Phase Three Three Stage Smart Charger

Phase Three Three Stage Smart Charger
Phase Three
Three Stage Smart Charger
Installation/Operation Manual
Models: PT-24-20U & PT-40U
Table of Contents
Section Topic
Page
QUICK REFERENCE GUIDE..................................................................................................... 2
I) GENERAL INFORMATION.................................................................................................. 3
II) IMPORTANT SAFETY INFORMATION........................................................................... 3
III) INSTALLATION..................................................................................................................... 5
A) Materials Provided..................................................................................................... 5
B) Location........................................................................................................................... 5
C) Mounting........................................................................................................................ 5
D) DC Output Wiring........................................................................................................ 5
E) Multiple Unit Parallel Wiring.................................................................................... 6
F) AC Input Wiring............................................................................................................ 7
IV) OPERATION.......................................................................................................................... 7
A) Three Stage Charge Regimen................................................................................ 7
B) Time-Out Circuit........................................................................................................... 8
C) Gel-Cell/Leac-Acid Selector Switch...................................................................... 8
D) Remote Panel Option: 12 Volt Model................................................................... 8
E) Temperature Compensation Option..................................................................... 8
F) Cooling Fan................................................................................................................... 9
G) Output Ammeter......................................................................................................... 9
H) Power-On Indicator..................................................................................................... 9
V) APPLICATION NOTES......................................................................................................... 10
A) Start-Up............................................................................................................................ 10
B) Constant Versus Occastional Use.......................................................................... 10
C) Proper Load Sizing....................................................................................................... 10
D) Operation with Enging.............................................................................................. 10
E) Operation as a DC Power Supply (Stand Alone DC Power Source).......... 10
VI) TROUBLE SHOOTING......................................................................................................... 11
VII) SPECIFICATIONS................................................................................................................ 12
VIII) BATTERY CARE TIPS......................................................................................................
12
IX) REFERENCE APPENDIX.................................................................................................... 13
X) UNIT DIMENSIONAL DRAWING..................................................................................... 14
M-PT2420U/40ULF
As of July 2010
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
Quick Reference Drawing
Optional Dripshield,Pg. 5
Charger Front Cover
Permanent Mounting
Holes x 4, Pg. 5 & 14
Charger Status LED,Pg. 5
Temporary Keyhole
Mounting Holes x 2,
Pg. 5 & 14
Ammeter,Pg. 9
Battery Selector Switch,
Pg. 8
Remote Panel Jack, Pg. 8
Temperature
Compensation Jack,
Pg. 8
Charger Dripshield
Output Terminals,Pg. 5
AC Input, Pg. 7
1/4-20 Chassis
Grounding Stud,
Pg. 4
2
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
1) General Information
II) Important Safety Instructions
Your Phase Three™ Series Battery Charger represents a
new phase in charger design and performance, employing
“smart” switching circuitry which puts batteries through the
optimum three-stage charge process, adapts for gel-cell or
lead-acid batteries, features precise voltage compensation
for varying battery temperature, is rated for continuous
duty and is housed in rugged stainless steel cover coated
with a durable white powder coat finish.
1. SAVE THESE INSTRUCTIONS – This manual contains
important safety and operating instructions for the
Phase Three Battery Charger.
Following is a brief listing of some of the more important
features/options of your Phase Three Charger. Each is fully
detailed later in this manual:
• Three step “smart” charging: bulk, absorption, float
• Gel-cell/lead-acid switch selects optimum charge/
float voltages based on battery type
• Multiple output banks charge independently based
on demand
• 115/230 VAC, 50-60 Hz input – can be used anywhere
in the world
• Current limited – prevents damage in case of over
loading
• Thermally controlled cooling fan allows continuous
operation at full-rated output
• High charge voltage time-out circuit prevents over
charging during continuous high amperage demand
• Optional temperature compensation sensor fine tunes
output voltage based on battery temperature
• Optional Remote Panel (12 volt only) allows battery
voltage monitoring of 1 or 2 banks, indicates battery
voltage too high/too low via multi segment LED bar
graph
• Use as a power supply without in-line battery; allows
continued use of DC powered electronics (when AC
is available) in the event that batteries must be taken
off-line or removed
• Built to last - rugged stainless steel and aluminum
case powder coated case with marinized internal
circuitry; optional-use dripshield provided
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 enjoy years of trouble-free service.
