User Manual DPS Series
Contents
1. 10 Fuse To Loads 2 10 INSTALLATION 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 e Both DPS units must be mounted to the chassis of the vehicle for external heat sinking e The DPS units must be mounted close to each other e The RED BROWN BLACK BLUE amp ORANGE wires from both units must be joined to their matching colour with the same size and length cables e The input output and earth wiring must be suitably sized to carry the constant high current Refer to REDARC s cable size guide for more information http www redarc com au handy hints how _to calculate_wire_gauge e Suitably rated fuses must be used Refer to page 3 Note Power wires must be Optional suitably sized refer to section 2 8 indicator and must be crimped using an LED appropriate crimp tool Output Voltage Selection Refer to section 2 4 To Loads to 12V or 24V Start Battery To Vehicle Igniton All ground points must be connected to chassis Fuse Ratings as per table on Page 3 earth Figure 2 10 1 Parallel Connection of two DPS units for increased output rating 11 3 TROUBLESHOOTING Start and run engine for 30 seconds leave engine running whilst troubleshooting S2. ensure a low resistance connection The REDARC FK40 and FK60 setup from the Fuse Kits 2 available from REDARC fuse kits are recommended Part number FK40 40A Blade type fuses not recommended as they can result in a 60 6 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 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 Blinking Unit is in Standby Unit is supplying power ____ 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 25
3. A for DPS1225 187 18 70 14 80 OUIPUT SATUS DPS1225 18 13 7 14 80 OUIPUT STATUS DPS1240 25A Switchmode Switchmode Voltage Reducer amp Voltage Reducer Supply 9 32V to 12V DE Supply 9 32 to 12V 20 ZUN 291 OUTPUT STATUS DPS2410 20 274M 20 OUTPUT STUS DPS2420 10A Switchmode EN 20A Switchmode Voltage Booster 4 Voltage Booster DG Supply 9 32V to 24V DE 9 32 to 24V Figure 1 1 1 The DPS Series Front Panels 1 2 PRODUCT FUNCTION 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 Good Heatsink Poor Heatsink Output Current rating Time 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 DPS1225 2 DPS1240 5 5 0252410 2 DPS2420 Loaded Input Voltag
4. 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 Not 24 0V output on the DPS2410 DPS2420 Connected Leave the ORANGE wire disconnected Orange Wire St Me For 13 7V output on the DPS1225 DPS1240 Orange Wire or gt 27 4V output the DPS2410 DPS2420 Connect the ORANGE wire to Common Ground For 14 5V output the DPS1225 DPS1 240 or 29 0V output on the DPS2410 DPS2420 Connect the ORANGE wire to the RED wire Input source positive 2 4 2 5 2 6 2 7 INSTALLATION BROWN wire Output load Positive The BROWN wire should be connected to the output 10 Loads 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 BLACK wire Common Ground The BLACK wire should be connected to a ground point that is common to both the Start battery and the Black Wire Load This point may be on the chassis of the vehicle the chassis of the trailer depending on your installation requirements 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
5. THE POWER OF In vehicle DC Power Supply DPS1225 DPS1240 DPS2410 amp DPS2420 THE DPS1225 DPS1240 DPS2410 amp 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 amp 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 A WARNING DO NOT USE THE DPS1225 DPS1240 DPS2410 DPS2420 TO CHARGE BATTERIES DOING SO MAY RESULT IN HARM TO THE USER AND OR DAMAGE THE DPS1225 DPS1240 DPS2410 DPS2420 A CAUTION 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 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 ma
6. e PRODUCT FUNCTION 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 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 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 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 2 2 2 3 INSTALLATION BLUE wire Ignition Control The BLUE wire should be connected to the vehicle s Vehicle ignition or if required a dedicated ON OFF switch Ignition 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 Blue Wire ORANGE wire Output Voltage
7. em Reduce loads or increase size of DPS as required Figure 3 1 DPS Troubleshooting Guide 12 4 NOTES 13 TWO YEAR PRODUCT WARRANTY Over the last three decades our company has established a reputation as the power conversion specialist 100 Australian owned company we have met the needs of customers in transport and other industries through exciting innovative thinking We believe in total customer satisfaction and practice this by offering our customers Our goods come wi any other reasonab Technical advice free of jargon and free of charge Prompt turnaround of orders throughout Australia and globally Friendly personalised professional service and product support In the unlikely event that a technical issue arises with a Redarc product customers are encouraged to initially contact the Redarc Technical Support Team on 08 8322 4848 or power redarc com au for prompt and efficient diagnosis and product support amount to a major failure The benefits of this provisions or rights Redarc Electronics authorised distributor il In this Warranty the term Products means 1 1 all products manufactured or supplied by Redarc excluding its solar products which are covered by Redarc s Solar Product Warranty and 1 2 any component of or accessory for any product in clause 1 1 manufactured or supplied by Redarc Offer and duration of product warranties Redarc warrants that its Products will be free under
