PT-32-25W Manual

PT-32-25W Manual
Phase Three
Three Stage Smart Charger
Installation/Operation Manual
Models: PT-24-45W
PT-32-25W
TABLE OF CONTENTS
1
Section Topic
QUICK REFERENCE DRAWING
I) GENERAL INFORMATION
II) IMPORTANT SAFETY INFORMATION
III) INSTALLATION
A) Materials Provided
B) Location
C) Mounting
D) D.C. Output Wiring
E) A.C. Input Wiring
F) Multiple Unit Parallel Wiring
G) Gel-Cell/Lead-Acid Selector Switch
H) Temperature Compensation Option
I) Alarm Contacts
IV) OPERATION
A) Three Stage Charge Regimen
B) Time-Out Circuit
C) Status Indicators
V) APPLICATION NOTES
A) Constant Versus Occasional Use
Page
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3
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4
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5
6
8
9
10
11
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11
11
11
12
12
B) Proper Load Sizing
C) Operation with Engine
D) Cooling Fans
E) Current Limit Circuit
VI) TROUBLESHOOTING
VII) SPECIFICATIONS
VIII) BATTERY CARE TIPS
IX) REFERENCE APPENDIX
X) UNIT DIMENSION DRAWING
12
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QuickReference
ReferenceDrawing
Drawing
Quick
Charger Status LED
Pg. 11
Optional Dripshield
Pg. 4
Charger Front Cover
Permanent
Mounting Holes X4
Pg. 5
Ammeter
Pg. 11
Temporary Keyhole
Mounting Holes X2
Pg. 5
Charger Front Cover
Output Terminal Cover
Pg. 6
AC Input Lable
Entry/Strain Relief
Pg. 7
1/4 - 20 Chassis
Grounding Stud
Pg. 6
2
Output Terminals
Pg. 6
AC Fail & DC Fail
Alarm Contacts
Pg. 11
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I) GENERAL INFORMATION
Your Phase Three Series Battery Charger uses the latest
microprocessor controlled three stage charging technology to
optimize the life and enhance the performance of marine, mobile
and fixed site battery systems and is housed in a rugged powder
coated stainless steel and aluminum case designed to withstand
harsh environmental conditions.
This charger line has been developed in response to demand for
increasingly sophisticated charger performance, as the technology
of new battery types and applications advances. The Phase Three
combines high power performance with adaptability to varied
charging requirements and environmental conditions. Batteries are
quickly and properly charged and maintained, assuring their long
life and optimum performance.
II) IMPORTANT SAFETY
INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS — This manual contains important
safety and operating instructions for the Phase Three Battery
Charger.
2. Before using this battery charger, read all instructions and
cautionary markings on (1) the battery charger (2) the battery, and
(3) any product powered by the battery.
3. CAUTION — To reduce the risk of injury, charge only 12 cell (24
volt models) gel-cell or lead-acid rechargeable batteries. Other
types of batteries may burst, causing personal injury and damage.
4. Do not expose charger to rain or spray.
Following is brief listing of some of the more important features/
options of your Phase Three Charger. Each is fully detailed later in
this manual:
5. Use of an attachment not recommended or sold by NEWMAR
may result in a risk of fire, electric shock or injury to persons.
• Micro-processor controlled three stage “smart” charging—bulk,
absorption, float—for optimum performance and long life of large
battery systems.
6. To reduce the risk of damage to the electric plug and cord (if
plugged into an A.C. outlet), pull by plug rather than cord when
disconnecting the charger.
• Precision regulated, high power output for rapid rejuvenation of
medium-to-large 24 and 32 volt battery systems; maintain batteries
at peak voltage, even with high D.C. system loads present.
7. Make sure the cord is located so that it will not be stepped on,
tripped over, or otherwise subjected to damage or stress.
• Gel-Cell/Flooded lead-acid switch selects optimum charge/float
voltages based on battery type.
• Three diode isolated output banks; (ammeter indicates total
output current.)
• Optional sensor adjusts output voltage for optimum voltage
based on battery temperature.
• Current limiting—prevents damage from overloading.
• L.E.D. and audible indicators show charger status and diagnose
shut-down conditions such as Battery Too Hot, Charger Too Hot,
Over-Voltage Protection Activated
• High charge time-out circuit prevents overcharge during
continuous high amperage demand.
• May be wired in parallel to create higher power systems.
• AC & DC present alarm contacts (Form C) provided
• Built to last—rugged stainless steel and aluminum powder coated
case with marinized internal circuitry; drip shield provided.
• Numerous Safety and EMC Compliances; all models carry the CE
mark.
In addition, your Phase Three Charger carries a full two year
warranty against defects in materials or workmanship from the
date of purchase. Careful attention to these instructions should help
you to enjoy years of trouble-free service.
3
8. An extension cord should not be used. Use of an improper cord
could result in a risk of fire and electric shock.
9. Do not operate the charger with a damaged cord or plug;
replace them immediately.
10. Do not operate the charger if it has received a sharp blow,
been dropped, or otherwise damaged; take it to a qualified
serviceman.
11. Do not disassemble the charger; take it to a qualified
serviceman when service or repair is necessary. Incorrect
reassembly may result in a risk of electric shock and fire.
12. To reduce the risk of electric shock, disconnect the charger from
A.C. source before attempting any maintenance or cleaning.
WARNING—RISK OF EXPLOSIVE GASES
1. WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS
DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING
NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF
UTMOST IMPORTANCE THAT BEFORE INSTALLING AND USING
YOUR CHARGER, YOU READ THIS MANUAL AND FOLLOW THE
INSTRUCTIONS EXACTLY.
2. To reduce the risk of battery explosion, follow these instructions
and those published by the battery manufacturer and by the
manufacturer of any equipment you intend to use in the vicinity of
the battery. Review cautionary markings on these products and on
the engine.
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PERSONAL PRECAUTIONS
III) INSTALLATION
1. Someone should be within range of your voice or close enough
to come to your aid when you work near a lead-acid battery.
A) Materials Provided
2. Have plenty of fresh water and soap nearby in case battery
acid contacts skin, clothing or eyes.
