Power Distribution System User`s Manual Model: PDS-100
Contents
1. PI TO TYPICAL HIGH Table 1 Recommended Input Power Feed Wire Size Single Unit CURRENT 32A MAX Max Total Load Wire Size AWG vs Wire Length 3 drop Current Amps s5 ft 5 10 ft 10 15ft 15 20ft 25 30 ft 25 10 6 6 4 2 50 6 4 2 2 0 75 6 2 1 0 3 0 100 4 2 0 2 0 4 0 Table 2 Recommended Circuit Load Wire Size Individual Circuit Wire Size AWG vs Wire Length 10 drop Load Current 1 5 ft 5 10 ft 10 15 ft 15 20 ft 20 30 ft 5 18 18 18 16 14 10 18 16 14 14 12 15 18 14 12 12 10 20 16 14 12 10 8 Table 3 Recommended Input Power Feed Wire Size for Multiple Units No of PDS 100 Units Wire Size AWG vs Wire Length 5 drop Max Load Current lt sft 5 10 ft 10 15 ft 15 20 ft 20 ft 2 200 Amps 2 0 2 0 3 0 Not Recommended 3 300 Amps 2x 2 2 x 0 2 x 0 2 2 0 Not recommended CE KUSSMAUL ELECTRONICS Phone 800 346 0857 West Sayville Fax 631 567 5826 New York 11796 www kussmaul com E Mail sales kussmaul com V LOAD GROUP POWER ACTIVATION PROGRAMMING Switch Guide Program SET Default Reset Button Button 6 5 4 o Load Group 1 Load Group 2 Load Group 3 Dip Switch Module Dip Switch Module Dip Switch Module Programming Overview The PDS 100 can be programmed to independently disconnect the 3 Load Groups based on vario2. Applying the Dip Switch Settings Once the dip switches have been set to the desired positions press and hold the SET switch for 1 second then release to save to memory The red status LED will flash for 4 seconds then extinguish The PDS dip switch settings are now stored in memory and the PDS will start operating with the new settings NOTE Even if power is completely removed from the PDS 100 or the reset button is pressed the new settings will not change Re Setting to Factory Defaults To set PDS to its factory default settings press and hold the SET button then press the RESET switch for 2 seconds when the status LED begins to flash Release the SET button The PDS is now reset to the factory settings KEYKUSSMAUL 170 Cherry Ave ELECTRONICS Phone 800 346 0857 West Sayville Fax 631 567 5826 New York 11796 www kussmaul com E Mail sales kussmaul com Default Factory Setting LOAD GROUP 1 MODE 1 ON with Ignition OFF with Ignition LOAD GROUP 2 MODE 2 ON with Ignition OFF with Timer TIMER 2 minutes LOAD GROUP 3 MODE 3 ON with Battery OFF with Programmed Voltage Disconnect LVD SET 11 5 volts Reconnect 13 0V VI OPERATION A Fuse Installation We recommend pre installing fuse values before powering PDS 100 The PDS 100 will accept ATO ATC style fuses 20 Amp maximum rating B Fuse Removal Firmly grip fuse with fingers or needle nose pliers and pull straight out C Fuse OK LED A green LED next to each f
3. 6 for reconnect voltages 20 second delay Master Disconnect High Voltage 16 0V OVS Low Voltage 10 5 UVS 20 second delay Operating Temperature Range 20 C to 60 C Mechanical Case Powder coated aluminum Protective Covers Battery bus and power out terminals Dimensions x W x D 5 6 x 4 75 x 3 1 Weight 2 Lbs KEYKUSSMAUL 170 Cherry Ave ELECTRONICS Phone 800 346 0857 West Sayville Fax 631 567 5826 New York 11796 www kussmaul com E Mail sales kussmaul com VIII Troubleshooting Problem Symptom No power to any of the six outputs Load Group set for timed disconnect turns off too soon Load Group set for timed disconnect does not disconnect Ignition controlled circuits not on when ignition is ON Load Group set for low voltage disconnect disconnects when battery is not below selected disconnect threshold 170 Cherry Ave West Sayville New York 11796 Possible Cause 1 No or low lt 10V input power 2 Bad power input ground connection 3 Defective unit 1 DIP switches not set correctly 2 Battery voltage is dropping below 10 0 VDC causing activation of Master Low Voltage Shutdown circuit 3 Unit may have been reset to Factory Default settings thus unit is not operating according to the dip switch positions observed 1 DIP switches not set correctly 2 Defective unit 3 Unit may have been reset to Factory Default settings thus unit is not oper