PRODUCT REGISTRATION
If you wish to register your Newmar charger with us and
provide comments or questions, please visit us online at
www.newmarpower.com/product_registration.html or for
immediate response to your questions or comments, please
call tech service at 1-800-241-3897 or email [email protected]
newmarpower.com.
2. Before using this battery charger, read all instructions
and cautionary markings on (1) the battery charger,
(2) the battery, and (3) product powered by the battery.
3. CAUTION – To reduce the risk of injury, charge only 6
cell (12 volt models) or 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.
5. Use of an attachment not recommended or sold by
NEWMAR may result in a risk of fire, electric shock or
injury to persons.
6. To reduce the risk of damage to the electric plug and
cord (if plugged into an AC outlet), pull by plug rather
than cord when disconnecting the charger.
7. Make sure the cord is located so that it will not be
stepped on, tripped over, or otherwise subjected to
damage or stress.
8. An extension cord should not be used unless absolutely
necessary. Use of an improper cord could result in the
risk of fire and electric shock. If an extension cord must
be used, make sure:
A) That pins on the plug of the extension cord are the same
number, size and shape as those on the plug of the charger.
B) That the extension cord is properly wired and in good
electrical condition.
C) That the wire size is large enough for the AC
amperage rating of the Phase Three Charger. Refer to
the SPECIFICATIONS SECTION to determine the full
load input current of your Phase Three Charger, and
then use the chart below to determine the correct
gauge wire for any extension cord used.
RECOMMENDED MINIMUM AWG SIZE FOR EXTENSION
CORDS FOR PHASE THREE BATTERY CHARGER
AC Input Rating, Amperes
Equal to or
greater than
Length of Cord, Feet
but less
25
50
100
150
than
Size of Cord (AWG)
4
6
6
8
16
16
16
14
12
16
12
10
3
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
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 to
a qualified serviceman.
11. Do not disassemble the charger; take it to a qualified
serviceman when service or repair is necessary. In
correct reassembly may result in a risk of electric
shock and fire.
12. To reduce the risk of electric shock, disconnect the
charger from AC 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 THE UTMOST IMPORTANCE THAT BEFORE
INSTALLING AND USING Y OUR 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.
PERSONAL PRECAUTIONS
1. Someone should be within range of your voice or close
enough to come to your aid when you work near a leadacid battery.
2. Have plenty of fresh water and soap nearby in case
battery acid contacts skin, clothing, or eyes.
3. Wear complete eye 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 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
high enough to weld a ring or the like 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 startermotor application. Do not use the charger for charging
dry-cell batteries that are commonly used with home
applications. 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 manufacturers’ specific precautions
such as removing or not removing cell caps while charging
and recommended rates of charge.
GROUND AND AC POWER CORD CONNECTION
1. The charger should be grounded to reduce risk of
electrical shock.
2. The Phase Three Charger is provided with IEC certified
AC power cord. If, for any reason, the plug on the cord
must be changed or replaced, observe color coding of the
AC wiring as follows:
Brown………………………AC Hot (fused)
Blue……....…………………AC Neutral
Green………………………AC Ground (safety/earth)
The charger must be plugged into an outlet that is properly
installed and grounded in accordance with all local
codes and ordinances.
DANGER: Never alter the AC cord or plug provided, unless
it is absolutely necessary for use with the AC outlet which
conforms to all relevant electrical codes. Any modification
of the cord must only be done by a qualified electrician.
Improper cord/outlet connection can result in a risk of
electrical shock.