3. Wear complete eye protection and clothing protection. Avoid
touching your eyes while working near a battery.
4. If battery acid contacts skin or clothing, wash immediately with
soap and water. If battery acid enters the eye, immediately flood
the eye with running cold water for at least 10 minutes and get
medical attention immediately.
5. NEVER smoke or allow a spark or flame in the vicinity of the
battery or engine.
6. Be extra cautious to reduce the risk of dropping a metal tool
onto the battery. It might spark or short-circuit the battery or other
electrical part and cause an explosion.
7. Remove personal metal items such as rings, bracelets, necklaces
and watches when working with a lead-acid battery. A lead-acid
battery can produce a short-circuit current high enough to weld a
ring or the like to metal, causing a severe burn.
8. Use the battery charger for charging gel-cell or flooded lead-acid
batteries only. It is not intended to supply power to a low voltage
electrical system other than in a starter-motor application. Do not
use the charger for charging dry-cell batteries that are commonly
used with home appliances. These batteries may burst and cause
injury to persons and damage to property.
9. NEVER charge a frozen battery.
PREPARING TO CHARGE
1. Be sure the area around the battery is well ventilated.
2. Clean battery terminals. Be careful to keep corrosion from
coming in contact with eyes.
3. Add distilled water in each cell until battery acid reaches level
specified by battery manufacturer. This helps purge excessive gas
from cells. Do not overfill. For a battery without cell caps, carefully
follow manufacturer’s recharging instructions.
4. Study all battery manufacturer’s specific precautions such
as removing or not removing cell caps while charging and
recommended rates of charge.
The Phase Three charger is provided completely assembled and
ready for installation. Because of numerous installation variables,
the installer will need to provide four suitable 1/4” mounting
screws/washers, as well as D.C. output wiring and connectors.
Proper sizes and gauges for the wire and connectors are noted in
section D following. A warranty registration/customer satisfaction
card has been included in the packaging. Upon completion of
the installation, please fill out this card and return it to the factory.
You will be contacted promptly if you have any problems with or
questions about your Phase Three charger.
Note: AC & DC Present Alarm Contacts mating connector wire
assembly. Contact Newmar and request P/N 773-1210-0. See
section III-I for more information.
B) Location
The charger should be mounted on a wall, bulkhead or other
suitable mounting surface as close to the batteries to be charged
as possible. Do not mount the charger directly over the batteries
as battery fumes may cause excessive corrosion. WARNING:
The charger is not ignition protected so it must not be located
in an area where ignition protected equipment is required. The
area should be well ventilated and free from excessive moisture,
exhaust manifolds and battery fumes.
Vertical mounting is preferred. However, horizontal mounting is
acceptable where absolutely necessary. Do not mount the charger
where water, spray or condensation can occur, as this will shorten
charger life. It should not be located where there is a possibility
of dust or debris being drawn into the unit through the fan. A
minimum of 2” clearance around the charger is recommended for
proper cooling.
Installation of the drip shield is recommended for areas where
moisture or liquids could drip from overhead. The drip shield is
mounted using the upper two mounting screws.
If the charger is located in an extreme heat area, such as an
unventilated engine room, and maximum operating temperature
is exceeded, an automatic thermal shutdown circuit will turn the
charger off. Thermal cycling will shorten the life of the charger,
so if this condition occurs repeatedly, the charger should be
relocated. For optimum performance and longer life the charger
should not be located in an area of extreme high temperature.
GROUNDING AND A.C. POWER CORD CONNECTION
C) Mounting
1. The charger should be grounded to reduce the risk of electric
shock.
Important Pre-Installation Notes: The wiring access port for A.C.
input is located on the bottom of the charger. If the factory-installed
A.C. cord must be changed for any reason, this should be done
before mounting, as access will be difficult afterwards. Also, the
drip shield will need to be removed prior to setting the gel/lead
acid selector or installing the optional temperature compensation
probe. The drip shield is removable with the charger mounted,
but if there is limited overhead clearance the installer may wish
to accomplish these tasks also, prior to mounting the charger. For
information on these installation procedures refer to sections III-E, G
and H.
(For marine applications only) EXTERNAL CONNECTIONS TO THE
CHARGER SHALL COMPLY WITH UL RECOMMENDATIONS AND/
OR UNITED STATES COAST GUARD ELECTRICAL REGULATIONS
(33CFR183, SUB-PART I)
(For marine applications only) THE INSTALLATION AND
PROTECTION OF VESSEL WIRING ASSOCIATED WITH BATTERY
CHARGERS SHALL COMPLY WITH ABYC STANDARDS; E-11) AC
& dc ELECTRICAL SYSTEMS ON BOATS, AND A-20) BATTERY
CHARGING DEVICES.
4
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The charger may be mounted on either a metal or non-metal
surface*. You will require four screws (wood or machine screws,
depending on mounting surface) with washers, sized for 1/4”
holes, to mount the charger, plus two temporary holding screws.
Note that, in addition to the four permanent mounting holes in the
flanges, there is a hole in each mounting flange which is “keyhole”
shaped. This is provided to ease vertical installation.
*To comply with ABYC D.C. chassis grounding conductor (ABYC
A-20), connect a suitable sized wire to the ¼”-20 chassis grounding
stud near AC cable feed through.
Make a mark on the wall or bulkhead where each of the
keyhole slots will be located. Then drive a screw about halfway
in at each of these marks. Hang the charger onto the bulkhead
using the keyhole slots. Doing this will save you from having to
support the charger’s weight while you are driving in the four
permanent mounting screws. Note: The keyhole slots may be
used for additional support screws but they are not to be used as
permanent mounting points, by themselves.
IMPORTANT: Although the charger is constructed of materials
and in a manner which makes it highly resistive to the corrosive
effects of moisture in the environment, the charger is not waterresistant. Do not mount the charger where there is a possibility of
water entering the unit. Evidence of water entry into the charger
will void the warranty.
D) D.C. Output Wiring
Note: Only qualified service personnel should access the output
terminals of the charger.