8. es it illegal unenforceable or invalid but can also be read in a way that makes it legal enforceable and valid it must be read in the latter way If any clause or part of a clause in this Warranty is illegal unenforceable or invalid that clause or part is be treated as removed from this Warranty but the rest of this Warranty is not affected Redarc s contact details 21 Redarc s contact details for the sending of Warranty claims under this Warranty are Redarc Electronics Pty Ltd 23 Brodie Road North Lonsdale SA 5160 Email power redarc com au Telephone 61 8 8322 4848 o oo Nog 14 THE POWER OF Free technical assistance please contact REDARC Electronics 23 Brodie Road North Lonsdale SA 08 8322 4848 power redarc com au www redarc com au Copyright 2015 REDARC Electronics Pty Ltd All rights reserved WARDPS REV1
9. 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 Crimp both wires to the butt splice using Solder the wires to the butt splice indent type crimpers Ensure that a good connection is made Keep heatshrink away until after soldering is complete and has cooled Figure 2 9 1 Ensuring a good wiring connection INSTALLATION Note Power wires must be Optional suitably sized refer to section 2 8 indicator and must be crimped using an LED appropriate crimp tool To Vehicle Igniton Output Voltage Selection Start Refer to section 2 3 All ground points must be connected to chassis earth Fuse Ratings as per table on Page 3 Fuse To Loads Figure 2 9 2 Standard 12V Input setup Note Power wires must be Optional suitably sized refer to section 2 8 indicator and must be crimped using an LED appropriate crimp tool To Vehicle Igniton Output Voltage Selection Refer to section 2 3 Black All ground points must be connected to chassis earth Fuse Ratings as per table on Page 3 Figure 2 9 3 Standard 24V Input setup
10. her than for any reasonable manufactured her occurrence oul purpose for which 6 9 any indirect or incidental damage of whatever nature Warranty claims in respect of a Produc postal address or email address specifi Such claims must include the following It and the circumstances surrounding the 7 1 details of the alleged defect or defect or fault must be made in ied clause 21 wi echnician or if non side the control of Product was outside the control of writing to Redarc at the hin the Warranty Period 7 2 evidence of the claim including photographs of the Product where the subject of the claim is capable of being ph otographed 7 3 the serial number of the Product specified on the label affixed to the Product and 7 4 proof of purchase documentation the Product from an authorised distributor or reseller of Redarc which clearly shows the date and place of purchase The return of any Products without the prior written instructions of Redarc will not be accepted by Redarc ith guarantees that cannot be excluded under the Australian Consumer Law You are entitled to a replacement refund for a major failure and compensation for ly foreseeable loss or damage You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not Warranty are in addition to other rights and remedie
11. hutdown the vehicle and rectify the problem Check the RED Is the wire 15 it installed with Output Status light ON appropriate gauge wire and or flashing connected to the source you require Yes Yes Is the BLUE wire connected DPS Needs 12 24V applied for DPS to operate If an External LED is fitted is it working as described on page 6 of this manual No 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 Yes Yes Are all load negative wires and BLACK DPS wire connected to a common ground point chassis No 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 Yes Check that the alternator is charging properly If the problem is still evident contact a qualified Auto Electrician or REDARC Electronics Is the input voltage RED wire between 9 32VDC No Yes 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 Is the load within the DPS s specified range Yes No Review syst
12. normal application installation use and service conditions from defects in materials and workmanship affecting normal use for 2 years from the date of purchase Warranty Period Where a Product malfunctions or becomes inoperative during the Warranty Period due to a defect in materials or workmanship as determined by Redarc then subject to further rights conferred by the Australian Consumer Law on the Purchaser Redarc will in exercise of its sole discretion either 2 6 3 1 repair the defective Product 3 2 replace the defective Product or 3 3 provide a refund to the Purchaser Product without charge to the Purchaser the purchase price paid for the defective The warranty given by Redarc in clause 3 covers the reasonable costs of delivery and installation of any repaired or replaced Products or components of Products to the Purchaser s usual residential address notified to Redarc together with the reasonable costs of removal and return defective If the Purchaser incurs expenses of the context of making a claim pursuant to nature referred to the Purchaser will be entitled to claim for reimbursement Redarc determines in exercise of its sole discretion to be reasonably incurred of any Products determined by Redarc to be in clause 4 in the his Warranty that is accepted by of those expenses which provided that the claim is notified to Redarc in writing at the postal addre
13. s available at law in respect of the Products and shall not derogate from any applicable mandatory statutory under the Australian Consumer Law Pty Ltd atf the Trust trading as Redarc Electronics Redare offers a warranty in respect of its Products where the Products are purchased from an or reseller of Redarc by person Purchaser on the terms and conditions and for the duration outlined below in this document Warranty 8 Without limiting any other clause in this Warranty Redarc has the right to reject any Warranty claim made by a Purchaser pursuant to this Warranty where 8 1 the Purchaser does not notify Redarc in writing of a Warranty claim within the Warranty Period 8 2 the Purchaser does not notify Redarc in writing of a Warranty claim within 1 month of becoming aware of the relevant circumstances giving rise to the claim so that any further problems with the Product are minimised 8 3 the serial number of the Product has been altered removed or made illegible without the written authority of Redarc 8 4 the Purchaser is unable to provide proof of purchase documentation in accordance with clause 7 4 or evidence that the Product was properly installed and removed if relevant and that proper maintenance has been performed on the Product by or under the supervision of a qualified auto electrician or technician in accordance with the instructions of Redarc 9 If the Product is found to be working sa