EXTERNAL CONNECTIONS TO THE CHARGER SHALL
COMPLY WITH UL RECOMMENDATIONS AND/OR UNITED
STATES COAST GUARD ELECTRICAL REGULATIONS
(33CFR183, WSUB-PART I)
THE INSTALLATION AND PROTECTION OF VESSEL WIRING
ASSOCIATED WITH BATTERY CHARGERS SHALL COMPLY
4
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
WITH ABYC STANDARDS E-11) AC & DC ELECTRICAL
SYSTEMS ON BOATS, AND A-31) BATTERY CHARGERS &
INVERTERS
III) INSTALLATION
A) Materials Provided
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
¼” mounting screws/washers, as well as DC output wiring
and connectors. Proper sizes and gauges for the wire and
connectors are noted in Section III-D following.
B) Location
The charger should be mounted on a wall, bulkhead or
other suitable mounting surfaces as close to the batteries to
be charged as possible. Do not mount the charger directly
over the batteries as fumes may cause excessive corrosion.
The area should be well ventilated and free from excessive
moisture, exhaust manifolds, and battery fumes.
Make a mark on the wall or bulkhead where each of the
keyhole slots will be located. Then drive a screw about
half-way 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.
D) DC 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, DC output wires must be attached
with 1/4” ring crimp lug terminals sized appropriately to
fit wire gauges as listed below
Vertical mounting is preferred in order to allow the dripshield
to protect the charger from any moisture which may fall
onto the charger. However, vertical mounting is acceptable
since the charger is forced-air cooled. It should not be
located where there is a possibility of debris being drawn
into the unit through the fans.
The DC 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
If the charger is located in an extreme heat area, such
as an unventilated engine room, and the cooling fans
are unable to maintain proper operating temperature,
output power will automatically be reduced to protect the
charger. For maximum performance, the charger should
not be located in an area of extreme high temperature.
DC Wire Size Table
IMPORTANT: Although the charger is constructed of
materials and in a manner which make it highly resistive
to the corrosive effects of moisture in the environment, the
charger is not waterproof. 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.
C) Mounting
The charger may be mounted on either a metal or nonmetal surface*. You will require four screws (wood or
machine screws, depending on mounting surface) with
washers, sized for ¼” 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.
DC Wire Size Table
Model
10
15
20
Wire Gauge AWG (mm)
PT-24-20U
#10 (6mm)
#10 (6mm)
#8 (10mm)
PT-40U
#6 (16mm)
#4 (25mm)
#2 (35mm)
* Based on ABYC 3% voltage drop table and NEC
minimum wire size chart
Figure 1: Simple D.C. Wiring (Preferred Method
Optional Temperature
Compensation Sensor.
See page 8 for installation.
Use provided cable clamps to
secrure probe cable.
*To comply with ABYC DC chassis grounding conductor
(ABYC A-31), connect a suitable sized wire to the ¼”-20
chassis grounding stud near AC cable connector.
* Per ABYC A-31: A D.C. chassis conductor shall be
5
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
connected from the case to the battery charger to the engine
negative terminal or its bus, and must be no more than
one size under that required for the D.C. current carrying
conductor and not less than 16 AWG
Note: The diagram Figure 1 does not illustrate a complete
system. Refer to ABYC standards E-11 AC & DC electrical
system on boats.
Note: If batteries are closer to charger than battery switch,
wire directly to battery posts.
It is recommended that DC 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 configurations
are best left to a qualified electrician.
If the battery was connected to the charger backwards,
the fuse should blow to protect DC wiring, however
damage to internal components may also have occurred.
If the replacement fuse blows, return the charger to an
electronics service professional or to the factory for a
thorough inspection.
Note: The internal fuses do not provide protection if there is
a short in the wiring between the charger and the battery.
The battery is itself a power source and charging leads
should be fused at the battery per ABYC standards.
Figure 2: Wiring with Battery Switch
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.
IMPORTANT NOTE: EVEN MOMENTARY REVERSE
POLARITY CONNECTION MAY SEVERLY DAMAGE YOUR
CHARGER. THE POSITIVE (+) TERMINAL MUST BE WIRED TO
THE POSITIVE POST OF THE BATTERY AND THE NEGATIVE
OR COMMON (-) TEMINAL TO THE NEGATIVE POST OF
THE BATTERY OR COMMON BUS.
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 the output bank, as a result.