Whether working with existing battery charger output wires or
installing new ones, make sure the battery(s) is disconnected
from these wires before connecting them to the charger’s output
terminals.
For a secure installation D.C. output wires must be attached with
1/4” crimp ring lug terminals sized appropriately to fit wire gauges
as listed below.
The D.C. wire size table below may be used to determine the
correct gauge wire, based on the model you have and the length
of the wire run from the charger to the batteries. Once the output
wiring has been attached to the chargers output posts, install the
clear plastic terminal cover provided with the charger.
D.C. Wire Size Table*:
Model
Distance from Batteries (in feet)
10’
15’
20’
Wire Gauge AWG (mm)
PT-24-45W
#6 (16mm) #6 (16mm) #4 (25mm)
PT-32-25W
#10 (6mm) #8 (10mm) #8 (20mm)
*Based on N.E.C. Minimum Wire Size Chart and ABYC 3% Voltage
Drop Chart
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Typical D.C. wiring configurations are illustrated in FIGURES 1 and
FIGURE 1: Simple D.C. Wiring (Preferred Method)
2 below.
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FIGURE 2: Wiring With Battery Switch
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When one or more of the available charger banks is not needed—
if, for instance, you have only two battery banks—it is not
necessary to jumper the output of that bank onto one of the others.
Nor will you get additional charging by running a second wire
from the extra bank to your load. The charger is able to deliver its
full rated output through a single bank, if necessary.
It is recommended that D.C. wiring from the charger to the
batteries be as direct as possible. Line voltage loss and electronic
noise interference of sensitive electronics are possible if the
charging leads are routed through a central electrical distribution
panel. Any elaborate wiring configurations are best left to a
qualified electrician.
CAUTION: ENSURE THAT LEADS ARE PROPERLY FUSED AT THE
BATTERY. (REFER TO ABYC RECOMMENDATIONS. SEE REFERENCE
APPENDIX AT THE END OF THIS MANUAL FOR ABYC CONTACT
INFORMATION.)
Ensure that your connections are tight and that correct polarity is
carefully observed at all times. The battery posts should be free of
any rust or corrosion.
CAUTION: SHORTING THE (+) AND (-) OUTPUTS (WHEN THE
CHARGER IS ON) OR REVERSE POLARITY BATTERY CONNECTION
(WHETHER OR NOT THE CHARGER IS ON) WILL CAUSE CHARGER
FAILURE. THE POSITIVE (+) TERMINAL MUST BE WIRED TO
6
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THE POSITIVE POST OF THE BATTERY AND THE NEGATIVE
OR COMMON (-) TERMINAL TO THE NEGATIVE POST OF THE
BATTERY OR COMMON BUS. DOUBLE-CHECK D.C. WIRING BEFORE
ATTACHING TO CHARGER OUTPUT TERMINALS.
CAUTION: Do not attempt to increase battery bank capacity by
splitting the output of one of the banks with a diode-type battery
isolator. Undercharging may occur on that output bank, as a
result.
A note about the D.C. fuse: The internal wiring of the Phase Three
charger is protected against dangerous overheating in the event
of an internal short, or reverse polarity hook-up, by an internal
D.C. fuse. The fuse is not user replaceable. If this fuse blows the unit
must be returned to NEWMAR or a qualified electronic technician
for repair. (See the TROUBLESHOOTING section of this manual.)
E) A.C. Input Wiring
The PT-24-45W is designed to operate on 230V A.C., 50-60 Hz
input only. The PT-32-25W is designed to operate on 115 VAC, 5060 Hz input only. Ensure that the charger is compatible with the
available A.C. power.
This model is designed to be hard wired in to the ship’s ac system.
16 AWG (1.5mm2) wire size is recommended. For A.C. wire runs
greater than 20 ft., use 14 AWG (2.5mm2) wire size.
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A.C. input must be routed through a separate dedicated fuse or
circuit breaker on an A.C. distribution panel with proper safety/
earth chassis ground in accordance with all applicable local codes
and ordinances. Use the table below to determine the proper fuse
or circuit breaker value:
A.C. Fuse/Circuit Breaker Table
Model
PT-24-45W
PT-32-25W
protect the unfused (formerly NEUTRAL, now HOT) lead.
AC Input hard-wiring procedure (refer to Figure 3):
1) Loosen (do not remove) the two screws on the bottom front of the
charger which holds the A.C. input wiring access plate in place.
Remove the cover plate to expose the A.C. input terminals as
shown in figure 3.
2) With a narrow blade (1/8”) flat tip screwdriver, loosen the
compression screw terminals on the right side of the A.C. input
terminal block. Do not loosen the factory-wired terminals.
Breaker or Fuse Value
10 amp
20 amp
CAUTION PT-24-45W: If A.C. input is derived from a source
consisting of two HOT leads (phase-to-phase or L1 & L2 230V A.C.
input voltage), an external fuse or circuit breaker must be used to
3) Loosen the compression nut on the A.C. input cable strain relief
and slip the nut over the A.C. input cable.
FIGURE 3: TP Probe/AC Input Wiring
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4) Cut away the outer jacket of the new three-wire A.C. input cable
so that individual wire leads are about 2” long. Strip about ¼” of
insulation off the ends of each wire and feed the cord through the
input cable strain relief.
5) Insert each A.C. input wire into the appropriate L1, L2/N or
EARTH GROUND terminal and tighten securely.
F) Multiple Unit Parallel Wiring
Multiple Phase Three chargers may be wired in parallel, if
necessary. They are diode protected against feedback from other
units and current limiting will prevent overloading, see figure 4.
Two reasons for paralleling chargers are:
1) To increase charging current of an existing system
2) Redundancy (in the event one charger fails, system can be
powered by redundant charger)
6) Tighten the compression nut on the input cable strain relief.
Replace the A.C. input wiring access plate and tighten the two
screws.
(In marine applications) All charger wiring should be installed in
accordance with UL, U.S. Coast Guard and/or A.B.Y.C. regulations
and recommendations, as well as all relevant local codes. See
section VIII) REFERENCE APPENDIX for sources.
