PT-14 et al Manual - Atlantis Marine Power

PT-14 et al Manual - Atlantis Marine Power
PT-14
PT-24-8
INSTALLATION/OPERATION MANUAL
Models:
PT-14, PT-25
PT-24-8, PT-24-13
CONTENTS
Section
Topic
I)
II)
III)
GENERAL INFORMATION.................................... 2
IMPORTANT SAFETY INFORMATION.................. 3
INSTALLATION.................................................... 5
A) Materials Provided................................. 5
B) Location................................................ 5
C) Mounting............................................... 6
D) d.c. Output Wiring................................. 6
E) Multiple Unit Parallel Wiring................. 8
F) a.c. Input Wiring.................................... 8
OPERATION........................................................ 10
A) Three Stage Charge Regimen.................10
B) Time-Out Circuit................................... 11
C) Gel-Cell/Lead-Acid Selector Switch....... 12
D) Remote Monitor Panel Option................ 13
E) Temperature Compensation Option....... 14
F) Equalize Timer Option........................... 15
APPLICATION NOTES.......................................... 16
A) Start-Up................................................ 16
B) Constant Versus Occasional Use............ 16
C) Proper Load Sizing................................. 17
D) Operation with Engine........................... 17
E) Operation as a d.c. Power Supply........... 17
SPECIFICATIONS................................................. 18
TROUBLESHOOTING........................................... 20
BATTERY CARE TIPS.......................................... 22
REFERENCE APPENDIX....................................... 24
IV)
V)
VI)
VII)
VIII)
IX)
Page
M-PT14ETAL
As of August 2004
1
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
I)
GENERAL INFORMATION
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-step 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 a rugged stainless steel case.
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
* "Universal" 115/230V a.c., 50-60 Hz input—can be used anywhere in the world
* Current limiting prevents damage from overload
* Load activated cooling fan allows continuous operation at full-rated output
* High charge voltage time-out circuit prevents overcharge during continuous high
amperage demand
* Optional temperature compensation sensor (model TCS-12/24) fine tunes output
voltage based on battery temperature
* Optional remote panel (model RP) allows remote monitoring of charger phase status
and manual re-initialization of three stage charge cycle.
* Optional equalization circuit connection.
* Use as a power supply without in-line battery; allows continued use of d.c. powered
electronics (when a.c. is available) in the event that batteries must be taken off-line
or removed.
* Rugged stainless steel case with drip shield
* Models PT-14 and PT-24-8 carry the CE mark.
* All models ignition protected per USCG CFR 183.410
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.
2
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
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 6 cell (PT-14 and PT-25) or 12
cell (PT-24-8 and PT-24-13) lead-acid rechargeable batteries (flooded, AGM, gel or
sealed). 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 a.c.
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. 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 all cautionary markings on these products.
3
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
PERSONAL PRECAUTIONS
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.
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, AGM 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.
4
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
GROUNDING AND a.c. POWER CORD CONNECTION
1. The charger should be grounded to reduce the risk of electric shock.
(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-8) AC ELECTRICAL SYSTEMS ON BOATS, E-9) DC ELECTRICAL SYSTEMS ON BOATS, AND A-20) BATTERY CHARGING DEVICES.
III)
INSTALLATION
A) Materials Provided
The Phase Three charger is provided completely assembled and ready for installation.
The installer must 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.
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. The charger is ignition protected so it is acceptable to locate the unit 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.
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 protection
circuit will shut the charger off. Although it will return to service automatically after
cooling sufficiently, thermal cycling will shorten the life of the charger. 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.
5
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
C) Mounting
Important Pre-Installation Note: 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.
The charger may be mounted on either a metal or non-metal surface*.
*Per ABYC A-20: A d.c. chassis grounding conductor shall be connected from the case of
the battery charger to the engine negative terminal or its bus, and must not be more than one size
under that required for the d.c. current-carrying conductors, and not less than 16 AWG.
Four screws (wood or machine screws, depending on mounting surface) with washers,
sized for 1/4" holes, are required to mount the charger. An additional two temporary
holding screws will ease vertical installation.
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. 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 water-resistant. 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.