4. Down Up Up Down 5 hrs Down Up Up Up 6 hrs Up Down Down Down 7 hrs Up Down Down Up 8 hrs Up Down Up Down 9 hrs Up Down Up Up 10 hrs Up Up Down Down 11 hrs Up Up Down Up 12 hrs Up Up Up Down 13 hrs Up Up Up Up KEYKUSSMAUL 170 Cherry Ave ELECTRONICS Phone 800 346 0857 West Sayville Fax 631 567 5826 New York 11796 www kussmaul com E Mail sales kussmaul com LVD Selection MODE 3 When the Load Group relay is set for mode 3 dip switch positions 1 though 4 will set the desired Low Voltage Disconnect and re connect trip points This is the level at which the Load Group is disconnected and re connected In this mode the ignition signal has no affect on the Load Group operation Table 6 Low Voltage Selection LV Disconnect Reconnect Switch 4 Switch 3 Switch 2 Switch 1 11 8 13 5 Down Down Down Down 11 7 13 5 Down Down Down Up 11 6 13 5 Down Down Up Down 11 5 13 5 Down Down Up Up 11 4 13 5 Down Up Down Down 11 3 13 5 Down Up Down Up 11 2 13 Down Up Up Down 11 1 13 Down Up Up Up 11 0 13 Up Down Down Down 10 9 13 Up Down Down Up 10 8 13 Up Down Up Down 10 7 13 Up Down Up Up 10 6 12 5 Up Up Down Down 10 5 12 5 Up Up Down Up 10 4 12 5 Up Up Up Down 10 3 12 5 Up Up Up Up Example Settings LVD Timer Level Duration Mode 2 gt Mode Q 2 6 Load Group 1 Load Group 2 Load Group 3 Timer mode Ignition LVD mode set set to 4 hrs ON OFF to 11 8V disconnect Saving and
5. West Sayville Fax 631 567 5826 www kussmaul com E Mail sales kussmaul com New York 11796 X Dimensional Drawing 5 200 180 F X4 170 Cherry Ave West Sayville New York 11796 1 958 WITH CLEAR COVER EYKUSSMAUL ELECTRONICS www kussmaul com WITH CLEAR COVER 12 Phone 800 346 0857 Fax 631 567 5826 E Mail sales kussmaul com
6. ating according to the dip switch positions observed 1 Ignition terminal on PDS 100 not receiving 12 vdc when ignition is on 2 Incorrect Mode programming selected for this Load Group 3 Unit may have been reset to Factory Default settings thus unit is not operating according to the dip switch positions observed 1 DIP switches not set properly 2 PDS 100 input wires under sized or too long resulting in excessive voltage drop 3 Unit may have been reset to Factory Default settings thus unit is not operating according to the dip switch positions observed EYKUSSMAUL ELECTRONICS www kussmaul com Solution 1 Remove protective plastic cover amp place a dc voltmeter or DMM across PDS 100 positive amp negative power input studs to verify input voltage If no voltage check for blown or tripped input fuse circuit breaker 2 If no power to PDS 100 input and fuse breaker is OK check for loose ground cable 3 Contact Kussmaul for RMA 1 Reset this Load Group for Mode 2 IGN with Timeout amp verify time period selected see Section V 2 Check for low voltage at the battery terminals If voltage is low recharge If problems persists check for faulty alternator or replace battery 3 Re program the unit see page 6 1 Verify DIP switches for this Load Group are set for Mode 2 IGN with Timeout amp verify time period selected see Section V 2 Contact Kussmaul for an RMA 3 Re progra
7. e 10 volts Programming Once the battery is first connected to the PDS 100 the microcontroller operates at the factory default settings To change any of the settings the PDS 100 will first need to be set to programming mode To do this 1 Jumper the IGN In terminal to the INPUT bus using the programming jumper wire provided then press and hold the SET button until the red status LED begins flashing 2 Release the button and LED will stay illuminated The PDS is now in programming mode Note if programming mode has been entered unintentionally or if you don t want to save any changes press the RESET switch at this point to abort programming mode Pressing reset will momentarily interrupt output voltage of all Load Groups Load Group Activation Selection Each