A note about the A.C. input fuse: The A.C. input of your charger
is protected by an input fuse which is located inside the unit.
Due to the current limiting characteristic of the charger, it is
highly unlikely that this fuse will blow unless there is some other
malfunction within the charger. This fuse is not user-replaceable.
Replacement of the input fuse must be performed by a qualified
service person. (See TROUBLESHOOTING section for further
information.)
Parallel wiring recommendations:
1) Use the same wire size on both chargers and wire both chargers
directly to the battery posts. If practical, use the same wire length
on output of each charger. This will help the chargers to share
current when they are both in the same charging stage.
2) If temperature compensation option is used, a separate sensor
must be provided for each charger (see section III-H Temperature
Compensation Option) and the sensor ends connected to the same
batteries.
3) Make sure both chargers are set for the same battery type (see
section III-G, Gel-Cell/Lead Acid Selector.
Note: Under certain line and load conditions, it is normal for
paralleled chargers to output different amounts of current. It is
also normal when ac power is connected or interrupted to see the
chargers in different charge modes (Float, Absorption or Bulk.)
FIGURE 4: Parallel Wiring for Increased Charging Current
Parallel Wiring For Large Capacity Battery Systems
PT-24-45W
PT-24-45W
+ ++ -
+
Bank 1
Note: This
diagram does
not illustrate
a complete
system. Refer
to ABYC
standards E-11
AC & DC
electrical
systems on
boats.
+ ++ -
+
Bank 2
+
-
Bank 3
To Loads
8
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plastic cover over this switch, remove cover.) This switch has 16
selector positions: 0,1,2,3,4,5,6,7,8,A,B,C,D,E,F. Positions 0 thru 7
correspond to Flooded/Lead Acid, positions 8 thru F correspond to
Gell-Cell/VRLA
G) Gel-Cell/Lead Acid Selector
Checking or Setting the Selector
The ideal charge/float regimen has been programmed into the
Phase Three Charger for either sealed gel-cell or flooded lead-acid
batteries depending on the selector position. The selector has been
factory set in the lead-acid position. In order to check or change
the gel/lead-acid selector setting, proceed as follows (see Figures
5 & 6):
4) Use a flat blade screwdriver to rotate the switch into the correct
position, with either “F” or “7” showing as illustrated below:
5) If installing the optional Temperature Compensation Sensor,
proceed with that installation (described in section H following).
6) Reinstall the access plate and tighten the two Phillips head
screws.
1) Ensure A.C. power to the charger is shut off.
2) Locate the access plate on top of the charger and loosen the two
Phillips head screws (DO NOT REMOVE SCREWS.) Remove access
plate.
3) Locate the gray circular switch which is recessed into the
internal black module. (Note: There may be a self-adhesive black
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FIGURE
5: Gell-Cell/Lead Acid Selector
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FIGURE 6: Gel-Cell/Lead-Acid Selector Positions
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9
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Gel/Lead-Acid Selector Function
According to battery manufacturers, the ideal charge regimen for
gel-cell and wet or flooded lead acid batteries differs somewhat.
5) Route the temp. sensor end of the TP through the black bushing
on the access plate. Insert the 5 pin connector end of the TP firmly
into the receptacle. Replace the access plate and tighten the two
Phillips head screws.
The gelled electrolyte in a sealed battery may be lost or damaged
by high voltage and, once lost, cannot be replaced as it can
with a wet lead acid battery. Manufacturers of gel-cells usually
recommend an ideal charge voltage which is slightly lower for a
gel-cell than a lead acid battery.
6) It is recommended that the cable running to the battery be
secured with the provided cable clamps to prevent the plug from
accidentally being dislodged. One cable clamp tie point (10-32
Phillips head screw with washers) has been provided to secure the
cable as it exits the top of the charger.
However, when the charger is in the float voltage mode over
lengthier periods of time, gelled electrolyte in a sealed battery
is not susceptible to evaporation, as is the non-immobilized
electrolyte of a wet lead acid battery. This evaporation can be
accelerated by the applied voltage. Consequently, the ideal float
voltage is slightly higher for a gel-cell than a lead acid battery.
7) The probe itself should be mounted on the inside of the battery
box, or more ideally, mounted directly onto one of the batteries
using a clamp or a small amount of silicon-type adhesive.
Some batteries are available which do not conform to
conventional descriptions as “gel-cell” or “lead-acid”. If you are
unsure about your battery type, consult the manufacturer and use
the battery type selector setting which most closely conforms to the
recommended voltages. See the SPECIFICATIONS section for the
actual preset charge and float voltages for each battery type and
charger model.
H) Temperature Compensation Option
Installing the Probe
The optional Temperature Compensation Probe (available from
NEWMAR, model TP is provided with 25’ of cable, with the probe
at one end and a keyed five-pin plug at the other. Installation of
the probe proceeds as follows:
1) Ensure A.C. power to the charger is shut off. The charger will go
into a shutdown mode if the temperature sensor is installed when
power is on.
2) If the drip shield is installed, remove it.
3) Refer to Figure 5. Locate the access plate on top of the PT-2445W and loosen the two Phillips head screws (DO NOT REMOVE
SCREWS.) Remove the access plate.
4) Locate the five-pin keyed receptacle which is recessed in the
black internal module. (Note: There may be a self-adhesive black
plastic cover approx. 1 1/2” x 1 1/2” square, over this receptacle,
remove cover.)
Battery
Temp° C
Important note: When wiring multiple units in parallel and using
the temperature compensation option, you must use a separate
probe for each charger, and the probes must be mounted close
together in the same battery box or on the same battery for proper
operation.
Temperature Compensation Probe Function
Because low battery temperature increases resistance to charging
and high battery temperature reduces impedance, requiring
a lower charge voltage, the ideal charging voltage will vary
depending on the temperature of the battery’s environment when
it is being charged.
If a charger has a fixed output voltage which is ideal at, say 77° F,
that same output may cause a battery charged in a consistently
high temperature environment to be overcharged, resulting in
excessive loss of electrolyte. Conversely, if the batteries are located
in a consistently cool environment, they may be chronically
undercharged, resulting in sulfation of the battery plates. Either of
these two conditions will shorten battery life.