The installer will need to provide output wires and four 1/4" ring lug connectors (for
attaching wires to output terminals). Use the table below to determine the correct gauge
wire, based on the length of the wire run from the charger to the batteries.
Model
PT-24-8
PT-24-13
PT-14
PT-25
Length of Wire from Charger to Batteries (in feet)
10'
15'
20'
Minimum Wire Gauge AWG
#14
#12
#10
#12
#10
#10
#10
#8
#6
#6
#6
#4
*Based on N.E.C. Minimum Wire Size Chart and ABYC 3% Voltage Drop Chart
6
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
ENSURE THAT LEADS ARE PROPERLY FUSED AT THE BATTERY. (REFER TO ABYC RECOMMENDATIONS.)
Typical d.c. wiring configurations are illustrated in FIGURES 1 and 2.
FIGURE 1: Simple d.c. Wiring (Preferred Method)
Note: These diagrams do not
illustrate complete systems.
Refer to ABYC Standards E-8)
AC Electrical Systems on Boats,
and E-9) DC Electrical Systems
on Boats
*
*Per ABYC A-20: A d.c.
chassis grounding conductor
shall be connected from the
case of the battery charger to
the engine negative terminal or
its bus, and must not be more
than one size under that
required for the d.c. currentcarrying conductors, and not
less than 16 AWG.
IMPORTANT: Install fuses at batteries
per ABYC recommendations.
FIGURE 2: Wiring With Battery Switch
*
*Per ABYC A-20: A d.c.
chassis grounding conductor
shall be connected from the
case of the battery charger to
the engine negative terminal or
its bus, and must not be more
than one size under that
required for the d.c. currentcarrying conductors, and not
less than 16 AWG.
7
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
An Important Note about the DC Output Fuse: DC output wiring is protected by an
externally mounted ATC blade-type output fuse. The fuseholder is located on the bottom
of the unit. To remove the fuse for checking or replacing simply pinch the fuse between
thumb and forefinger and pull firmly downward.
The current limiting circuit of the Phase Three charger should prevent the fuse from
blowing under normal operating conditions. If the fuse blows, this may indicate a reverse
polarity hook-up or an internal short. If the battery is connected to the charger backwards, the fuse should blow to prevent a dangerous short circuit, however damage to the
internal components is possible, as well. If, after replacing this fuse, it blows again upon
application of power, return the charger to an electronics service professional or to the
factory for a thorough inspection.
Always replace the fuse with another of the same type and value. The values for the d.c.
output fuses are listed in the table below:
d.c. Output Fuse Table
Model
PT-14
PT-25
PT-24-8
PT-24-13
Fuse Value
ATC 20 amp
ATC 30 amp
ATC 15 amp
ATC 20 amp
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 only 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 by itself.
F) a.c. Input Wiring
For the convenience of the installer an a.c. power cord has been factory installed. It is a
three-conductor stranded type, 16 AWG. The cord is terminated with a plug suitable for
standard USA outlets and uses standard USA color coding of conductors.
8
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
a.c. input is "universal". Models PT-14 and PT-24-8 operate in a range of 85-264 VAC, 4763 Hz. No switch setting is required for either 115V a.c. or 230V a.c. applications. Models
PT-25 and PT-24-13 operate in a range of 90-132 or 180-264V a.c., 47-63 Hz. Input voltage selection for these models is made via a slide switch on the right hand side of the
charger. It is factory set for 115V. For 230V a.c. applications use a ball point pen or
similar tool to slide the switch into the 230V position.
a.c. input for the charger must be routed through 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. Caution (230V applications only): If a.c. input is derived from a source consisting of two HOT leads (phase-to-phase 230V a.c. input voltage) an external fuse or cicuit breaker
must be used to protect the unfused (formerly NEUTRAL, now HOT) lead.
