unit Performance Characteristics
The DPS Should be mounted to the vehicle’s chassis to allow adequate heat-
sinking. If the DPS experiences extreme ambient temperatures its output power
may decrease until a steady-state is achieved. Better heat-sinking will enable
greater power output.
The DPS is able to overcome substantial voltage drop by acting as a voltage
booster. Voltage drop (as a result of inadequate input cable size) can cause
excessive heat to be generated in the wiring. To ensure the wiring is protected the
DPS will try to limit the difference between input and output voltage by reducing
the current draw on the input of the unit. To ensure full power output is maintained
suitable cable size (as outlined in section 2.8) should be used.
Time
Output Current rating
DPS Tem
p
eratur
e
DPS Temperature
Good Heatsink
Poor Heatsink
85
°
C
Loaded Input Voltage
Output Current rating
9V 12V 24V 32V
DPS1225
DPS1240
DPS2410
DPS2420

6
1 PRODUCT FUNCTION
1.3 Error Codes
In the event of a fault with the unit, installation, input supply or output loads,
both the External LED and ALL the LEDs on the unit will flash to indicate the
fault type. Flashing sequences are described in the table below.
LED State Description
1 flash (1 flash followed by 3.5 second off) Internal Hardware Fault
2 flash (2 flash followed by 3.5 second off) Not Used
3 flash (3 flash followed by 3.5 second off) Unit over temp fault
4 flash (4 flash followed by 3.5 second off) Output over voltage
5 flash (5 flash followed by 3.5 second off) Not Used
6 flash (6 flash followed by 3.5 second off) Input over voltage
7 flash (7 flash followed by 3.5 second off) Reverse polarity
NOTE: The unit will operate optimally below 55°C with good airflow. At higher
temperatures the unit will de-rate output current.
NOTE: Appropriate connections must be made to the wires with continuous current
ratings as per the specifications table on page 3.
2 INSTALLATION
The DPS cannot be installed in direct heat environments such as the vehicles
engine bay, the DPS performs at its best when the unit is mounted to the chas-
sis for external heat sinking. The DPS1225/DPS1240/DPS2410/DPS2420 has 6
wires and should be installed as described over the following pages.
2.1 RED wire - Input Source Positive
The RED wire should be connected to the positive
input from the vehicle’s starter battery.
Appropriate size fuses should be used as per the
specifications table on page 3.
Start
Battery
Red Wire
Fuse

7
2 INSTALLATION
2.2 BLUE wire - Ignition Control
The BLUE wire should be connected to the vehicle’s
ignition or, if required, a dedicated ON/OFF switch.
When connected in this way, the power supply will
only run the connected loads when the vehicle ignition
is ON, guaranteeing that the power supply will not
drain the start battery.
2.3 ORANGE wire - Output Voltage Select
The ORANGE wire is used to select the output voltage. This is achieved by
connecting in the following way:
For 12.0V output on the DPS1225/DPS1240
or
24.0V output on the DPS2410/DPS2420
Leave the ORANGE wire disconnected.
For 13.7V output on the DPS1225/DPS1240
or
27.4V output on the DPS2410/DPS2420,
Connect the ORANGE wire to Common Ground.
For 14.5V output on the DPS1225/DPS1240
or
29.0V output on the DPS2410/DPS2420
Connect the ORANGE wire to the RED wire (Input
source positive)
Vehicle
Ignition
Blue Wire
OR
OR
Orange Wire
Red Wire
Start
Battery
Fuse
Not
Connected
Orange Wire
Orange Wire

8
2 INSTALLATION
2.4 BROWN wire - Output load Positive
The BROWN wire should be connected to the output
load’s positive terminal. This should be a maximum of
1 metre in cable length from the DPS. Appropriate size
fuses should be used as per the specifications table
on page 2.
2.5 BLACK wire - Common Ground
The BLACK wire should be connected to a ground
point that is common to both the Start battery and the
Load. This point may be on the chassis of the vehicle
or on the chassis of the trailer depending on your
installation requirements.
2.6 GREEN wire - Optional External LED Indication
The GREEN wire is provided to optionally connect an
external indicator LED which can be mounted away
from the unit (for example on the vehicle’s dashboard).
Connect the positive lead of the LED to the green
wire, and the negative lead to the common ground.
No external resistors are required. “12V” LEDs and
filament globes are not suitable.
This LED will illuminate constantly when the DPS is
supplying power, it will flash a fault code if the DPS
has detected an error.
2.7 Earth Isolation
If the DPS is installed on a vehicle fitted with an earth isolation switch, the BLACK
wire must run to chassis earth/ground and NOT the supply battery’s negative
post. This ensures that the DPS is also disconnected when the isolation switch
is activated.
Green Wire
Optional
LED
Brown Wire
Fuse
to Loads
Black Wire