Therefore, the Phase Three charger is designed to utilize
an optional probe which provides automatic temperature
compensation. The function of the probe is to signal the charger to
fine tune its output voltage so that it is properly optimized for the
temperature of the battery or battery environment. The adjustment
rate is approximately -5 mV per cell per °C.
To give some idea of the effect of the temperature compensation
probe, the chart below lists the charge/float output voltages of the
charger when no sensor is installed (or when batteries are at 25°
C) and some sample charger output voltages at colder or hotter
battery temperatures with the probe installed:
24 Volt
Lead Acid/AGM
32 Volt
GEL
Lead Acid/AGM
GEL
Float
Absorption
Float
Absorption
Float
Absorption
Float
Absorption
10
28.0
29.6
28.4
29.2
37.3
39.5
37.9
38.9
20
27.4
29.0
27.8
28.6
36.5
38.7
37.1
38.1
25
27.1
28.7
27.5
28.3
36.1
38.3
36.7
37.7
30*
26.8
28.4
27.2
28.0
35.7
37.9
36.3
37.3
40
26.2
27.8
26.6
27.4
34.9
37.1
35.5
36.5
50
25.6
27.2
26.0
26.8
34.1
36.3
34.7
35.7
* Output voltages with no Temperature Probe installed
10
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I) Alarm Contacts
The charger provides one set each of dry alarm contacts: A.C.
Fail and D.C. Fail. These can be used to activate a light or buzzer
if connected to a supervisory alarm system. Contacts are rated: 30
VDC @ 1 Amp, 110 VDC @ 0.3 Amps. For mating connector wire
assembly, contact Newmar and request P/N 773-1210-0.
C
C
OK
lower float voltage level. This float charge keeps batteries at peak
condition without overcharging. The charger may be left in this
stage for lengthy periods of time without attention (though periodic
checks of electrolyte level in flooded batteries is recommended). It
is not necessary or recommended to shut the charger off when this
stage is reached.
A typical three stage charging cycle is illustrated in FIGURE 7.
FIGURE 7: Typical Charger Output Graph (into battery
without load)
OK
BULK PHASE
FAIL
DC
FAIL
ABSORPTION PHASE
FLOAT PHASE
AMP
S
FAIL
AC
FAIL
VOLTS
S
VOLT
A
M
IV) OPERATION
PS
A) Three Stage Charge Regimen
The Phase Three Battery Charger features the three stage charge
regimen which is widely recommended by battery manufacturers
for allowing the fastest possible recharge time without loss of
batteries’ electrolyte (gel or liquid) which may be caused by
sustained charging at higher voltages.
TIME
* Approximately 10 hours maximum at factory setting.
This three stage regimen is initiated each time A.C. is first applied,
when drained batteries are most likely to be encountered, and
proceeds slowly or quickly through each stage depending on the
battery’s relative state of charge. The L.E.D. Status Indicator on the
front panel indicates which stage the charger is in.
Note: If a load is applied during the absorption phase, the charger
may revert to the bulk phase depending on the total current draw.
When the charger switches to the float phase, it will remain in that
phase regardless of current draw. The charger is still able to deliver
full output current when in the float phase. To re-initialize the three
stage process shut the charger off momentarily, then back on
again.
The regimen proceeds as follows:
B) Time-Out Circuit
1) Bulk Charge - Status Indicator: Glowing Yellow. When batteries
are significantly discharged the charger responds initially by
delivering a high amount of D.C. current, at or near the charger’s
maximum rated output, in order to rapidly replenish them. It is
during this stage that chargingcurrent is maintained at a high level
as battery voltage increases. Bulk charging continues until battery
voltage reaches the “charge” voltage level (where batteries are at
about 75-80% of capacity). A power limit circuit prevents charger
overload during this maximum output stage. Note: During this bulk
phase the charger is in a “constant power” mode; therefore, as
output current increases, output voltage decreases, and vice versa.
Full output voltage is achieved and maintained only when the
charger switches to the absorption stage.
Batteries have a tendency to lose their electrolyte and may be
damaged if they are maintained for long periods of time in the
elevated voltage of the absorption phase. Therefore, the Phase
Three Charger employs a special high charge rate time-out circuit.
This circuit is initialized each time A.C. is first applied to the charger
and runs for a pre-set interval of approximately 10 hours before
forcing the charger to go into the float (lower voltage) mode.
2) Absorption Charge - Status Indicator: Glowing Green.
During this second stage of the charge cycle, battery voltage is
maintained at the “charge” voltage level. Output current begins to
taper off as the battery plates become saturated. Charge voltage
is maintained until the current sensing circuit detects that output
current has tapered to about 5-15 % of charger rating*. At this
point the batteries are at about 95 % of full charge and the charger
switches to the third and final stage of the charge cycle.
If current demand continues to remain above the 5-15 percentof-capacity threshold, the charger will remain in the bulk or
absorption phase (depending on total current draw) until it is
forced into the float mode by the time-out circuit.
* Note: The absorption phase may also be ended by the time-out
circuit. See section B following for an explanation of the purpose
and functioning of the time-out circuit.
3) Float Charge - Status Indicator: Blinking Green. For extended
battery life the Phase Three then automatically switches to a
11
If the current demand of the batteries/load falls below 5-15 percent
of the charger’s output capacity prior to the circuit timing-out, the
charger will switch to the float mode and will remain in that mode
until the charger is shut off and restarted, although it will continue
to respond to any current demand within charger rating.
C) Status Indicators
The Phase Three Charger is equipped with an L.E.D. (located to the
left of the output ammeter) which signals each of the three normal
operational stages (described in detail above), and which also, in
combination with an audible tone indicator, provides warning and
diagnostics of abnormal conditions which result in charger
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shutdown (described below). Note: If the Status Indicator L.E.D.
is not lit, this probably indicates either disconnection from A.C.
power (check A.C. input) or thermal cycling (see Note in item 1,
below).
