INSTALLATION INSTRUCTIONS & OWNER`S MANUAL Model 9C

Issue 1 Print 3
PM #t
POWER ISOLATION TRANSFORMER
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
LT-PM3201-1
INSTALLATION INSTRUCTIONS
& OWNER’S MANUAL
Model 9C-PM3-A
LT-PM3201-1
Issue 1 Print 3
INTRODUCTION AND APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warranty/Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Environmental Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Application Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Damaged Unit Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLING THE PM#t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Choosing an Electrical Wiring Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wired as an Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Choosing a Mounting Location for the Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Choosing a Mounting Location for the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Choosing the Appropriate Wire Type and Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Choosing Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Overcurrent Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Securing Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installing and Wiring the Remote Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATING THE PM#t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Proper Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
EXPLANATION OF THE REMOTE DISPLAY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Normal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Separate Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Source 1 and Source 2 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Off Mode (Only Available from the Setup Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Voltage Boosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Interruptions and Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remote Display Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manual Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
POST INSTALLATION VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Voltage Boosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Phase Inverting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Digital Multi-Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
MAINTAINING THE PM#t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
WARRANTY AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Service Center and Correspondence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
APPENDIX A − SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
APPENDIX B − SAMPLE OF NON-VOLATILE ERROR MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
APPENDIX C − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
LT-PM3201-1
Issue 1 Print 3
INTRODUCTION AND APPLICATION
The PM is an intelligent isolation transformer unit that takes potentially varying shoreline AC power and controls the output voltage to the boat providing consistent AC usage. This functionality allows for uninterrupted power consumption to appliances requiring electricity. Up to two display units are available with the PM providing
a convenient display of AC power consumption at all times.
The PM operates using an automatic voltage boosting, phase correcting, and isolation transformer system
intended for boats with up to two 208 VAC to 240 VAC shoreline connections, capable of up to 12 KVA each.
When properly installed, it will electrically isolate the two AC shoreline power connections to the boat’s AC power
system, reducing galvanic current corrosion associated with the AC shore power connection. Should the power
source fluctuate, the input voltage will automatically adjust, if necessary, and will safely combine the two inputs
from the power source on shore creating a regulated output on the boat. This functionality is transparent during
power usage.
The PM has two power connections capable of 12 KVA input each, for a total of 24KVA 120/240 VAC. When
only one source is available, the outputs are placed in parallel with each other to allow AC voltage up to 12KVA to
be supplied to a boat’s AC system.
With the utmost safety in mind, the boat’s AC system and grounding conductor are not actually connected to the
shore-side system when you use the PM. This design is intended to minimize shock hazards associated with
the use of AC equipment. Power is transferred from the shore-side AC system to the boat’s AC system by magnetic couplings. This means that there is no direct AC connection between the primary (shore) and the secondary
(boat) transformer windings. For safety, a metallic shield is placed between the primary and secondary windings
of each transformer. This shield assures AC current isolation on the boat by providing a protective layer between
primary and secondary windings within the transformer. In the unlikely event of a breakdown within the transformer, the shield can withstand the fault current of a properly sized shore supply circuit breaker long enough for the
breaker to trip.
Warranty/Registration
Before proceeding, complete and mail back your Warranty Registration card.
Manual Purpose
With your personal safety in mind, this manual lists important safety precautions first, then covers installation,
operation, maintenance, troubleshooting, warranty, and service information.
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS. This manual contains important safety and operating instructions
for the PM#t. Read the entire manual before usage.
DANGER
This device is not ignition protected. Avoid serious injury or death from fire or explosion. Do not
install in compartment containing gasoline fueled engines or gasoline tanks, or in areas where
ignition protected equipment is required.
DANGER
To avoid serious injury or death from high voltage electrical shock disconnect AC shore power before
opening panel.
WARNING − FIRE HAZARD
Primary and secondary overcurrent protection and conductor sizing must be in accordance with
manufacturer’s installation instructions.
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
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LT-PM3201-1
Issue 1 Print 3
WARNING − FIRE HAZARD
Do not store equipment on or next to the PM#t. In operation, the PM#t’s transformers can reach
high temperatures and must have free air flow to prevent overheating or possible damage to
adjacent materials.
WARNING − ELECTRICAL SHOCK AND FIRE HAZARD
Non-metallic strain relief connectors must be used to prevent wires from chafing on the metal case,
causing an electrical short. See installation instructions for suitable connector types or call the
Charles Marine & Industrial Group to order a strain relief kit.