of the three Load Group relays can be programmed independent of each other to one of four activation modes using dip switch positions 5 amp 6 refer to the Switch Guide KEYKUSSMAUL 170 Cherry Ave ELECTRONICS Phone 800 346 0857 West Sayville Fax 631 567 5826 New York 11796 www kussmaul com E Mail sales kussmaul com The modes are as follows 1 ON with Ignition OFF with Ignition Circuits will be energized anytime the ignition signal is 25 volts and de energized if s5 volts with 1 second delay When this mode is selected dip switches 1 through 4 of that relay group have no effect 2 ON with Ignition OFF with Timer Relay will stay energized after the
8. f two circuits KEYKUSSMAUL 170 Cherry Ave ELECTRONICS Phone 800 346 0857 West Sayville Fax 631 567 5826 New York 11796 www kussmaul com E Mail sales kussmaul com Figure 2 Multiple Unit Wiring Drawing 300 AMP MAX FUSE OR BKR TO 12V BATTERY FEED PARALLEL BUS KIT PBK N O 1898988 IAN SIGNAL ON gt 5V S OFF lt 5V IGNITION SIGNAL JUMPERS JARAS RAZAR CfoeeeooO INN PARALLEL BUS KIT PBK OPTIONAL O O annann 88 NGO lo Pao 20 flo 29 20 20 25 Pao IN O x JBATTERY Ba S TO TYPICAL LOAD
9. fic eEYKUSSMAUL CE ELECTRONICS Power Distribution System User s Manual Model PDS 100 Section Page Product 1 General 2 Important Safety 2 HD Instalatom 3 A Materials 3 viens 3 3 D System Expansion Parallel Units 3 IV Wiring Instructions amp Diagrams 3 V Load Group Power Activation Programming 6 VI Operall0oN aaa nA Ka 9 Default 9 9 10 Warranty ima 11 X Dimensional 12 Manual Part M KPDS100 KE KUSSMAU As of June 2013 170 Cherry Ave ELECTRONICS Phone 800 346 0857 West Sayville Fax 631 567 5826 New York 11796 www kussmaul com E Mail sales kussmaul com Product Overview Battery Input OK Green Status LED Red e Programming Status e Ignition OFF Over Voltage Shutdown e Under Voltage Shutdown Circuit ID ATC ATO Fuse 20 Amp Max Fuse Ok LED Green Master Low Voltage Disconnect Disables Power to All Loads When Input Volta
10. ge 9 Setting to Factory Defaults we recommend first programming the PDS 100 on a bench for convenience before installation See page 6 Section V Load Group Power Activation Programming A Materials Provided Qty Description Installation Operation Manual M PDS100 PDS 100 Power Distribution System Protective plastic cover 7 jumper wire with 1 4 female fast on and ring terminal use to jumper power from input bus to IGN terminal when programming unit on bench _ gt xd mh Cover attachment screws nylon black Sheet metal mounting screws 10 x 1 2 self tapping Phillips Pan Head S S a fast on terminal 90 insulated Ignition sense Programming data card and holder to record settings entered A N Rubber boot battery power feed Note Fuses not provided B Location Select position in the interior of the vehicle where there will be ample space for wire routing and access to the fuses and where it will be subjected to extreme heat moisture liquids or impact by tools or other items stored the compartment C Mounting Always attach to the vehicle metal frame so that it cannot come off in an accident or heavy breaking situations Use provided self tapping sheet metal screws 4 ea Mount with fuse side up Do not mount under the hood in engine compartment D System Expansion Parallel Units Circuit capacity can be expanded by wiring a second and third PDS unit to the f
11. ge is Less Than 10 5V DC 170 Cherry Ave West Sayville New York 11796 12V DC Battery In Parallel Bus Tie Point PDS 100 POWER DISTRIBUTION SYSTEM fc Ey KUSSMAUL eed ELECTRONICS www kussmaul com 800 346 0857 RATING 12V DC NEG GROUND 100 AMPS INSTALL 100A FUSE CIRCUIT BREAKER ON INPUT REPLACE PROTECTIVE COVER AFTER INSTALLATION SERVICE CAUTION 20 AMPS MAX ATC ATO FUSE LOAD GROUP 1 LOAD GROUP 2 LOAD GROUP 3 1 2 3 5 6 Battery Ground Parallel Bus Tie Point KE KUSSMAUL ELECTRONICS www kussmaul com Ignition Sense Terminals 1 4 Male Fast On Dip Switch Modules Set Power Activation Parameters Per