NORMAL OPERATING MODE
The three indications in the Normal Operating Mode are as
follows: Glowing Yellow, Glowing Green and Blinking Green.
These correspond respectively with the Bulk, Absorption and Float
charger stages, which are fully described in the previous section,
A) Three Stage Charge Regimen.
SHUTDOWN MODE/SELF-RESET ADVISORY MODE
There are three warning/diagnostic indications to alert the user to
a condition in which the charger is currently shut down. In each
case, a flashing red L.E.D. is accompanied by an audible “beep”.
Additionally, there are two diagnostic indications to advise that
the charger shut itself down but has since resumed operation. The
warning/diagnostic indications are as follows:
1) One Red Flash-Beep: Cause: The charger’s internal module
is too hot and the charger output has shut off. This may be due
to high ambient temperature, insufficient clearance around the
charger resulting in poor ventilation, or debris causing a blockage
of the fan intake vent at the bottom of the charger. Corrective
Action: Turn charger off at the AC source. Verify proper clearance,
remove debris and, if necessary, relocate charger to a cooler
location. Turn charger back on to resume normal operation and
L.E.D. indications. Note: Even if no corrective action is taken, when
thecharger cools sufficiently by itself then it will automatically
return to service and the L.E.D. indicator will begin to display a
series of single yellow flashes (see item 5 below). If this type of
thermal cycling is noted, and continues after all of the above
corrective actions are taken, please contact the factory.
Note: Overheating will normally result in the above indication.
However, there is a second thermal switch mounted to an internal
diode heat sink and, in certain cases of extreme overheating, this
switch may temporarily shut off A.C. input to the charger entirely.
In this case the L.E.D. will be extinguished and there will be no
audible indication, but the charger will probably be warm to the
touch.
2) Two Red Flash-Beeps: Cause: The Over Voltage Protection
(OVP) circuit has been activated and charger output has shut
down. The purpose of this circuit is to protect batteries and load
against damaging high output voltage in the event of an internal
malfunction or component failure. This circuit may also be
activated if the charger is putting out high current into heavily
discharged batteries and the batteries are abruptly switched off of
the output (called a load dump). The abrupt removal can cause
an output voltage spike which triggers this circuit. Corrective
Action: Verify proper connection of charger output terminals to
batteries. Turn charger off for a few seconds, then back on again
to resume normal operation and L.E.D. indications.
3) Three Red Flash-Beeps: Cause: Battery temperature is too hot
and the charger is shut off. (Note: The optional thermal probe must
be installed for this diagnostic function to operate. See section IIIH for complete information.) This may be due to extremely high
ambient temperature in the battery environment, such as when
installed in a hot engine room. It may also be due to a shorted
cell in one of the batteries, causing “thermal runaway”. Corrective
Action: Turn charger off. Relocate batteries to a cooler area
or improve ventilation and/or check for a shorted cell in each
battery—refer to BATTERY CARE TIPS section for procedure or refer
12
to battery manufacturer for recommendations. Turn charger back
on to resume normal operation and L.E.D. indications.
Note: This shutdown/warning will also occur if the temperature
sensor is plugged in or unplugged while the charger is in
operation. If this is the case, make sure the plug is properly inserted
and shut the charger off and then back on; normal operation will
resume.
If the battery cools sufficiently for safe charger operation, the
charger will automatically return to service, however the L.E.D.
indicator will begin to display a series of three yellow flashes (see
item 5 below).
4) One Yellow Flash: Cause: Charger was too hot and shut down
but has cooled sufficiently and has returned to service. Corrective
Action: Refer to Item 1 of this list of indications.
5) Three Yellow Flashes: Cause: Battery was too hot but has cooled
sufficiently and charger has returned to service. Corrective Action:
Refer to Item 3 of this list of indications.
In each of the above cases, if corrective action has been taken and
the charger has been shut off and turned back on, but does not
resume normal operation, refer to the TROUBLESHOOTING section
or contact the factory for assistance.
V) APPLICATION NOTES
A) Constant Versus Occasional Use
In general, it is recommended that the charger be left connected
continuously to A.C. power so that it will be in operation whenever
A.C. is available. This will maintain batteries at peak voltage and
will automatically compensate for the natural self-discharge of the
battery system. When a load is applied to the battery system the
charger’s output will automatically increase to supply the current
which would otherwise draw battery voltage down. Repeatedly
allowing batteries to become completely discharged before
recharging will greatly shorten their life. Leaving the charger on
continuously will prevent this.
While the output regulation of the charger will minimize battery
gassing and water loss, monthly checks of the electrolyte level
(for wet lead acid batteries) are still strongly recommended.
Some water loss is an inevitable aspect of the charging process,
and maintaining the correct electrolyte level in your batteries is
the most important thing you can do to assure their maximum
performance and long life.
B) Proper Load Sizing
The Phase Three Charger is rated for continuous duty. While
the charger cannot be damaged by overloads that exceed its
continuous rating, excessive load demands may draw battery
voltage down faster than the charger can resupply it. If battery
voltage continues to drop, check to ensure that your average D.C.
loads are not exceeding the charger’s rated output at full (float)
voltage. (Refer to SPECIFICATIONS section for Max Current ratings.)
If loads exceed this rating, you may wish to consider adding
another charger in parallel to provide sufficient power for your
requirements. (See section III-F) Multiple Unit Parallel Wiring.)
C) Operation With Engine
It is perfectly acceptable to allow the charger to remain on
when the engine is started and while it is running. The current
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limit feature of the Phase Three Charger will protect against any
damage due to the high current demands of engine cranking.
Output diodes will prevent any back-feed of current into the
charger from the alternator while the engine runs.
No lubrication or maintenance is required. Simply ensure that there
is a free flow of air around the charger (approximately 2 or more
inches around all sides) and that there is no debris clogging the
ventilation perforations in the charger chassis.
As the alternator starts to charge the battery, the charger output
will decrease. When the battery voltage exceeds the rated output
voltage of the charger it will cease charging and will have no
output as long as the batteries are in this high state of charge. If
the battery voltage should drop below the charger’s rated output
voltage it will automatically return to service.
