Progressive Dynamics PD4560, PD4560LI, PD4575, PD4575LI, PD4590 Installation And Operation Manual
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Installation and Operation Guide for
PD4500 Series Power Control Center
LIMITED WARRANTY
I. LIMITED WARRANTY: Progressive Dynamics, Inc. warrants its power control center to be free
from defects in material or workmanship under normal use and service; and limits the remedies to
repair or replacement.
II. DURATION: This warranty shall extend for a period of two years from the original date of purchase,
and is valid only within the continental limits of the United States and Canada.
III. WARRANTY EXCLUSIONS: This warranty specifically does not apply to:
A. Any product which has been repaired or altered in any way by an unauthorized person or service
station;
B. Damage caused by excessive input voltage, misuse, negligence or accident; or an external force;
C. Any product which has been connected, installed or adjusted or used other than in accordance with
the instructions furnished, or has had the serial number altered, defaced or removed;
D. Cost of all services performed in removing and re-installing the power converter; and
E. ANY LOST PROFITS, LOST SAVINGS, LOSS OF USE OF ENJOYMENT OR OTHER
INCIDENTAL DAMAGES ARISING OUT OF THE USE OF, OR INABILITY TO USE, THE
PRODUCT. THIS INCLUDES DAMAGES TO PROPERTY AND, TO THE EXTENT
PERMITTED BY LAW, DAMAGES FOR PERSONAL INJURY. THIS WARRANTY IS IN
LIEU OF ALL OTHER WARRANTIES, INCLUDING IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
IV. PROOF OF PURCHASE: A warranty claim must be accompanied by proof of the date of purchase.
V. CLAIM PROCEDURE: Upon discovery of any defect, Progressive Dynamics, Inc. shall be supplied
the following information at the address listed in this manual:
A. Name and address of the claimant;
B. Name, model and serial number of the product;
C. Application in which product was installed. (Includes manufacturer, model and model year where
applicable)
D. Date of purchase; and
E. Complete description of the claimed defect.
Upon determination that a warranty claim exists (a defect in material or workmanship occurring under
normal use and service,) the converter section shall be shipped postage prepaid to Progressive
Dynamics, Inc. together with proof of purchase. The product will be repaired or replaced and returned
postage prepaid.
Progressive Dynamics Inc.
507 Industrial Rd.
Marshall, MI 49068
Extended warranties are
available for purchase at
www.progressivedyn.com
service@progressivedyn.com
www.progressivedyn.com
110030F
INSTALLATION INSTRUCTIONS
MOUNTING:
The PD4500 series POWER CONTROL CENTER should be installed vertically (converter section down) or horizontally
(converter section to the right).
Unit is NOT ignition protected.
Do not mount in the LP gas or the battery compartment.
The INTELI-POWER converters are not designed for zero clearance compartments.
The POWER CONTROL CENTER is not designed for wet or damp locations. Install in an interior / dry location.
Cut mounting hole to approximately 10-1/8” x 13-1/4”.
The OEM should test the POWER CONTROL CENTER converter under full load conditions in its intended mounting
location to ensure proper ventilation. Failure to provide adequate ventilation will prevent the converter from supplying full
output power.
AC ELECTRICAL:
Connect wiring system using proper connections and appropriately sized cable clamp.
Connect CONVERTER AC HOT (black) wire to a 15A circuit breaker (PD4560) or 20A circuit breaker (PD4575 & PD4590).
Approved breakers (main and branch):
o ITE/Siemens – QP, QT
o Thomas & Betts – TB & TBBD series
o Square D – HOM & HOMT series
o Cutler Hammer/Bryant – BR & BRD series
o GE – HACR series
A closure plug kit for any unused Romex connectors may be purchased
from Progressive Dynamics, Inc. Part Number PD812374.
Approved Filler Plates
o ITE/Siemens – QF3
o GE – TQLFP1
Torque Data
AC Breakers: see breaker mfg data
AC NEU & GND bars: #8 AWG – 30 IN LBS
#10-14 AWG – 25 IN LBS
DC ELECTRICAL:
For installations without an external DC disconnect switch:
1. Connect battery POS (+) lead to the BATTERY POSITIVE (+) lug.
2. Connect battery NEG (-) lead to the BATTERY GND (-) lug.
3. The BATTERY DISCONNECT (+) lug is not used.
DC Terminal block: 7 – 9 IN LBS
DO NOT REMOVE TERMINAL BLOCK SCREWS
Torque Data
DC Lugs: 30 – 50 IN LBS
For installations incorporating an external DC disconnect switch:
1. Connect battery POS (+) lead and the BATTERY POSITIVE (+) lead to the same pole on the external disconnect switch.
2. Remove the JUMPER.
3. Connect the BATTERY DISCONNECT (+) lead to other pole on the external disconnect switch.
4. Connect battery NEG (-) lead to the BATTERY GND (-) lug.
Wiring Diagram
(Below image may vary, depending on model)
MAIN BREAKER
(NOT SUPPLIED)
AC IN NEUTRAL
(WHITE)
CONVERTER
NEUTRAL
(WHITE)
AC IN HOT 1
(BLACK)
AC IN
GROUND
(GREEN)
AC IN HOT 2
(RED)
CONVERTER
HOT (BLACK)
CONVERTER
GROUND
(GREEN)
Consult a licensed electrician or RV technician for installation assistance
CHASSIS GROUND
(OPTIONAL)
MAIN BREAKER
HOLD DOWN
BLOWN FUSE LED
INDICATOR
(OPTIONAL)
BATTERY
GND/WHT (-)
BATTERY
POS/BLK (+)
BATTERY
DISCONNECT
POS (+)
JUMPER
BATTERY POS (+)
INDICATOR LIGHT
WIZARD MANUAL BUTTON
CONVERTER POS. (+)
CONVERTER NEG. (-)
GENERAL OPERATION
The INTELI-POWER series converter will supply "clean"
power from input voltages that range from 105 - 130VAC.