Load Group Powered Only With Ignition e Timed Disconnect Always On with Adjustable Load Group LVD Always On No Load Group LVD 12V Load Terminals Ground Load Terminals Phone 800 346 0857 Fax 631 567 5826 E Mail sales kussmaul com 1 GENERAL INFORMATION The PDS 100 provides emergency and public safety vehicle electronics installers with a convenient efficient safe and dependable method for adding distribution circuit protection timer and power control to communication electronics and electrical devices Its compact size allows installation under consoles and in interior compartments not intended for installation in engine compartment As a standalone power distribution system there is no interference with the vehicles factory installed w
12. ignition signal reaches lt 5 volts for a period of time set by dip switches labeled 1 through 4 of that relay group 3 ON with Battery Power OFF by Load Group LVD Relay will stay energized until the battery voltage drops below a specified level for 20 seconds set by dip switches 1 through 4 of that relay group The ignition signal has no affect on this group mode 4 Always ON Relay energized no matter state of ignition signal OFF only by Master Under Voltage Shutdown UVS NOTE Under Voltage Shutdown UVS or Over Voltage Shutdown OVS will de energize all relays in any MODE If the UVS or OVS threshold is reached before timer times out power will be disconnected from load group Table 4 Power Activation Selection Table Switch Position 1 IGN ON OFF Down Down 2 IGN with Timeout Down Up 3 LVD Up Down 4 Always ON Up Up Timer Duration Selection MODE 2 When the Load Group mode is set for mode 2 dip switch positions 1 though 4 will set the desired timeout duration which is the time from when the vehicle IGN is shut off to when the load is disconnected see Table 5 for timer selection Timer is reset when IGN input voltage is again sensed when ignition switch is turned on Table 5 Timer Duration Selections Duration Switch4 Switch3 Switch2 Switch 1 2 min Down Down Down Down 10 min Down Down Down Up 30 min Down Down Up Down 1hr Down Down Up Up 2 hrs Down Up Down Down 3 hrs Down Up Down Up 4 hrs
13. ire harness the PDS wires directly to the vehicle battery Each of the 6 circuits are individually fused ATO ATC type and wired to power on fuse fail indicator LED s which simplifies circuit troubleshooting The 6 distribution circuits are configured into 3 load groups of two power control to each individually group is programmable via 4 user selectable options e Always ON ON with Ignition OFF with Ignition ON with Ignition Timed OFF adjustable time interval with Ignition e ON with Battery OFF upon Low Voltage sense LVD adjustable disconnect point with 20 second delay In addition the unit contains a master Under Voltage sense circuit that de activates the whole unit 10 5V to save the vehicle battery from extreme discharge and automatically reconnects when battery charge recovers Contact factory for custom Master Under Voltage Shutdown threshold A Hight Voltage Shutdown circuit is also built in that de activates the whole unit 16 0V protecting loads against damage due to malfunctioning alternators System capacity can easily be expanded by wiring additional PDS in parallel 18 circuits maximum see options below Optional Accessories 1 Parallel Bus Bar Kit allows up to three PDS 100s inputs to be paralleled for additional circuits One kit required for two PDS 100s two kits for three PDS 100s Order model PBK part number 390 5723 0 2 Parallel Load Terminal Kit allows two output circuits in the same Load Grou