E) Current Limit Circuit
D) Cooling Fans
To maximize the life of the internal components and to allow
continuous operation at full rating, the Phase Three charger
employs multiple integral cooling fans. Both variable speed and
thermally cycling fans are used. Whenever load and/or ambient
temperature cause a significant rise in the internal temperature,
these fans will adjust automatically or cycle on and off, as
necessary, to cool components, extending their operating life.
Under no load and cool ambient temperature no fan movement
may be detected, but this does not indicate fan failure. Increased
load and/or rising ambient temperature should cause fan
activation.
The Phase Three Charger is self-limiting and protected against
overloads by a fast-acting current limit circuit which automatically
reduces output voltage to protect the charger when a current
demand is encountered which exceeds the charger’s power limit
rating. This may be due to extremely discharged batteries which
are beyond the recommended amp-hour rating, or a large D.C.
load being applied while batteries are heavily discharged, for
instance. (See SPECIFICATIONS section for maximum power limited
amps and recommended battery capacity ratings.) If a check of
the output voltage is taken when the charger is under this extreme
current draw, it may measure only a fraction of normal output
voltage. This is a normal function of the current limit circuit. To
check proper charger operation, simply remove the overload and
observe that normal output voltage has automatically resumed.
Important Note: The current limit circuit will not protect the
charger against a dead short across the (+) and (-) output
terminals when the charger is turned on. Charger failure will
result.
VI) TROUBLESHOOTING
Note 1: The Phase Three charger incorporates a self-contained A.C. to D.C. conversion module. This module houses several automatic
protection circuits, as well as the A.C. input and D.C. output fuses to protect internal wiring. Under most circumstances these fuses will
fail only if the charger has an internal fault. They are not user-replaceable. The following section deals primarily with the charger’s
protection features (some requiring manual charger reset; others auto-resetting). If an apparent charger fault cannot be corrected using
any of the recommendations in this section, the charger should be returned to the factory or place of purchase for inspection and repair
or replacement.
Note 2: Certain charger or battery problems are self-diagnosing with the Phase Three charger. For any shutdown condition which has
caused the charger’s Status Indicator to signal with one or more Red L.E.D. “Flash/Beeps” or Yellow Flashes, refer to section IV-C Status
Indicators to diagnose and resolve the problem.
Condition
Possible Cause
Solution
A) Status Indicator show charger
has shifted into float stage but
batteries are not coming up to
full charge.
1) High-rate time-out circuit has activated,
but extremely discharged batteries requiring
longer recharge time.
1) Turn off all D.C. loads and allow charger 2448 hours to recharge batteries. See section IV-B for
explanation of time-out circuit.
2) Charger limiting its output due to
overload.
2) Reduce D.C. load.
3) Charger output is not properly connected
to batteries.
3) Refer to D.C. wiring section of this manual and
verify compliance with instructions and diagrams
1) D.C. load drawing current from batteries
(not a problem condition).
1) To confirm charger will output minimal amperage
to fully charged batteries, shut off all D.C. loads
or turn off main battery switch to D.C. distribution
panel.
2) Bad cell in one of the batteries to which
charger is connected.
2) Check for shorted cell in all flooded type batteries
– see Battery Care Tips section. Refer to manufacturer
for testing maintenance-free batteries.
B) Charger continues to charge
at 3 amps or more – does not
taper back into charge
13
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Condition
Possible Cause
Solution
C) Front panel status indicator is
not lit and there is no indication
of charger output.
1) Charger is not receiving A.C. input
voltage or is connected to incorrect A.C.
voltage
1) Confirm charger model is compatible with 115V or
230V A.C. voltage being applied. Check for proper
input voltage with A.C. voltmeter. Check input
wiring connections.
2) Extreme overheating of charger has
caused thermal switch to temporarily shut off
A.C. input.
2) If charger is warm to the touch while the Status
Indicator is extinguished, refer to section IV-C, item 1,
which explains the two types of thermal shutdown
indications and solutions.
3) Reverse polarity connection or direct short
across output terminals has caused failure.
3) Refer to factory contact information below.
D) Charger repeatedly trips
input circuit breaker with no
batteries connected.
Internal Short
Refer to factory contact information below.
E) High output voltage
measured across output
terminals.
Batteries not connected to charger
Check for tight connection of charging leads to
batteries.
If a problem with your charger persists after you have applied the above-outlined solutions, or if you have any questions about the
installation and proper operation of your charger, please contact NEWMAR’s Technical Services Manager:
Phone: 714-751-0488 — From the hours of 7:00 A.M. to 4:30 P.M. weekdays, P.S.T.
Fax: 714-957-1621 — Anytime
E-Mail: techservice@newmarpower.com — Anytime
We will respond no later than the following business day and are always happy to consult with you to resolve any problem you may
have. If it appears the charger must be returned to the factory for repair we will issue a Return Materials Authorization at that time.
VII) SPECIFICATIONS
Model
Input
Output
VAC±10%
50-60 Hz
Max
Amps
Max Amps
@ P.L.*
Max Amps
@ F.V.**
Banks
PT-24-45W
230
8
45
38
3
PT-32-25W
115
15
27
24
3
Battery
Capacity
(Amp-Hour)
Weight
Lbs.
Kg.
90-450
12.2
5.6
50-300
12.2
5.6
* P.L. = Maximum amps at Power Limit
** F.V. = Maximum amps at Full (Float) Voltage—See OUTPUT VOLTAGES below
CASE SIZE
Inches
Centimeters
HxWxD
HxWxD
13.8 x 9.8 x 5.0
35.0 x 24.9 x 12.7
Add 1.27” (3.2 cm) to height and 1.1” (2.8 cm) to depth with drip shield installed.
OUTPUT VOLTAGES
14
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(without Temperature Compensation option installed):
24 VOLT MODEL
Float
32 VOLT MODEL
Setting
Charge
Gel-Cell
28.0 V D.C.
27.2 V D.C.
37.3 V D.C.
36.2V D.C.
Lead Acid
28.4 V D.C.
26.8 V D.C.
37.8V D.C.
35.7V D.C.
