🛠️ Troubleshooting Guide

Product: PM535J (Jayco Intelli-RV)
Last Updated: April 2026

📘 Scope & Applicability

This article applies to the PM535J Intelli-RV Power Management System.

Use this guide for the following issues:

• ⚡ Not charging (AC / Solar / Vehicle)
• 🔌 No 12V output
• ☀️ Solar not working
• 🚗 DC-DC charging not working
• 🔴 Red fault LED active
• 📊 Incorrect battery SOC

📌 Important:
Always complete troubleshooting before replacing any components.

🔽 Flow 1 – Unit Not Charging (AC / Solar / Vehicle)

🔹 Step 1 – Confirm Power Source

• ⚡ AC plugged in and ON
• ☀️ Solar in sunlight
• 🚗 Vehicle engine running

➡️ Not active → restore
➡️ Active → proceed

🔹 Step 2 – Check LEDs

• ⚡ Mains LED = ON
• ☀️ Solar LED = ON / Flashing
• 🚗 AUX LED = ON

➡️ Abnormal → check wiring, polarity, connections

🔹 Step 3 – Battery Switch

• Ensure switch is ON
• Check remote switch (if installed)

🔹 Step 4 – Battery Voltage

• 🔋 Lead Acid < 10.5V → no charge
• 🔋 Lithium < 11.2V → no charge

➡️ Recharge externally

🔽 Flow 2 – No 12V Output / Appliances Not Working

🔹 Step 1 – LOAD Setting

• Ensure LOAD = ON on display

🔹 Step 2 – LVD Check

• 🔴 1 flash = low voltage
• Measure battery

➡️ Recharge battery

🔹 Step 3 – Output Class

• Class A / C → disconnect on LVD
• Class D → remains active

🔹 Step 4 – DC Fuses

• Inspect fuses
• Replace only after root cause identified

🔽 Flow 3 – Solar Not Charging

🔹 Step 1 – Solar LED

• OFF → no input
• Flashing → abnormal

🔹 Step 2 – Open Circuit Voltage

• Must be < 42V DC

➡️ Above → reconfigure panels

🔹 Step 3 – Polarity & Wiring

• Check polarity
• Inspect cables & connectors

🔹 Step 4 – Battery Full?

• Fully charged battery = no solar charge

✔️ Normal behaviour

🔽 Flow 4 – Vehicle (DC-DC) Charging

🔹 Step 1 – AUX LED

• OFF → no input
• Flashing → fault

🔹 Step 2 – Vehicle Voltage

• Without D+ → >13.8V
• With D+ → ≥12.2V

🔹 Step 3 – D+ Wiring

• Ignition source OR
• Trailer plug Pin 12

🔹 Step 4 – Wiring Check

• Correct cable size
• Secure grounding

🔽 Flow 5 – Red Fault LED

🔹 Fault Code Table

🔹 Step 2 – Power Cycle

1. Disconnect AC
2. Disconnect battery
3. Wait 2 minutes
4. Reconnect battery
5. Reconnect AC

➡️ If issue remains → escalate

🔽 Flow 6 – Incorrect SOC Reading

🔹 Step 1 – Load Wiring

• All loads must go via PM535J
• Direct battery wiring = inaccurate SOC

🔹 Step 2 – Calibration Charge

• Fully charge via AC
• Reach FLOAT stage

🔹 Step 3 – High Current Loads

• Inverters / aircon present?

➡️ Install PMShunt

🌬️ Installation & Ventilation

• Minimum 50mm clearance
• Do NOT install in sealed enclosure
• Vent size: 144mm x 54mm

📌 Key Insight:
Poor ventilation = most common fault cause

🔧 Maintenance

• 🔋 Charge every 2 weeks (usage)
• 🔋 Charge every 3 months (storage)
• 🔋 Full charge after battery replacement

🚨 Escalation Criteria

Escalate if:

• Fault persists after reset
• No charging from any source
• Fault code 9 repeats
• Physical damage or burnt smell

Call Projecta Helpline on 1800 422 422 OR

Click here to Submit a Support Request