14. irst see Figure 2 each additional PDS provides 6 additional load circuits 18 circuits maximum IV Wiring Instructions amp Diagrams Refer to Figure 1 wiring diagram for a single unit wiring amp Figure 2 for multiple unit wiring Refer to Tables 1 2 4 on page 5 for recommended wire size for input power feed load wiring 4 multiple unit input power feed Battery CAUTION Install a fuse or circuit breaker on the positive battery power feed wire as close to the battery as possible in order to protect the input power feed wires Size fuse or circuit breaker 125 150 of the maximum load current For single PDS 100 installations see Table 1 Recommended Input Power Feed Wire Size Identify the total amperage of all loads to be connected to PDS 100 and then identify recommended wire size based on the cable distance between the vehicle battery and the PDS 100 mounting location Note For any wire runs that fall between wire length shown in tables on page 5 use the longer wire run to determine wire size Slide provided rubber boot over positive battery feed cable before crimping 1 4 stud For multiple PDS 100 installations refer to Table 3 Recommended Input Power Feed Wire Size for Multiple Units for EYKUSSMAUL 170 Cherry Ave ELECTRONICS Phone 800 346 0857 West Sayville Fax 631 567 5826 New York 11796 www kussmaul com E Mail sales kussmaul com battery wire size Use 1 4 crimp ring terminals to
15. m the unit see page 6 1 Check ignition wiring check for blown ignition source fuse 2 See Mode selection section on page 6 3 Re program the unit see page 6 1 See Table 6 for LVD disconnect voltage choices 2 See Table 1 Recommended input power feed wire size and increase wire size or reduce wire length 3 Re program the unit see page 6 10 Phone 800 346 0857 Fax 631 567 5826 E Mail sales kussmaul com No output power from individual fuse Blown fuse Determine reason for blown fuse correct fault amp replace fuse output IX WARRANTY All products of Kussmaul Electronics Company Inc are warranted to be free of defects of material or workmanship Liability is limited to repairing or replacing at our factory without charge any material or defects which become apparent in normal use within 3 years from the date the equipment was shipped Equipment is to be returned shipping charges prepaid and will be returned after repair shipping charges paid Kussmaul Electronics Company Inc shall have no liability for damages of any kind to associated equipment arising from the installation and or use of the Kussmaul Electronics Company Inc products The purchaser by the acceptance of the equipment assumes all liability for any damages which may result from its installation use or misuse by the purchaser his or its employees or others KUSSMAUL 170 Cherry Ave ELECTRONICS Phone 800 346 0857
16. make the wire connection to the 12V and ground input studs on single PDS 100 installations and 5 16 crimp ring terminals Parallel Bus Bar Kit model PBK for multiple PDS 100 installations Slide rubber boot over positive stud after securing cable to stud Loads CAUTION Maximum load group circuit fuse value is 20 amps Fuses should be sized to 125 150 of the load current to prevent nuisance fuse blowing Refer to Table 2 Recommended Circuit Load Wire Size for recommended wire size for each load Use ring or fork crimp terminals to make the wire connections to the 12V load terminal block and ground load terminals Ignition wire size of 18 AWG or greater should be used to make the ignition input connection to the PDS 100 An insulated 16 14 AWG 1 4 female fast on 90 is provided Figure 1 Single Unit Wiring Drawing FUSE OR CIRCUIT BREAKER SIZED TO YOUR LOAD NO 8 LARGER THAN 100 AMP BARAHA 12V IGNITION SIGNAL 12 VOLT O o BATTERY OFFSSV 20 AMPS MAX PER CIRCUIT AA TAL THE TE 0 TO TYPICAL LOAD Optional Parallel Load Terminal Kit provides single high power 32 amp circuit by paralleling output o