Color coding of the installed a.c. cord is as follows:
Black.................................a.c. Hot (fused)
White.................................a.c. Neutral
Green................................a.c. Ground (safety, earth)
If the factory-installed cord must be replaced use a cord of equal or larger AWG rating
with stranded (not solid) conductors. Remove the a.c. input terminal cover by removing
the three phillips head screws securing it. Loosen the strain relief to slide the cover
assembly down the cord for terminal access. Note the configuration of terminal block
wiring as follows:
BLACK
WHITE
Internal Wiring
GREEN
FIGURE 3: a.c. Input Wiring (as viewed from bottom of charger)
Do not loosen these terminals
TERMINAL BLOCK
HOT
NEUTRAL
GROUND
Wire these terminals to AC cord
(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 REFERENCE APPENDIX at the end of this manual 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
9
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
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.
IV)
OPERATION
A) Three Stage Charge Regimen
The Phase Three Battery Charger utilizes 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 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. (This also occurs when the
reinitialize button on the optional remote panel is activated; see Remote Panel Option
section for more information). Note: An audible "clicking" noise from an internal relay may be
heard when the charger switches from one phase to another. This is normal operation. The
charge regimen proceeds as follows:
1) Bulk Phase: 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 charging
current 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 current limit circuit prevents charger overload during this maximum output stage. At this point the charger switches to the second stage.
2) Absorption Phase: 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 time-out circuit.
3) Float Phase: 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 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.
10
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
A typical three stage charging cycle is illustrated in FIGURE 4.
FIGURE 4: Typical Charger Output Graph (into battery without load)
The bulk/absorption stages last approximately 10 hours maximum at factory setting.
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 (or press the reinitialize button on the optional remote panel)
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 a.c is first applied to the charger (or when the reinitialize button on
the optional remote panel is activated) 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 % of the charger’s output
capacity prior to the circuit timing-out, the charger will automatically switch to the float
mode. If demand rises to about 10-20 % of charger output capacity, it will return to the
elevated output voltage of the absorption phase. This switching back and forth between
modes may occur until the circuit times-out (8-10 hours after a.c. is first applied), after
which the charger will remain at float voltage, until the circuit is re-initialized, either
by turning the charger off and then on again or by presssing the re-initialize button on
the optional remote panel.
Installation Note: The time-out circuit of the PT charger has been set at about 8-10
hours, which is appropriate for battery systems within the capacity range specified on
the front panel of the charger. If the charger is used with a battery system with a capacity near (or outside) the upper or lower ranges of the specified range of the charger,
11
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
adjustment of the internally located time-out circuit adjustment pot may be recommended. The procedure is as follows:
(Caution: Ensure a.c. input has been disconnected before proceeding)
1) Remove the two phillips head screws on the front panel (bottom right and just above
the output terminals), as well as the two phillips head screws on each side of the unit.
2) Carefully lift the main cover off of the charger base. It is not necessary to remove the
drip shield.
3) Locate the potentiometer labeled "TIMER ADJ" on the lower right hand side of the
front-facing charger function circuit board.
4) Using a small flat tip screwdriver, turn the potentiometer:
* clockwise to increase the amount of time the charger remains in the absorption
mode before timing out
* counterclockwise to decrease the amount of time.
The approximate ranges are illustrated below.
FIGURE 5: Adjusting the Time-out Circuit
8-10 Hours
5-7 Hours
11-13 Hours
Note: Once the time-out circuit has put the charger into float mode, the charger will
remain in this mode. Since the Phase Three Charger is well regulated, it is able to
deliver its full rated output current in this mode and battery discharge will not
occur (provided load current does not exceed charger rating and output wiring is
properly sized).
C) Gel-Cell — Flooded/AGM Switch
According to most battery manufacturers, the ideal charge regimen for gel-cell and
flooded (wet) lead-acid or AGM (Absorbed Glass Mat) batteries differs somewhat.
The gelled electrolyte in a sealed battery may be lost or damaged by high voltage and,
12
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
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. (The charge regimen recommended for AGM batteries is typically similar to that of flooded lead-acid batteries.)
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 or AGM battery.
The ideal charge/float regimen has been programmed into the Phase Three Charger for
either sealed gel-cell or flooded lead-acid/AGM batteries. Simply make the proper selection for your battery type via the slide switch on the front of the charger. The switch
positions are indicated on either side of the switch access port. Use a ball point pen or
similar object to slide it into the correct position.
Note: A wide variety of batteries are now 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 model.