If you wish to add another isolated battery bank, use of
NEWMAR’s Battery Integrator is recommended. Contact
the factory for details. Be sure to replace the clear plastic
terminal cover to prevent accidental shorting of the output
terminals in the future.
An Important Note about the DC Output Fuse(s): internal
DC wiring is protected by the internal DC output fuse(s). The
current limiting circuit of the Phase Three Charger should
prevent these fuses from blowing under normal operating
conditions. If the DC fuse(s) blow, this may indicate a
reverse polarity hook-up or an internal short.
Always disconnect AC to the charger before checking
fuses. To check or replace the DC fuse, the cover must be
removed. To do this requires removal of four screws from the
front of the unit and three screws on each side. The DC fuse
is mounted on the main circuit board. Be sure to replace
with the same type and value as indicated on the fuse.
Optional Temperature Compensation Sensor. See page
8 for installation. Use provided cable clamps to secure probe
cable.
* Per ABYC A-31: A D.C. chassis conductor shall be
connected from the case of the battery charger to the engine
negative terminal or its bus, and must no be more than
one size under that required for the D.C. current carrying
conductor and not less than 16 AWG
Note: The diagram Figure 1 does not illustrate a complete
system. Refer to ABYC standards E-11 AC & DC electrical
system on boats.
E) Multiple Unit Parallel Wiring
If increased power or system redundancy is required, a
second charger may be wired in parallel. The unit is diode
protected so it will not be damaged by feedback from the
second unit and current limiting will prevent overloading
in the case of a failure of one of the units.
Observe the following guidelines when wiring a parallel
unit.
1) Use another identical charger model. Do not use a
different charger model, either from NEWMAR or from
another manufacturer.
2) Wire length and gauge and wire lug size must be
identical for each charger to ensure proper load sharing.
3) Wire gauge for each charger must be the same used as
if a single charger were wired into the system itself.
6
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
F) AC Input Wiring
NOTE: (For marine applications) 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-31) BATTERY CHARGERS & INVERTERS
These models are provided with an IEC certified AC cord
which may be plugged into the charger and a proper
outlet. If the plug is not suited to the available outlet, 1)
obtain an IEC cord with appropriate plug or 2) obtain the
correct plug for the outlet and install it on the provided
IEC cord. When installing the plug, pay careful attention
to the pin wiring as follows:
Brown…….............................................AC Hot (fused)
Blue………......................................…...AC Neutral
Green (or Green with Yellow Stripe…AC Ground (safety/
earth)
As shipped from the factory, the AC input is “universal”
and will accept AC voltage in the range of 90-264 VAC,
47-63 Hz.
A power cord cable clamp has been provided to prevent
accidental disconnect of the AC cord. After the plug has
been inserted into the charger, snap the pre-formed clamp
around the AC input cable as close to the insertion point
as practicable and use a screw to fasten the clamp tightly
to the wall or bulkhead on which the charger is mounted.
Hard Wiring AC Input
If desired, the AC input to your charger may be hard-wired
directly to the AC distribution panel. Install the charger
end of the provided input cord as described above, then
cut off the plug and splice onto three conductor marinegrade cable with crimp but connectors, observing color
codes and fuse/circuit breaker ratings as above. For all
models, use minimum 16 AWG cable.
All charger wiring should be made in accordance with
UL, U.S. Coast Guard and/or ABYC regulations and
recommendations, as well as all relevant local codes.
See REFERENCE APPENDIX for sources.
AC input for the charger must be plugged into an
appropriate, over-current protected three prong outlet
OR routed through a separate dedicated fuse or circuit
breaker on an AC distribution panel with proper safety/
earth chassis ground in accordance with all local codes
and ordinances.
CAUTION (230 VAC applications only): If AC input is
derived from a source consisting of two HOT leads (phaseto-phase 230 VAC input voltage), an external fuse or circuit
breaker must be used to protect the unfused (formerly
NEUTRAL, now HOT) lead.
A note about the AC Input Fuse: The AC input of your
charger is protected by an input fuse located inside the
unit. Due to the current limiting characteristics of the
charger, it is highly unlikely that this fuse will blow unless a
malfunction occurs within the charger. The fuse is not user
replaceable. Replacement of the fuse must be preformed
by a qualified service person.
