BCA LEISURE PDU MK II

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Summary

Product Description and Installation

Product Description

Details the 230Vac and 12Vdc power distribution capabilities of the PDU.

PDU Dimensions

Provides the physical dimensions of the PDU unit required for installation.

PDU Installation Procedures

Mounting and Fixing

Instructions on how to fix the PDU to vertical or horizontal surfaces using fixing lugs.

Connector Access

Guidance on ensuring PDU connectors are accessible only with tools or secure enclosures.

Power Connection and Maintenance

Mains Supply Connection

Details on connecting the PDU to the mains supply via connector or hard wiring.

Storage Guidelines

Recommendations for storing the PDU unit in a suitable dry environment.

Servicing Checks

Annual checks for RCD, MCB connections, earth terminals, fixings, and 12V fuses.

PCB Variants and Pin Information

PCB-268-MD (Caravan)

Pin assignments and functions for the caravan-specific PCB version.

PCB-269-MD (Motorhome)

Pin assignments and functions for the motorhome-specific PCB version.

LIN50 PDU-MK2 Board (V2.3)

Diagram and pin/circuit information for the LIN50 PDU-MK2 board.

The document describes the PDU MK II, a Power Distribution Unit manufactured by BCA Leisure Ltd. This device is designed for use in caravans and motorhomes to manage both 230Vac and 12Vdc power distribution.

Function Description:

The PDU MK II serves as a central hub for power distribution within a habitation area. It handles two main power types:

230Vac Distribution: The unit distributes 230Vac power to various appliances and sockets throughout the caravan or motorhome. This distribution is managed through suitable protection devices, ensuring safety and proper operation of connected high-voltage equipment. The specific circuits for 230Vac distribution are designed according to customer specifications, indicating a degree of customization in its application.
12Vdc Distribution: For lower voltage needs, the PDU distributes 12Vdc power throughout the habitation area. This is achieved via a system of relays and fused circuits. The use of relays allows for controlled switching of 12V circuits, while fused circuits provide essential overcurrent protection for the various low-voltage loads.

Important Technical Specifications:

Dimensions: The PDU MK II has specific physical dimensions:
- Width: 330mm
- Height: 275mm
- Depth: 180mm These dimensions are crucial for installation planning and ensuring adequate space within the vehicle.
Power Ratings (Examples from PCB-268-MD and PCB-269-MD): The internal PCBs (PCB-268-MD for caravans and PCB-269-MD for motorhomes) detail various fused circuits with specific current ratings:
- 230V Circuits (implied by context, though specific 230V fuses are not explicitly listed in the PCB tables, the general function implies their presence): While the PCB tables primarily detail 12V circuits, the overall function of the PDU includes 230Vac distribution, which would necessitate appropriate protection devices (e.g., RCDs, MCBs mentioned in maintenance).
- 12V Circuits (examples from PCB tables):
  - Leisure Battery Positive Feed: F3 (20Amp)
  - Master Switch Controlled Circuits: F10 (10Amp), F2 (10Amp), F8 (10Amp), F11 (10Amp), F9 (10Amp), F1 (10Amp), F14 (10Amp), F12 (10Amp)
  - Permanent Feeds: F13 (5Amp), F15 (5Amp), F14 (5Amp)
  - Fridge Feed Out: F4 (20Amp), F5 (15Amp), F10 (20Amp)
  - Lights Out (Master switched controlled and lights relay controlled): F7 (15Amp), F6 (15Amp)
  - Ignition Feed: F1 (20Amp)
  - Low Current Signals: F17 (0.1Amp), F16 (0.1Amp), F19 (2.5Amp)
  - Solar Panel Circuit (PCB-269-MD): F3 (15A)
PCB Versions:
- PCB-268-MD: Designed specifically for caravans.
- PCB-269-MD: Designed specifically for motorhomes. These two versions indicate tailored functionalities or circuit layouts to suit the specific requirements of each vehicle type.

Usage Features:

Fixing: The PDU can be fixed to either a vertical or horizontal surface. It utilizes fixing lugs (four points, A or B) for secure mounting. All four fixing points MUST be used to prevent damage from vibration, highlighting the importance of robust installation in a mobile environment.
Connector Access: Access to the connectors at the rear of the PDU (specifically point A on Fig 3 for mains supply) is restricted. It should only be accessible by using a tool, either due to its location or by being enclosed within a securely fastened enclosure behind the PDU. This design choice emphasizes safety, preventing unauthorized or accidental access to live connections.
Mains Supply Connection: The connection to the mains supply can be made via a supplied connector (Fig 3 point A) within a suitable enclosure, accessible with a tool. Alternatively, hard wiring to the supply inlet is also possible. A critical safety instruction is to ensure the mains supply is switched off before connecting the PDU. All electrical work MUST be carried out by a competent person.
Dual Stage Power Supply Support: For systems using a dual-stage power supply, the charging side must be connected to CHG 1, and the power supply output to CHG 2. If a single-stage power supply is used, the two tabs (CHG 1 and CHG 2) must be linked. This feature provides flexibility for different charging system configurations.
Non-Replaceable Fuses: Some fuses (marked with '!') are non-replaceable. To reset these, power must be disconnected if a fault has been cleared. This indicates a specific type of resettable fuse or circuit breaker that requires a power cycle for reset, rather than physical replacement.

Maintenance Features:

Annual Service Checks: Regular annual servicing is recommended to ensure the continued safe and efficient operation of the PDU. Key checks include:
- RCD and MCB Connections: Inspect for loose connections on conductors and busbars. Loose connections can lead to overheating and potential fire hazards.
- Earth Terminal: Check for loose connections on the earth terminal, which is vital for electrical safety and fault protection.
- Fixing Lugs: Inspect the casing's fixing lugs for any loose fixings or signs of damage. This ensures the unit remains securely mounted and protected from vibration-induced stress.
- 12V Fuses: Verify the correct installation of all 12V fuses. Incorrectly installed fuses may not provide adequate protection or could lead to circuit malfunctions.
Storage: The PDU MUST be stored in a dry area suitable for electrical and electronic equipment. This prevents moisture damage and corrosion, which can compromise the unit's functionality and safety.
Ventilation: The PDU requires a minimum surrounding clearance of 75mm around its ventilation slots. Proper ventilation is crucial to prevent overheating, which can lead to reduced performance, component damage, or even fire. The unit MUST be installed in a way that external heat sources do not detrimentally affect its normal operation, reinforcing the importance of thermal management.