D) Remote Monitor Panel Option
A Remote Monitor Panel is available from NEWMAR (model RP) which will enable you to
monitor the charger’s status at-a-glance from a remote location. Red and green L.E.D.’s
indicate whether the charger is in the bulk, absorption or float phase of the charge
cycle. In addition, the panel features a re-initialize button, which, when pressed, will
cause the charger to restart the three phase cycle. This resets the time-out circuit (see
section B: Time-out Circuit, above). Note: The charger may not stay in the bulk or absorption mode after pressing the re-initialize button. If batteries are at or near full charge,
the charger will quickly revert to the float mode.
The panel comes pre-wired with 30' of cable and 4 mounting screws. Simply install the
panel at the desired location and insert the plug on the end of the cable into the remote
panel jack which is located and identified on the front panel of the charger. Note:
Inadvertantly putting the remote panel plug into the temp compensation jack (or vice
versa) will not harm the charger. If the panel does not appear to function correctly,
check to see that it is plugged into the correct jack.
In case additional cable length is required, extension cables are commonly available
from most electronics supply retailers such as Radio Shack/Tandy. Request a 6 conductor modular-to-modular line cord (part number 279-422, 25 feet long) and 6 pin modular
in-line non-reversing coupler (279-423).
13
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
E) Temperature Compensation Option
Because low battery temperature increases resistance to charging and high battery
temperature reduces impedence, 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 a 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 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 -5 mV per cell per °C. (Note: The temperature
compensation option is strongly recommended for sealed, valve-regulated, AGM or gelcell batteries.)
The remote sensor is provided with 30' 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 7.) The location of temp sensor jack is identified on the front panel.
In case additional cable length is required, extension cables are commonly available
from most electronics supply retailers such as Radio Shack/Tandy. Request a 6 conductor modular-to-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 accidentally puncture the case of any battery inside the box.
Important note: When wiring multiple chargers in parallel (see section 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.
Without the temperature sensor installed the output of the charger will be at the nominal voltages specified in the chart on the following page at 72° F (22.2° C). The absorption/float output voltage settings at that temperature are listed in the chart.
To provide some examples which clarify the effect of the temperature compensation
14
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
sensor, the chart lists the absorption/float output voltages of the charger when batteries
are at 72° F (or when the sensor is not installed), and at cold (50° F) or hot (90° F) battery temperatures with the sensor installed:
Temperature Compensation Chart
Battery
Temperature
°F
°C
Output V d.c : 12 Volt Models
Output V d.c : 24 Volt Models
Charge
Float
Charge
Float
Gel-Cell Lead Acid Gel-Cell Lead Acid Gel-Cell Lead Acid Gel-Cell Lead-Acid
50
72
90
14.4
14.0*
13.7
10
22.2
32.2
14.6
14.2*
13.9
14.0
13.6*
13.3
13.8
13.4*
13.1
28.8
28.0*
27.4
29.2
28.4*
27.8
28.0
27.2*
26.6
27.6
26.8*
26.2
* Factory pre-set voltages without temperature compensation option installed
F) Equalize Timer Option
Some manufacturers of flooded lead-acid batteries recommend a charging process known
as equalization for extended battery life. This process involves occasionally charging a
wet lead-acid battery at a very high voltage for a short period of time in order to completely de-sulphate each of the battery plates, essentially equalizing their voltage. The
installer of the Phase Three charger may choose to wire in this option at the time of
installation.
Note: The equalization process is not recommended for sealed valve regulated or gelcell batteries.
The equalize circuit (connector located inside the PT charger) should be wired through a
manual or electric timer which provides a closed contact when engaged and an open
circuit when timed out (SPST — Single Pole Single Throw). Do not use a manually operated switch for activating the equalize circuit. This is because unless the charger is
reverted to a safe float voltage in a timely manner, the batteries will almost certainly be
damaged or destroyed. The timer should be a 0-12 hour type, capable of carrying a minimum of 100 mA at 5V d.c.
CAUTION: Do not install the timer in an area requiring ingnition protected equipment unless it has been certified to meet ignition protection requirements.