All charger wiring should be made in accordance with
UL, U.S. Coast Guard and/or ABYC regulations and
recommendations, as well as all relevant local codes.
See section IX) REFERENCE APPENDIX for sources.
IV) OPERATION
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.
This three stage regimen is initiated each time AC is first
applied, when drained batteries are most likely to be
encountered. The regimen proceeds as follows:
1) Bulk Charge – When batteries are significantly discharged
the charger responds initially by delivering a high amount
of DC current, at or near the charger’s maximum rated
output, in order to rapidly replenish them. It is during this
stage that charging current is maintained at a high level
as battery voltage increases. Bulk charging continues until
battery voltage reached the “charge” voltage level (where
batteries are at about 75-80% of capacity). A current limit
circuit prevents charger overload during this maximum
output stage
2) Absorption Charge – 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 Phase Three charger switches to the third
and final stage of the charge cycle.
*Note: The absorption phase may also be ended by the
time-out circuit. See section B following for a complete
explanation of the purpose and functioning of the timeout circuit.
3) Float Charge – For extended battery life, the Phase
Three then automatically switches to a lower float voltage
level. This float charge keeps batteries at peak condition
without overcharging. The charger may be left in this
stage for months without attention (though periodic checks
of electrolyte level in flooded batteries is recommended.)
7
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
FIGURE 3: Typical Charger Output Graph (into
batterywithout load)
*Approximately 10 hours maximum at factory setting.
B) Time-Out Circuit
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 time-out circuit.
This circuit is initialized each time AC is first applied to
the charger and runs for a pre-set interval before forcing
the charger to go into the float (lower voltage) mode. The
functioning of the charger during this interval is as follows:
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 automatically switch to the
float mode. (For instance, with model PT-40U, the charger
will drop into float mode at about 2-6 amps output.) If
demand rises to about 10-20 percent of capacity (4-8 amps
with PT-40U, for instance), the charger will return to the
elevated output of the absorption phase. This switching
back and forth between modes may occur until the circuit
times-out (8-10 hours after AC is first applied), after which
the charger will remain at float voltage, until the circuit is
re-initialized by turning the charger off and then on again.
Note: The Phase Three Charger is able to deliver its full
rated output current while in float mode.
C) Gel-Cell/Lead Acid Selector Switch
According to most battery manufacturers, the ideal
charging regimen for gel-cell and wet or flooded lead acid
batteries differs somewhat.
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.
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 nonimmobilized 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.
The ideal charge/float regimen has been programmed into
the Phase Three Charger for either sealed gel-cell or flooded
lead acid batteries. Simply make the proper selection for
your battery type via the slide switch on the right side of
the charger. The switch positions are indicated on the front
panel (up for Gel-Cell batteries, and down for Lead-Acid/
AGM type batteries). Use a ball point pen or similar object
to slide it into the correct position. The charger is shipped
from the factory set for Lead-Acid/AGM batteries.
Note: A wide variety of batteries are available which do
not conform to conventional descriptions as “gel-cell” or
“lead-acid”. You are advised to consult the manufacturer
of your particular battery as to proper charging regimen,
and use the battery type selection switch 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/charger model.
D) Remote Monitor Panel Option
A remote battery monitor (for 12 volt model, PT-40U only) is
available from NEWMAR, model EVM-12-2, which enables
you to monitor when the battery charger is “on” and the
batteries’ state of readiness at a glance of two (2) battery
banks only. Red, yellow, and green bar LEDs indicate
the batteries state of charge, and a green “Charger On”
LED is illuminated whenever AC power is connected to
the PT-40U. Flashing red bars indicate when High or Low
voltage is detected. The display has a sleep mode to
conserve power and gives periodic flashing indication of
the battery voltage level even when the boat or vehicle
and the charger are off. In the event battery voltage drops
to a critical level, the display will automatically come
out of sleep mode into full operation to alert the operator.
