Manual - PT-7 - Newmar Power

Manual - PT-7 - Newmar Power
INSTALLATION/OPERATION MANUAL
Model:
PT-7
CONTENTS
Section
Topic
I)
II)
III)
GENERAL INFORMATION.................................... 2
IMPORTANT SAFETY INFORMATION.................. 2
INSTALLATION.................................................... 5
A) Materials Provided................................. 5
B) Location................................................ 5
C) Mounting............................................... 5
D) d.c. Output Wiring................................. 6
E) a.c. Input Wiring.................................... 7
F) Gel-Cell/Lead-Acid Selector Switch....... 8
OPERATION........................................................ 9
A) Three Stage Charge Regimen.................9
B) Start-Up................................................ 10
C) Constant Versus Occasional Use............ 11
D) Proper Load Sizing................................. 11
E) Operation with Engine........................... 11
F) Operation as a d.c. Power Supply........... 11
SPECIFICATIONS................................................. 12
TROUBLESHOOTING........................................... 13
BATTERY CARE TIPS.......................................... 15
REFERENCE APPENDIX....................................... 17
IV)
V)
VI)
VII)
VIII)
Page
M-PT7
As of APR 2003
1
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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, 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
* Dual output banks charge independently based on demand
* "Universal" 115/230V a.c., 50-60 Hz input—can be used anywhere in the world
* Charger Status indicator light—changes color according to output
* Current limiting prevents damage from overload
* Load activated cooling fan allows continuous operation at full-rated output
* 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.
* "Float" selector switch protects batteries when charging under continuous load
* Rugged stainless steel case with drip shield
* Carries the CE mark.
* 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.
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.
2
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3. CAUTION — To reduce the risk of injury, charge only 6 cell 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.
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
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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.
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.
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.
4
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III)
INSTALLATION
A) Materials Provided
The PT-7 charger is provided completely assembled and ready for installation. The installer must provide mounting hardware, as well as d.c. output wiring and connectors.
Proper sizes and gauges for the hardware, wire and connectors are noted in sections C
and 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.
C) Mounting
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 # 10 screws (wood or machine screws, depending on mounting surface) with washers, are required to mount the charger.
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 environ5
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ment, 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.
D) d.c. Output Wiring
Note: Only qualified service personnel should access the output terminals of the
charger.
The installer must provide output wires for attaching the charger to the battery. Use the
table below to determine the correct gauge wire, based on the length of the wire run
from the charger to the batteries.
Length of Wire from Charger to Batteries (in feet)
10'
15'
20'
Minimum Wire Gauge AWG
#14
#12
#10
*Based on N.E.C. Minimum Wire Size Chart and ABYC 3% Voltage Drop Chart
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: This diagram does not
illustrate a complete system.
Refer to ABYC Standards E-8)
AC Electrical Systems on
Boats, E-9) DC Electrical
Systems on Boats and A-20)
Battery Charging Devices
*
*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.
Warning: Utilize
bottom terminals
only for output
wiring
IMPORTANT: Install fuses at batteries
per ABYC recommendations.
6
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FIGURE 2: Wiring With Battery Switch
Note: This diagram does not
illustrate a complete system.
Refer to ABYC Standards E-8)
AC Electrical Systems on
Boats,E-9) DC Electrical
Systems on Boats and A-20)
Battery Charging Devices
*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.
Warning: Utilize
bottom terminals
only for output
wiring
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: ATC 10 amp.
E) a.c. Input Wiring/Voltage Selection
For the convenience of the installer an a.c. power cord has been factory installed. It is a
three-conductor stranded type, 18 AWG. The cord is terminated with a plug suitable for
standard USA outlets and uses standard USA color coding of conductors (see page following).
The PT-7 operates within a "universal" range of 82-132 or 176-264V a.c., 47-63 Hz input.
Input voltage selection is made via a slide switch on the bottom 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.
7
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a.c. input for the charger must be routed through a 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.
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 plug on the factory-installed cord is unsuitable for the available outlet it may be
cut off and replaced. Pay careful attention to color coding of the wires as noted above. Do
not attempt to replace the entire cord by removing the charger cover. Evidence of entry into the
charger will void the warranty.
(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
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. Contact the factory if you
suspect a blown input fuse. (See Troubleshooting section.)
F) Setting the 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,
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, prior to turning
the unit on.
Note: A wide variety of batteries are now available which do not conform to conventional
8
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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.
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.
Note: The Charge Cycle Select switch on the front panel must be in the "Charge" position for the
three stage cycle to occur. In the "Float" position, the charger will have a fixed output voltage which
depends on the setting of the Battery Type Selector. (See Specifications section for output voltages. See also the warning about the switch setting at the end of this section.)
During the first two stages (referred to collectively as the "Charge" stage) the indicator
light on the front panel will glow red. When charging is complete and the charger has
switched to the "Float" stage, the indicator will glow green.
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). 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.
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
9
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overcharging. The charger may be left in this stage for lengthy periods of time without
attention (though periodic checks of electrolyte level in flooded batteries is recommended). It is not necessary or recommended to shut the charger off when this stage is
reached.