The equalization circuit of the Phase Three charger boosts output voltage to approximately 8 % above float voltage. Refer to the battery manufacturer’s instructions when
deciding the appropriate time period setting for this voltage to achieve proper equalization, while ensuring batteries are not damaged by increased battery temperature. This
installation should only be performed by a qualified technician.
Installing the timer requires a mating connector with dual wires which are plugged into
a jack on the internal charger function circuit board. The connector/wire assembly is
available from NEWMAR. Request part number 873-3716-0, CFB Equalize 2 pin assembly.
Proceed with the installation as follows:
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P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
(Caution: Ensure a.c. input has been disconnected before proceeding)
1) Remove the two phillips head screws on the front panel (bottom right and just above
the output terminals), as well as the two phillips head screws on each side of the unit.
2) Carefully lift the main cover off of the charger base. It is not necessary to remove the
drip shield.
3) Locate the two-pin header labeled "J2" just over the cut-out on the bottom of the frontfacing charger function circuit board. Insert the mating connector and route the two
control wires through the 1/4" hole on the bottom of the charger, beside the d.c. output
fuseholder. Connect the wires to the timer.
4) Replace the charger cover. Spread it slightly when lowering it onto the base to avoid
damaging the rubber seals on either side of the internal heat sink.
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 d.c. loads on the batteries. Apply a.c. power. Observe
the d.c. ammeter on the front panel. This meter displays the total d.c. 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 d.c.
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 10-20 % of the charger’s rated capacity, the
charger will go into the absorption mode and remain there until current drops below 515 % 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 a.c.
distribution system 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.
16
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
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.
C) Proper Load Sizing
The Phase Three Charger is rated for continuous duty (e.g., model PT-14 is rated at 14
amps continuous, PT-25 at 25 amps continuous, etc.). 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 battery voltage continues
to drop and the output current is at maximum while the charger is in service, check to
see that your average d.c. 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 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 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 charge 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 d.c. Power Supply (stand-alone d.c. power source)
Most battery chargers are not suitable for powering electonic devices directly, without a
battery attached to the output, as the high ripple and pulsing d.c output ( i.e., rectified
a.c. output) can interfere with the operation of the device. However, this charger employs a circuit that produces an extremely well-filtered d.c. output. Therefore it is able to
power virtually any d.c. 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 a.c. is
still available). All but the most sensitive d.c. 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.
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P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
VI)
SPECIFICATIONS
Model
PT-14
PT-25
PT-24-8
PT-24-13
Input VAC (50-60 Hz.):
85-264
90-132 or
180-264
85-264
90-132 or
180-264
2.8
1.4
6.5
4
2.8
1.4
6.5
4
[email protected]
.7
[email protected]
.7
Output Voltage (Nominal):
12
12
24
24
Output Amps (Continuous):
14
25
8
13
Output Banks:
3
3
3
3
28-140
50-250
16-80
26-130
7.5
8.5
7.5
8.5
CG,CE
CG
CG,CE
CG
Input Amps @ Full Load:
@ 115 VAC
@ 230 VAC
P.F. Rating:
Battery Capacity (Amp-Hours):
Weight (Lbs./Kg.):
Compliance References:
Compliance References*:
CG
Ignition protected per USCG CFR 183.410
CE
Carries the CE Mark
* Numerous other Safety and EMC compliances may also apply. Contact
factory if further compliance information is required.
Temperature Rating (all models):
-10°C to +60°C; Derate linearly from 100% @ 50°C to 60% @ 60°C
Nominal Output Voltages at Gel/Flooded Switch Settings (without Temperature Compensation option
installed or at 22.2°C (72°F) with Temperature Compensation option installed):
12 Volt Models
24 Volt Models
Charge
Float
Charge
Float
Setting
@ 50 % load
@ .5 amp load
@ 50 % load
@ .5 amp load
Gel-Cell
14.0V d.c.
13.6V d.c.
28.0V d.c.
27.2V d.c.
Flooded/AGM 14.2V d.c.
13.4V d.c
28.4V d.c.
26.8V d.c.