The INTELI-POWER series of converters are primarily
designed for use with a battery, however, the output of the
INTELI-POWER converters are a regulated, filtered DC
voltage that can power sensitive electronics without the need
for a battery or other filtering.
At normal input voltages (105 – 130VAC) the full load rated
capacity is available. At input voltages less than 105 VAC the
converter may not supply full rated output capacity.
PD4500LI - The full rated load is available for load, battery
charging or both. When functioning as a regulated battery
charger the converter has a nominal voltage output of 14.6
VDC. The system is designed to sense voltage on the battery
and will taper the charging current as the battery becomes
charged.
CAUTION
The 4500LI series converter/chargers are designed
to recharge lithium iron phosphate (LiFePO4)
batteries only.
DO NOT USE TO RECHARGE LEAD/ACID
BATTERIES!
See website for detailed explanation of Charge Wizard
REVERSE BATTERY PROTECTION CIRCUIT
If a battery is accidentally hooked up backwards, the converter will be protected. Easily accessible ATC type fuses will blow when a
battery is connected in reverse. Correct battery wiring and replace fuses with same type and rating. Appropriate fuse size is indicated
on the circuit board.
Amp/Model #offuses Fusesize(A)
60325
75425
90425
NOTE: Disconnect all power to the converter prior to checking or changing fuses!
The DC Section:
The DC panel features up to 18 fused positions rated for up to 30 amps, depending on model, for accessories including ten low-to-full
current rated branches. These can be used for lower current devices such as smoke and CO detectors. Each branch has an optional
LED to indicate a blown branch fuse.
PD4500
charging or both. When functioning as a regulated battery
charger the converter has a nominal voltage output of 13.6
VDC. The system is designed to sense voltage on the battery
and automatically selects one of three operating modes
(normal, boost and storage) to provide the correct charge level
to the batteries.
BOOST MODE: If the converter senses that the battery
voltage has dropped below a preset level the output voltage is
increased to approximately 14.4 VDC to rapidly recharge the
battery.
NORMAL MODE: Output voltage set at approximately 13.6
VDC.
STORAGE MODE: When there has been no significant
battery usage for 30 hours the output voltage is reduced to
13.2 VDC for minimal water usage. When in storage mode,
the output voltage will periodically increase to 14.4 VDC to
help prevent sulfation of the battery plates.
- The full rated load is available for load, battery
CAUTION
IT IS IMPORTANT THAT THE FLUID LEVELS OF
ANY CONNECTED BATTERIES BE CHECKED
ON A REGULAR BASIS. ALL BATTERIES WILL
“GAS” AND LOSE SOME FLUID WHEN
CONTINUOUSLY CONNECTED TO ANY
CHARGING SOURCE
®
function
FOR CONTINUED PROTECTION AGAINST RISK OF
FIRE OR ELECTRICAL SHOCK, REPLACE ONLY WITH
Consult a licensed electrician or RV technician for installation assistance
CAUTION
SAME TYPE AND RATING FUSE.
Specifications
(Specifications subject to change without notice)
Model
AC Section
PD4560(LI) PD4575(LI) PD4590(LI)
240/120 VAC 50 Amps Maximum*
120 VAC 50 Amp Maximum* – 12 Branch Circuits
PROBLEM POSSIBLE CAUSES
No Output
Low Output
Intermittent or no
Output on Generator,
works on Shore Power
Battery does not charge
but circuits have power
NOTES:
DC Section
Converter
Section
Input: 105-130VAC 50/60 Hz
1000 Watts
Output: 13.6 VDC (14.6 VDC)
60 Amps
Weight: 8 lbs
12 VDC 100 Amp Max. - 18 Branch Circuits
Input: 105-130VAC 50/60 Hz
Input: 105-130VAC 50/60 Hz
1250 Watts
Output: 13.6 VDC (14.6 VDC)
Output: 13.6 VDC (14.6 VDC)
75 Amps
Weight: 8.5 lbs
1550 Watts
90 Amps
Weight: 10 lbs
* Maximum continuous loads on main or branch circuits not to exceed 80% of the circuit
breaker ratings
TROUBLESHOOTING GUIDE
ACTION
Proper AC power not connected
Reverse battery fuses blown
Short circuit
Unit has shutdown due to overheating
Unit has shutdown due to over voltage
(Converter will shut down if the input voltage exceeds 132 VAC)
Compartment gets too hot
Excessive load for converter
Input voltage not between 105-130 VAC
Bad battery cell(s) Replace battery
Unit has shutdown due to over voltage.
Some generators exhibit excessive voltage spikes
on the AC power output, this may cause the over
voltage protection to shut the unit down
Reverse battery fuses blown.
No battery connection.
See website www.progressivedyn.com for more troubleshooting information and return instructions
Connect power supply
Check AC distribution panel for proper operation
Check for reverse battery connection.
Replace fuses with same type and rating
Trace circuits for possible fault
Check air flow
Allow unit to cool
Check input voltage
Correct input voltage
Check air flow to the converter
Improve ventilation to the compartment
Reduce load requirements or install larger converter
Correct input supply voltage
Add another load to the generator, this may reduce the “spikes” to
an acceptable level
Contact generator manufacturer for possible defect in the generator
Check battery polarity. Correct if necessary. Replace fuses.
Check wiring to battery including possible inline fuse.
Consult a licensed electrician or RV technician for installation assistance
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