A typical three stage charging cycle is illustrated in FIGURE 3.
FIGURE 3: Typical Charger Output Graph (into battery without load)
A WARNING ABOUT THE CHARGE CYCLE SELECT SWITCH: Whenever a load of approximately 3 amps or more is applied, the charger will go into the elevated voltage
"Charge" mode, as indicated by the glowing red indicator on the front panel. (See
specifications for actual charge/float voltages.) Battery electrolyte may be damaged
or lost by extended exposure to this higher voltage. If there is a d.c. load on the
battery system of 3 amps or more for periods lasting 8 hours or more, it is strongly
recommended that the Charge Cycle Select switch on the front panel be placed in the
"Float" position.
B) 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 Charger Status indicator on the front panel. If it glows red and stays red for a while,
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 indicator glows red briefly,
then switches to green it is an indication that the batteries are at or nearing full
charge, and the charger has switched to the "Float" (maintenance) mode.
2) After the indicator has switched to green, apply a load to the charger by switching on
some lights, a pump or some other d.c. appliance. Observe the indicator. As current is
demanded from the battery system, the charger will automatically increase its output in
response to the increased load demand and the charger will switch to the higher current (and higher voltage) "Charge" mode. As long as the load current exceeds approxi10
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mately 3 amps, the charger will remain in the charge mode (unless the Charge Cycle
Select switch is put into the "Float" position).
C) 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.
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.
D) Proper Load Sizing
The PT-7 is rated for continuous duty at 7 amps. 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.
E) 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 electronic 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, the PT-7 employs a
11
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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. When using the PT-7 as a regulated power supply
without battery in-line, place the Charger Cycle select switch in the "FLOAT" position for
maximum regulation.
V)
SPECIFICATIONS
Model:
PT-7
Input VAC (50-60 Hz.):
82-132 or 164-264
Input Amps @ Full Load:
@ 115 VAC
2
@ 230 VAC
1
Output Voltage (Nominal VDC):
12
Output Amps (Continuous):
7
Output Banks:
2
Battery Capacity (Amp-Hours):
14-70
Weight (Lbs./Kg.):
3.2/1.5
Compliances: Ignition protected per USCG CFR 183.410, Carries the CE Mark
Temperature Rating: -10°C to +60°C; Derate linearly from 100% @ 50°C to 60% @ 60°C
Nominal Output Voltages at Gel/Flooded Switch Settings:
Charge
Float
Setting
@ 50 % load
@ .5 amp load
Flooded/AGM 14.0-14.2V d.c. 13.4V d.c
Gel-Cell
13.8-14.0V d.c. 13.6V d.c.
Protection: Input/Output Fuses, Current Limiting, Thermal Protection, Forced Air Cooling, Drip Shield
Case Dimensions (Inches):
12
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VI)
TROUBLESHOOTING
Note: The PT-7 charger incorporates a self-contained a.c. to d.c. conversion module
which utilizes 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, it is 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
13
U.S.A. HEADQUARTERS
P.O. Box 1306, Newport Beach, CA 92663
Phone: 714-751-0488 Fax: 714-957-1621
E-Mail: [email protected]
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D. Reverse polarity connection has caused charger to
have no output
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
E. High voltage measured
across charger output terminals
Batteries not connected to
charger. It is normal to read
1/2 volt higher across any
output bank when no batteries are connected.
Check for tight connection
of charging leads to batteries
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.
14
U.S.A. HEADQUARTERS
P.O. Box 1306, Newport Beach, CA 92663
Phone: 714-751-0488 Fax: 714-957-1621
E-Mail: [email protected]
ELECTRONIC POWER PRODUCTS
COMMUNICATION ! NAVIGATION
www.newmarpower.com
EURO WAREHOUSE
Phone:+31-35-603-2494
Fax:+31-35-603-2149
VII)
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
15
U.S.A. HEADQUARTERS
P.O. Box 1306, Newport Beach, CA 92663
Phone: 714-751-0488 Fax: 714-957-1621
E-Mail: [email protected]
ELECTRONIC POWER PRODUCTS
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Phone:+31-35-603-2494
Fax:+31-35-603-2149
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
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
16
U.S.A. HEADQUARTERS
P.O. Box 1306, Newport Beach, CA 92663
Phone: 714-751-0488 Fax: 714-957-1621
E-Mail: [email protected]
ELECTRONIC POWER PRODUCTS
COMMUNICATION ! NAVIGATION
www.newmarpower.com
EURO WAREHOUSE
Phone:+31-35-603-2494
Fax:+31-35-603-2149
you have a reading over .1 amp, there is a source of current drain from the batteries
which must be located and removed.
VIII) 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
17
U.S.A. HEADQUARTERS
P.O. Box 1306, Newport Beach, CA 92663
Phone: 714-751-0488 Fax: 714-957-1621
E-Mail: [email protected]
ELECTRONIC POWER PRODUCTS
COMMUNICATION ! NAVIGATION
www.newmarpower.com
EURO WAREHOUSE
Phone:+31-35-603-2494
Fax:+31-35-603-2149
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