Temperature Compensation: - 5 mV per cell per ° C. Sensor supplied with 25' cable and plug-in connector
Remote Panel, Model RP: LED's indicate charger output stage. Button allows manual reinitialization of three
stage charge cycle. Supplied with 25' cable and plug-in connector. Panel dimensions: 3" H x 4.75" W
Protection (all models): Input/Output Fuses, Current Limiting, Thermal Protection, Forced Air Cooling, Drip
Shield
Case Size: (See dimensional drawings on page 19)
18
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
Dimensional Drawings:
19
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
VII
TROUBLESHOOTING
Note: These chargers incorporate self-contained a.c. to d.c. conversion modules which
utilize numerous automatic protection circuits. The a.c. input fuse which protects internal wiring is housed inside the charger with the module. Under most circumstances the
fuse will fail only if the charger has an internal fault. Hence, they are not intended to be
user-replaceable and any condition which has caused a blown a.c. fuse will likely require repair of other internal circuitry by a qualified technician. 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.
PROBLEM
POSSIBLE CAUSE
SOLUTION
A. Batteries not coming up to
full charge
1. Extremely discharged
batteries requiring long recharge time
1. Turn off all d.c. loads and
allow charger 24-48 hours to
recharge batteries
2. Charger limiting its output
due to overload or overtemperature conditions
2. Reduce d.c. load and/or
determine cause of overtemperature condition (see
section III-B, Location)
1. d.c. load connected to
batteries drawing current (not
a problem condition)
1. Turn off main battery
switch to d.c. electrical panel
or turn of all d.c. loads if you
wish to confirm charger will
output minimal amperage to
fully charged batteries
2. Bad cell in one of the
batteries to which the charger
is connected
2. Check for shorted cell in
wet lead-acid batteries using
a hydrometer. Refer to manufacturer for testing maintenance-free batteries
B. Charger continues to
charge at 3 amps or more—
does not taper back
C. No charger output, even
Blown input fuse or other
when all connections have
internal defect
been checked, a.c. is applied
to the charger, and d.c. load
is applied to the batteries
Return to servicing dealer
for failure analysis or contact
NEWMAR for Return Authorization Number
D. Reverse polarity connec20
P.O. Box 1306
Newport Beach,
California 92663
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Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
tion has caused charger to
have no output
E. High voltage measured
across charger output terminals
F. Charger will not stay in
bulk/absorption phase when
re-initialize button on remote
panel is pressed.
d.c. output fuse and other
internal components likely
blown
Replace output fuse with
like type and value. If still
no output, return to servicing dealer for failure analysis or contact NEWMAR for
Return Authorization Number
1. Batteries not connected
to charger. It is normal to
read 1/2 volt higher across
any output bank when no
batteries are connected.
1. Check for tight connection of charging leads to
batteries
2. Equalize function is activated
2. Check to verify proper
installation and operation of
equalize timer
Batteries at or nearing full
charge (not a problem condition)
Verify proper operation by
cycling a.c. off and on (or
press reinitialize button on
optional remote panel) then
applying a large d.c. load
Factory Contact Information
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: [email protected] — Anytime
We will be 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.
21
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
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.
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.
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, battery use, charge voltage, etc. It is normal for batteries
22
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
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:
Battery Condition Table
Specific Gravity
Measured by
Hydrometer
Open Circuit Voltage
1.265
1.225
1.190
1.155
1.120
12 Volt System
12.6 or more
12.4
12.2
12.0
11.7 or less
24 Volt System
25.2 or more
24.8
24.4
24.0
23.4 or less
State of
Discharge @ 80° F
Fully Charged
25 % Discharged
50 % Discharged
75 % Discharged
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.
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.
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 the input fuse 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 power reduction circuit to protect the charger from
overheating. If you suspect this is the case, refer to the INSTALLATION section for
information about proper charger location.
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
23
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
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
*
For more information about boat wiring to conform to U.S. Coast Guard regulations, write:
Superintendent of Documents
Government Printing Office
Washington, DC 20402
Request : 33 CFR 183 Subpart I
*
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 systems: Section E8
DC systems: Section E9
A-20: Battery Charging Devices
*
For additional installation instructions, refer to:
ANSI NFPA 302
24
P.O. Box 1306
Newport Beach,
California 92663
www.newmarpower.com
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: [email protected]
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