@ .5 amp load
Charge
Float
@ .5 amp load
TEMPERATURE COMPENSATION: - 5 mV per cell per ° C
PROTECTION FEATURES
Input Fuse
Output Fuse
Self-Limiting (Current Limited)
Over Voltage Protection
(Latching circuit; resets when A.C. is cycled off and on)
Cooling Fans
Automatic Thermal Shutdown
COMPLIANCES
Safety: EN60335-1
Routine Checks and Maintenance
Batteries should periodically be “exercised” (slowly discharged and
then recharged) to keep them in top condition. New batteries may
need to be exercised before they will be capable of their full rating.
If your batteries are not the sealed type, distilled water should be
added to them whenever needed. The electrolyte should cover
the plates by about 1/2”, allowing a small air space at the top. Do
not fill the cells up to the filler cap as this could cause the battery
to sputter out electrolyte when it is being charged. Only distilled
water should be used never plain tap water. Tap water contains
chemicals and elements that can alter the properties of the
electrolyte, including specific gravity. Some chemicals may also
create an insulating coating on the battery plates which will retard
current flow.
The rate that water is lost by the battery is dependent on several
factors; battery condition, ambient temperature, battery use,
charge voltage, etc. It is normal for batteries which are not
maintenance-free to require topping off about once a month.
A battery’s state of charge may be monitored by checking the
specific gravity or by open circuit voltage. You may use the
following table to evaluate the condition of your batteries:
EMC: IEC 1000-4-2, -4
EN55014
Carries the CE Mark
Battery Condition Table
VIII) BATTERY CARE TIPS
Regular maintenance and proper care will assure you reliable
service from the most depended upon and sometimes most
neglected items, your batteries and battery charger. NEWMAR
battery chargers are designed to keep your batteries fully charged
but your batteries also need proper regular maintenance to
provide a maximum life of service.
ALWAYS READ AND FOLLOW THE BATTERY MANUFACTURER’S
INSTRUCTIONS
Battery Installation
Batteries must be securely mounted to prevent them from falling
over when the vehicle or boat is in motion. A loose battery can
do serious damage. Batteries should be mounted in a battery
box to contain any acid spill. Batteries give off a certain amount
of hydrogen gas when they are charging. When concentrated,
this gas is highly explosive. Therefore make sure they are in an
accessible place with adequate ventilation for any hydrogen gas
discharge.
Specific Gravity
Measured by
Hydrometer
Open Circuit Voltage
State of
Discharge @
80° F
24 Volt
System
32 Volt
System
1.265
25.2 or more
33.5 or mre
Fully Charged
1.225
24.8
33.0
25% Discharged
1.190
24.4
32.5
50% Discharged
1.155
24.0
32.0
75% Discharged
1.120
23.4 or less
31.1 or less
100% Discharged
* Note: Wait at least 5 minutes after charging or discharging before
checking specific gravity or open circuit voltage. The battery’s
voltage needs to stabilize in order to get an accurate reading.
* Note: Wait at least 5 minutes after charging or discharging before
checking specific gravity or open circuit voltage. The battery’s
voltage needs to stabilize in order to get an accurate reading.
Troubleshooting Your Battery System
If your battery will not accept or hold a charge, one of the
following conditions may exist:
Cleaning Batteries
Dirt and electrolyte salts can build up on the top of your batteries.
This accumulation conducts electricity stored in the battery and
can cause the battery to discharge by itself. Therefore, at least
twice a year, it is a good idea to disconnect the battery cables
and scrub the battery with a baking soda solution. Rinse with fresh
water and dry with a clean cloth.
15
You may wish to purchase a set of terminal post corrosion
prevention rings. These are alkali-saturated felt rings that slip over
the battery post to reduce corrosion. Do not apply grease to any
part of the battery terminals, but you may use an occasional light
spray of silicone lubricant.
1. A BAD BATTERY. You may have a battery with an open or
shorted cell, a battery without any “life” left. Check by charging
the battery until all cells have a specific gravity of 1.225 or greater
at 80° F. If you are unable to obtain 1.225 in each cell, replace
the battery. For maintenance-free or gel-cell batteries consult the
manufacturer.
www.newmarpower.com
P.O. Box 1306, Newport Beach, California 92663 • Phone: 714-751-0488 • Fax: 714-957-1621 • E-Mail: techservice@newmarpower.com
2. A BAD BATTERY CHARGER. If the battery open circuit voltage is low and/or the hydrometer indicates your batteries are low, the
battery charger should be providing current to the batteries. If it is not, check A.C. input and check to see that you have charging
voltage on the output with no battery attached. Note: You will not get an accurate voltage reading on the output of the charger with no
batteries attached. This is checked merely to ensure that you do not have an open circuit on the output.
The battery charger has a thermal cutout switch to turn the charger off if it is overheating. If you suspect this is the case, refer to the
information regarding charger location in the Installation section and cooling fans in the Application Notes section.
3. ELECTRICAL LEAKAGE. You may have a previously unsuspected source of current drain from the battery. To check for a leakage of
this sort, disconnect the battery ground cable and connect an ammeter between the negative battery post and ground. If you have a
reading over .1 amp, there is a source of current drain from the batteries which must be located and removed.
IX) REFERENCE APPENDIX
X)IX)
UNIT
UnitDIMENSION
DimensionDRAWING
Drawing
* For more information about boat
wiring to conform to U.S. Coast
Guard regulations, write:
Superintendent of Documents
Request : 33 CFR 183 Subpart I
Government Printing Office
Washington, DC 20402
* For information about
American Boat and Yacht Council
recommendations for boat wiring,
write to:
American Boat and Yacht Council
3069 Soloman’s Island Road
Edgewater, MD 21037
Request: Standards and
Recommended Practices for Small
Craft.
AC & DC systems: Section E11
A-20: Battery Charging Devices
* For additional installation
instructions, refer to: ANSI NFPA 302
16
www.newmarpower.com
P.O. Box 1306, Newport Beach, California 92663 • Phone: 714-751-0488 • Fax: 714-957-1621 • E-Mail: techservice@newmarpower.com
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