The EVM-12-2 requires a 22-5 cable (NEWMAR part
number 712-2205-0, sold by the foot). The EVM interface
plugs into the EVM jack on the PT-40U and wires to the
Charger’s output.
E) Temperature Compensation Option
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 72° F that same output may cause a battery
charged in consistently high temperature environment to
be overcharged, resulting in excessive loss of electrolyte.
Conversely, if the batteries are in a consistently cool
environment, they may be chronically undercharged,
resulting in sulfation of the battery plates. Either of these
8
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
two conditions will shorten battery life.
Therefore, the Phase Three Charger is designed to utilize
an optional remote sensor (available from NEWMAR,
model TCS-12/24) which provides automatic temperature
compensation. The remote sensor will signal the charger to
fine tune its output voltage so that it is properly matched to
the temperature of the battery/battery environment. The
adjustment rate is approximately -3mV per cell per °C.
(Note: The temperature compensation option is strongly
recommended for sealed, valve-regulated or gel-cell
batteries.)
The remote sensor is provided with 30’ of cable (model
TCS-12/24-40 is provided with 40’ of cable). One end of the
cable is plugged into the temperature compensation jack
which is located on the right side of the charger. (See FIGURE
5.) The temp sensor jack is identified on the front panel.
If additional cable length is required, additional cable is
commonly available from most electronics supply retailers
as Radio Shack/Tandy. Request a 6 conductor modularto-modular line cord (part number 279-422, 25 feet long)
and 6 pin modular in-line non-reversing coupler (279-423).
The sensor itself should be mounted on the inside of the
battery box, or more ideally, mounted onto one of the
batteries using a clamp or a small amount of silicon-type
adhesive. The sensor has a hole in the center which will
accommodate a #6 screw. If you have access to the exterior
of a wall of the battery box, you may drill a hole in the
wall of the box and run the screw through to mount the
sensor onto the interior wall. Use caution when drilling
so that you do not accidently puncture the case of any
battery inside the box.
Important note: When wiring multiple units in parallel (see
section III-E) and using the temperature compensation
option, you must use a separate sensor for each charger,
and the sensors must be mounted close together in the
same battery box or on the same battery for proper
operation.
FIGURE 5: Temperature Compensation Sensor and
EVM-12-2 Panel Installation
Temperature Compensation Charts:
Battery Temperature
°F
°C
Output V DC: 12 Volt Models
Charge
Gell-Cell
LeadAcid
Float
Gell-Cell
LeadAcid
50
10
14.4
14.6
14.0
13.8
72
22.2
14.0*
14.2*
13.6*
13.4*
90
32.2
13.7
13.9
13.3
13.1
* Factory pre-set voltages without temperature compensation option
installed.
Battery Temperature
Output V DC: 24 Volt Models
Charge
Float
°F
°C
Gell-Cell
LeadAcid
Gell-Cell
LeadAcid
50
10
28.8
29.2
28.0
27.6
72
22.2
28.0*
28.4*
27.2*
26.8*
90
32.2
27.4
27.8
26.6
26.2
* Factory pre-set voltages without temperature compensation option
installed.
To give some idea of the effect of the temperature
compensation sensor, the chart on the following pages list
the charge/float output voltages of the charger when no
sensor is installed (or when batteries are at 72° F), and at
cold (50° F) or hot (90° F) battery temperature with temp
sensor installed:
G) Cooling Fan
To maximize the life of the internal components and to
allow continuous operation at full rating, the Phase Three
Charger employs two integral cooling fans. The fans draw
air through the bottom of the unit and expel it out the top
to improve cooling and reduce the possibility of drawing
in water drops (an optional dripshield is provided for extra
protection). Note: Under most circumstances, the fans will
be in operation when the charger is on. However, fan
speed/audible may vary under no load and/or ambient
temperature conditions.
H) Output Ammeter
This will indicate total charging output current for all
battery banks connected.
Gel-Cell/Flooded/AGM Switch
I) Power-On Indicator
This green LED will glow whenever the charger is receiving
AC power.