14. ss or email I address specified in clause 21 and incl ludes 5 1 details of the relevant expenses incurred by the Purchaser and 5 2 proof of the relevant expenses having been incurred by the Purchaser Exclusions and limitations This Warranty will not apply to or include any defect damage fault failure or malfunction of a Product which Redarc determines in exercise of its sole discretion to be due to 6 1 normal wear and tear or exposure to weather conditions over time 6 2 accident misuse abuse negligence vandalism alteration or modification 6 3 non observance of any of the instructions supplied by Redarc including instructions concerning installation configuring connecting commissioning use or application of the Product including without limitation choice of location 6 4 failure to ensure proper maintenance of the Product strictly in accordance with Redarc equipment or machinery 6 5 repairs to the Product that are not strictly in accordance with Redarc s instructions instructions or failure to ensure proper maintenance of any associated 6 6 installation repairs or maintenance of the Product by or under the supervision of a person who is not a qualified auto electrician or genuine or non approved parts have been fitted 6 7 faulty power supply power failure electrical spikes or surges lightning flood storm hail extreme heat fire Redarc 6 8 use ot
15. 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 Optional 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 2 8 INSTALLATION 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 Recommended Wire Size Closest BAE B amp S AWG mm 51225 DPS2410 2 9 0 50020 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
16. tisfactorily on return to Redarc or upon investigation by Redarc the Purchaser must pay Redarc s reasonable costs of esting and investigating the Product in addition to shipping and transportation charges Where Redarc is in possession of the Product the Product will be returned to the Purchaser on receipt of the amount charged 10 Any replaced Products or components of Products shall become the property of Redarc 11 Redarc may in exercise of its sole discretion deliver another type of Product or component of a Product different in size colour shape weight brand and or other specifications in fulfilling its obligations under this Warranty in the event Redarc has discontinued manufacturing or supplying the relevant Product component at the time of the Warranty claim or where such Product or component is superior to that originally purchased by the Purchaser Other conditions of Warranty 2 If the Purchaser acquired a Product for the purpose of resupply then this Warranty shall not apply to that Product 3 In particular the sale of a Product via an online auction online store or other internet website by a party that is not an authorised distributor or reseller of the Product will be deemed to be a resupply within the meaning of the Australian Consumer Law and will render this Warranty void as Redarc has no control over the storage handling quality or safety of Products sold by such persons 4 A Purchaser shall only be en
17. titled to the benefit of this Warranty after all amounts owing in respect of the Product have been paid 5 While Redarc warrants that the Products will be free from defects in materials and workmanship in the circumstances set out in this Warranty to the maximum extent permitted by law Redarc does not warrant that the operation of the Products will be uninterrupted or error free the maximum extent permitted by law Redarc s determination of the existence of any defect and the cause of any defect will be conclusive Spare parts or materials for the Products are guaranteed to be available for a period of at least 2 years after purchase of the Products he agents officers and employees of any distributor or reseller of the Products and Redarc are not authorised to vary or extend the terms of this Warranty shall not be responsible or liable to the Customer or any third party in onnection with any non performance or delay in performance of any terms and onditions of this Warranty due to acts of God war riots strikes warlike conditions or other epidemic fire flood blizzard hurricane changes of public policies and other events which are beyond the control of Redarc In such circumstances Redarc may suspend performance of this Warranty without liability the period of the delay reasonably attributable to such causes 20 If a clause or part of a clause in this Warranty can be read in a way that mak
18. y result in a risk of electric shock or fire and may void the unit warranty 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 The DPS1225 DPS1240 DPS2410 DPS2420 will achieve best results when proper load and vehicle maintenance is regularly performed SAL FOR Instruction Manual DPS 00 1090 Version 1 4 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 4 Notes 13 5 Two Year Product Warranty 14 SPECIFICATIONS ee ee ree Input Voltage Range Voltage Range 9 32V Recommended Input Fuse E ee ae FK60 recommended recommended recommended recommended Recommended Output Fuse E S Output vonage Selected with 1 Please refer to FUSING below FUSING REDARC recommend using MIDI style bolt down fuses as they single fuse and holder
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