17. p to be paralled for loads that exceed the single circuit 20 amp capacity providing up to a 32 amp circuit One kit includes one fork terminal with hardware to allow one heavy cable to land on to two 12V load terminals of the same Load Group Load ground cable connects to single 6 screw located on the Battery Ground bar Order model PTK part number 390 5725 0 IMPORTANT SAFETY INFORMATION CAUTION e Read and fully understand the installation operation manual before making any wiring connections e To avoid reverse polarity confirm correct polarity before connecting cables to PDS 100 Stud ends are color coded with polarity RED 12 VDC Positive BLACK 12 VDC Negative e Install fuse circuit breaker on 12 VDC power feed input wire to PDS 100 Size to match your loads and wire size e Connect high current feeder cables to the provided 4 studs only e Run separate dedicated ground cable 12 VDC to PDS 100 ground stud Do not rely on chassis frame for grounding connections 20 Amp maximum fuse Use ATC ATO style fuses only e 12 VDC nominal negative ground systems only Donot exceed 100 Amps total load per unit e Replace protective cover after installation KEYKUSSMAUL 170 Cherry Ave ELECTRONICS Phone 800 346 0857 West Sayville Fax 631 567 5826 New York 11796 www kussmaul com E Mail sales kussmaul com INSTALLATION IMPORTANT NOTICE If not using the factory default programming see pa
18. us selected conditions There are 3 input elements to the programming process 1 Dip Switches Programming is provided though three sets of dip switch modules One per each Load Group Each set is divided into two sections The first section made up of switches 5 amp 6 is for selecting the power activation MODE to the Load Group The second section made up of switches 1 through 4 is for setting either a TIMER duration or Low Voltage Disconnect and reconnect LVD level of the Load Group dependent on MODE selected Use a screwdriver or pen to adjust dip switch positions there are two positions up and down 2 SET Button This switch is used to put the PDS 100 into programming mode and save settings to memory Also used for resetting the PDS 100 to factory defaults see Setting to Factory Defaults on page 9 3 RESET Button This switch resets the microcontroller Use it to exit the programming mode without saving any settings and when resetting the PDS 100 back to factory defaults WARNING pressing the RESET switch will momentarily interrupt power to loads Programming the Load Group Relays easier performed on test bench rather than in vehicle Note A short programming jumper wire is provided to aid in programming the PDS 100 Before programming ensure 12 volt power is properly applied to unit Connect power to INPUT stud and the power return to the ground bus stud The PDS 100 will not power up unless input power is abov
19. use will illuminate when a good fuse is installed Note If using blown fuse indicating type fuses a minimum load of at least 20 milliamps is required for proper indication D Master Under Voltage Shutdown UVS amp Over Voltage Shutdown OVS UVS If the INPUT bus voltage drops below 10 5V for more than 20 seconds all Load Group relays will de energize and all loads will disconnect from the INPUT bus and will reconnect when battery voltage is restored to 13V OVS If the INPUT bus increases to over 16V all Load Groups relays will de energize and loads will disconnected from the INPUT bus and will restore 15V E Input Power and Power Mode Indicators INPUT POWER LED indicates the presence of voltage on INPUT bus gt 6 volts POWER MODE LED rate of flashing light indicates different power conditions OVS Over Voltage Shutdown all circuits off constant flashing at a rate of once every 1 second UVS Low Voltage Shutdown all circuits off constant flashing at a rate of once every 2 seconds IGN Ignition not present quickly flashes 3 times every 2 seconds VII Specifications Electrical Input 12V neg ground Power Consumption Idle 8mA Active 180 mA circuit Maximum Load 100A per PDS 20A max per fuse position Maximum System 3 PDS wired in parallel 18 circuits Fuse Type ATC ATO Programmable Timer Range 2 min 13 hours Low Voltage Disconnect Point Range Selectable per load group 10 3 to 11 8V see table
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