Remote Panel Jack
Temperature Compensation
Jack
9
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
V) Application Notes
A) Start Up
1) Before powering up your charger, check for tight electrical
connections to each battery in your system. Switch off any
DC loads on the batteries. Apply AC power. Observe the
DC ammeter on the front panel. This meter displays the
total DC output of the charger, through all banks. It will
give some indication of the overall state of charge of your
batteries. If the meter is reading mid-scale or higher, it is an
indication that the batteries are in a relatively low state of
charge. The charger, sensing this, is supplying high current
to the batteries. If the meter needle is at or near the bottom
of the scale the batteries are at or nearing full charge.
2) Apply a load to the charger by switching on some
lights, a pump, or some other DC appliance. Observe the
charger meter. It should read approximately the same as
the expected current draw of the appliance. As current
is demanded from the battery system, the charger will
automatically increase its output in response to the
increased load demand. When load current exceeds 1020% of the charger’s rated capacity, the charger will go
into the absorption mode and remain there until current
drops below 5-15% of capacity or until the time-out circuit
cycle is complete.
B) Constant Versus Occasional Use
In general, it is recommended that the charger be left
connected continuously to the AC distribution system so that
it will be in operation whenever AC 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 you
can do to assure their maximum performance and long life.
while the charger is in service, check to see that your
average DC loads are not exceeding the charger’s rated
output. If they are, you may wish to consider adding
another charger in parallel to provide sufficient power
for your requirements. (See section III-E, Multiple Unit in
Parallel Wiring.)
D) 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 limit feature of the Phase Three Charger will protect
against any damage due to the high current demands
of the engine cranking. Output diodes will prevent any
back-feed of current into the charger from the alternator
while the engine runs.
As the alternator starts to charger the battery, the charger
output will decrease. When the battery voltage exceeds the
rated output voltage of the charger, it will shut off and stay
off 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) Operation as a DC Power Supply (stand alone DC
Power Source)
Most battery chargers are not suitable for powering
electronic devices directly, without a battery attached to
the output, as the high ripple and pulsing DC output (i.e.,
rectified AC output) can interfere with the operation of the
device. The Phase Three charger is different. It employs a
circuit that produces an extremely well-filtered DC output.
Therefore the charger is able to power virtually any DC
powered device (within the unit’s rating) without the
battery attached in-line (if, for instance, the battery must
be removed for any purpose and AC is still available).
All but the most sensitive DC powered electronic devices
will function as normally as if powered by a battery. In
addition, the current limiting circuitry enables the charger
to handle the high start-up surges associated with inductive
loads, such as DC motors in radar sets.
C) Proper Load Sizing
The Phase Three Charger is rated for continuous duty (e.g.,
the PT-40U can deliver up to 40 amps continuously, 24 hours
a day, seven days a week). While the charger cannot be
damaged by overloads that exceed this continuous rating,
excessive load demands may draw battery voltage down
faster than the charger can resupply it. If the battery voltage
continues to drop and the output current is at maximum
10
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
VI) TROUBLESHOOTING
Condtion
Possible Cause
Solution
A) Batteries are not coming up to full 1) Extremely discharged batteries
charge.
requiring long recharge time.
1) Turn off all D.C. loads and allow
charger 24-48 hours to recharge
batteries. See section I V-B for
2) Charger limiting its output due explanation of time-out circuit.
to overload or over temperature
conditions.
2) Reduce D.C. load and/or determine
cause of over temperature state
3) Fan not operating properly causing (See section III-B, “Location”).
charger to protect against overheating by shutting off.
3) Return for analysis/repair by
servicing dealer where charger was purchased or contact NEWMAR
for a Return Materials Authorization
number.
B) Charger continues to charge
at 3 amps or more – does not
taper back into charge.
1) DC load drawing current from 1) Turn off main battery switch to
batteries (not a problem condition).
DC electrical panel or turn off all DC
loads if you wish to confirm charger
2) Bad cell in one of the batteries to will output minimal amperage to fully
which charger is connected.
charge batteries.
2) Check for shorted cell in all wet leadacid batteries using a hydrometer.
Replace battery if cell is shorted.
Refer to manufacturer for testing
maintenance-free batteries.