9
2 INSTALLATION
2.8 Cable sizing
Below is a table outlining the required cable size for a given cable install length.
Always choose a wire diameter equal to or greater than what is specified below.
Part Number Cable Install Length
(m)
Recommended Wire Size
(mm²)
Closest (BAE, B&S, AWG)
DPS1225/
DPS2410
1 - 5 7.71 8
5 - 9 13.56 6
DPS1240/
DPS2420
1 - 5 13.56 6
5 - 9 20.28 4
2.9 Wiring
The heavy gauge wires on the DPS1225, DPS1240, DPS2410 and DPS2420
unit carry peak currents of up to 40Amps and it is important to make a good,
low resistance, electrical connection that will not degrade over time. Failure to
make a good, reliable contact may result in breakdown of the wire insulation and
cause a short circuit, or worst case a fire. We recommend that this activity be
undertaken by an appropriately trained person.
REDARC recommends using a soldered butt splice crimp connection that is
covered with heatshrink. See Figure 2.9.1. REDARC does not recommend using
standard red/ blue/yellow blade connections as they are not rated for either the
current required or gauge of wire supplied on the unit.
Crimping provides good mechanical connection, soldering provides a long
lasting electrical connection and forming of the heatshrink will reduce the risk of
shorting/contact with your vehicle chassis.
Figure 2.9.1 - Ensuring a good wiring connection
Crimp here.
Crimp both wires to the butt splice using
indent type crimpers.
Solder Both Ends Here.
Solder the wires to the butt splice.
Ensure that a good connection is
made. Keep heatshrink away until after
soldering is complete and has cooled.

10
2 INSTALLATION
Fuse*
All ground points must
be connected to chassis
earth.
Fuse*
Note: Power wires must be
suitably sized (refer to section 2.8)
and must be crimped using an
appropriate crimp tool.
Output Voltage Selection
(Refer to section 2.3)
To Vehicle Igniton
Optional
indicator
LED
*Fuse Ratings as per table on Page 3
Red
Blue
Orange
Black
Brown
Green
Start
Battery
12V
INPUT
To Loads
Figure 2.9.2 - Standard 12V Input setup
Figure 2.9.3 - Standard 24V Input setup
Fuse*
All ground points must
be connected to chassis
earth.
Fuse*
Note: Power wires must be
suitably sized (refer to section 2.8)
and must be crimped using an
appropriate crimp tool.
Output Voltage Selection
(Refer to section 2.3)
To Vehicle Igniton
Optional
indicator
LED
*Fuse Ratings as per table on Page 3
Red
Blue
Orange
Black
Brown
Green
Start
Battery
24V
INPUT
To Loads

11
2 INSTALLATION
2.10 Connecting in Parallel
It is possible to connect two DPS units in parallel to increase the current output.
For example; two DPS1240s connected in parallel would produce a maximum of
80Amps for a load. Parallel connection requires specific installation;
• Both DPS units must be mounted to the chassis of the vehicle for external
heat sinking.
• The DPS units must be mounted close to each other.
• The RED, BROWN, BLACK, BLUE & ORANGE wires from both units must be
joined to their matching colour with the same size and length cables.
•The input, output and earth wiring must be suitably sized to carry the constant
high current.
• Suitably rated fuses must be used; Refer to page 3.
Fuse*
Fuse*
Note: Power wires must be
suitably sized (refer to section 2.8)
and must be crimped using an
appropriate crimp tool.
Output Voltage Selection
(Refer to section 2.4)
To Vehicle
Igniton
To Loads
Optional
indicator
LED
*Fuse Ratings as per table on Page 3
Red
Orange
Black
Brown
Green
Fuse*
All ground points must
be connected to chassis
earth.
Red
Blue
Orange
Black
Brown
Green
Blue
to 12V or 24V
Start Battery
Figure 2.10.1 - Parallel Connection of two DPS units for increased output rating

3 TROUBLESHOOTING
Are all
load negative wires,
and BLACK
DPS wire connected to a
common ground point?
(chassis)
Is the input
voltage (RED wire)
between 9-32VDC?
Is the load within
the DPS’s specified
range?
Check the connection
to the DPS, and the
orientation of the LED as per
the install diagrams. If the problem
is still evident contact a qualified
Auto Electrician, or REDARC
Electronics.
The DPS is operating correctly. If a low
output voltage occurs - check
BROWN wire is making a good connection
to the load(s). If the problem is still evident,
have a qualified Auto Electrician
inspect the system.
The DPS is not operating
correctly. Have a qualified
Auto Electrician check the wiring,
fuses, batteries and charging
system or contact REDARC
Electronics for more information.
Check that the alternator
is charging properly. If
the problem is still evident
contact a qualified Auto
Electrician or REDARC
Electronics.
Review system:
Reduce loads or increase size
of DPS as required
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
Start and run engine
for 30 seconds - leave
engine running whilst
troubleshooting.
Shutdown the
vehicle and rectify
the problem.
Is the
‘Output Status’ light ON
or flashing?
If an External LED
is fitted, is it working as
described on page 6
of this manual?
Is the BLUE
wire connected?
(DPS Needs +12/24V applied
for DPS to operate)
Check the RED
wire. Is it installed with
appropriate gauge wire and
connected to the source
you require?
Figure 3.1 - DPS Troubleshooting Guide
Accept no compromises, choose only quality batteries & power sources.