C) Charger does not charge.
1) Charger is not receiving AC input 1) Using a voltmeter, confirm, AC input
voltage or is not receiving correct AC voltage, check input connections.
input voltage.
2) Refer to DC wiring installation
2) Charger output is not properly diagram for proper connections to
connected to batteries.
batteries.
3) Blown wiring fuse.
4) Defective charger.
3) Replace with another of correct
value (see section III-D, “DC Output
Wiring”).
4) Return for analysis/repair by
servicing dealer where charger was
purchased or contact NEWMAR for
a Return Materials Authorization
number.
D) Charger repeatedly blows input fuse 1) Short in AC wiring feeding power 1) Locate and correct wiring short
or circuit breaker feeding AC power to charger
to charger
2) Return for analysis/repair by
2) Internal short
servicing dealer where charger was
purchased or contact NEWMAR for
a Return Materials Authorization
number.
E) Reverse polarity connection to DC Output fuse and possibly other Replace output fuse with another of
charger has caused charger to stop components blown.
correct value. If fuse blows, return to
charging.
servicing dealer or contact NEWMAR
for Return Materials Authorization.
11
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
Condition
Possible Cause
Solution
F) High output voltage measured Batteries not connected to charger. It Check for tight connection of charging
across charger output terminals.
is normal to read ½ volt higher across leads from charger to batteries.
any output bank when no batteries
are connected.
MANUFACTURER’S INSTRUCTIONS
VII) Specifications
Battery Installation
INPUT RANGE (ALL MODELS): 90-264 VAC; 47-63 HZ
(automatic)
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.
OUTPUT BANKS (ALL MODELS): 3
Model
Output
Input Amps
115/230 VAC
Volts
Amps. Cont.
PT-40U
6.8/3.4
12
40
PT-24-20U
6.8/3.4
20
20
12 Volt Model
Setting
Cleaning Batteries
24 Volt Model
Charge
Float
Charge
Float
@ 50%
Load
@ 1 amp
Load
@ 50%
Load
@ 1 amp
Load
Gell-Cell
14.0 VDC
13.6 VDC
28.0 VDC
27.2 VDC
Lead Acid
14.2 VDC
13.4 VDC
28.4 VDC
26.8 VDC
Temperature Compensation: -5mV per cell per °C
Temperature Ratings: -20° C to + 60° C; Derate linearly
from 100% @ 50° C to 60% @ 60° C
Case Size/Weight: 13.85” H* x 9.5” W x 4.8” D* / 11 Lbs.
35.2* x 24.1 x 12.2 (cm) / 5 Kgs.
* With drip shield installed, add .75” (1.9 cm) to the height
and 1.35” (3.4 cm) to the depth.
Protection Features: Input fuse; Output fuse for reverse
polarity protection; Current limiting; Automatic high
temperature power reduction; Time adn load controlled
high rate charge circuit; Ignition protected; IP-21
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
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.
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.
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,
12
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
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:
Open Circuit Voltage
Specific Gravity
Measured by
Hydrometer
12 Volt
System
24 Volt
System
State of
Discharge
@ 80° F
1.265
12.6 or more
25.2 or more
1.225
12.4
24.8
25% Discharged
1.190
12.2
24.4
50% Discharged
1.155
12.0
24.0
75% Discharged
1.120
11.7 or less
23.4 or less
100% Discharged
Fully Charged
IX) REFERENCE APPENDIX
• For more information about boat wiring to conform
to US Coast Cuard regulations, write: Superintendent of
Documents and Request: 33 CFR 183 Subpart I.
• For more information about American Boat and Yacht
Council recommendations for boat wiring, write to:
American Boat and Yach Council
3069 Soloman’s Island Road
Edgewater, MD 21037
Request: Standards and Recommended Practices for
Small Craft.
AC & DC systems: Section E-11
A-31: Battery Charging Devices
• For additional installation instructions, refer to:
ANSI NFPA 302
* 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:
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.
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 AC 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.
13
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
XI) Unit Dimensional Drawing
14
P.O. Box 1306
Newport Beach
California 92663
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
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