Installation Precaution
Boat wiring is a complex task that can pose shock, corrosion and other hazards if not done properly by trained,
experienced personnel. For more information on this subject contact the American Boat and Yacht Council
(ABYC) or see the standards and regulations below:
American Boat and Yacht Council
E-11 “Alternating Current (AC) Electrical
Systems on Boats”
3069 Solomon’s Island Road
Edgewater, MD 21037
Telephone: 410.956.1050
FAX:
410.456.2737
NFPA Standard 302
“Pleasure and Commercial Motor Craft”
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02169−7471
U.S.A.
Telephone: 800.344.3555
Rules and Regulations for Recreational Boats
Excerpts from the United States Code (USC) and
the Code of Federal Regulations (CFR) (U.S. Coast
Guard Regulations) are available from the American Boat and Yacht Council listed above.
Note:
Installation of the PM#t must be made in accordance with all applicable standards and regulations.
Environmental Precaution
The PM is intended for installation inside an engine room or elsewhere on the interior of the boat. Be careful
that the location will not subject the unit to rain, snow, excessive moisture, or excessive heat.
Application Precaution
These units are intended for hard-wired, permanent, on-board applications. Use of attachments not recommended or sold by the Charles Marine & Industrial Group may result in risk of fire, electrical shock or personal
injury.
Damaged Unit Precaution
Do not operate the PM if it has received a sharp blow, been dropped, immersed in water or otherwise damaged. See the section in this manual on Warranty & Customer Service for repair and replacement information.
Disassembly Precaution
Do not disassemble the PM. See the sections in this manual on Maintaining the PM#t, Troubleshooting, and
Warranty and Service.
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Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
LT-PM3201-1
Issue 1 Print 3
Figure 1. PM#t − Control Unit
Figure 2. PM#t − Transformer
INSTALLING THE PM#t
The PM consists of two transformer units, a control unit and a remote display panel. A second remote display
panel can be purchased to provide an additional power output monitoring location on-board the boat.
Choosing an Electrical Wiring Method
There are two wiring methods that are acceptable for installation of the PM as an isolation transformer in accordance with the American Boat and Yacht Council (ABYC) Alternating Current (AC) Electrical Systems on
Boats standard. See Figure 3 and Figure 4.
Note:
Figure 3 and Figure 4 are reprinted with permission from the American Boat and Yacht Council (ABYC).
To obtain the complete standard referenced or any other standards contact the ABYC.
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
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LT-PM3201-1
Issue 1 Print 3
Wired as an Isolation Transformer
The difference between the two methods below is that in Method 2, a main shore power circuit breaker with
Ground Fault Protection (GFP) must be used instead of a conventional circuit breaker, and the shore grounding
conductor is not wired past the inlet of the boat. Method 1 is most commonly used.
Note:
The following electrical diagrams do not illustrate complete systems. Refer to the appropriate ABYC text.
Isolation Transformer System with Single-Phase 240-Volt Input, 120/240-Volt Single-Phase Output with Boat Grounded Secondary. Shield
Grounded on Shore and Metal Case Grounded on Boat (Figure 3). The ungrounded shore current-carrying conductors are connected from the
power inlet to the primary winding of the isolation transformer through an overcurrent protection device which simultaneously opens both current-carrying conductors. Do not connect the shore neutral. Fuses shall not be used in lieu of simultaneous trip devices.
240-Volt branch circuit breakers and switches simultaneously open all current-carrying conductors.
120-Volt branch circuit breakers are permitted to use single-pole breakers in the ungrounded current-carrying conductors.
Polarization of conductors must be observed in all circuits.
The green grounding wire from the shore is connected to the shore power inlet shell which is insulated from metal-hulled boats. Do not connect
the shore green wire to the boat ground.
The grounded neutral from the secondary of the isolation transformer and the case of the transformer are connected to the system ground,
neutral conductor and engine negative terminal or its bus.
Figure 3. Electrical Diagram − Method 1
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Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
LT-PM3201-1
Issue 1 Print 3
Isolation Transformer System with Single-Phase 240-Volt Input, 120/240-Volt Single-Phase Output, Ground Fault Protection and a Grounded
Secondary. Shield and Metal Case Grounded on Boat (Figure 4) − The ungrounded shore current-carrying conductors are connected from the
power inlet to the primary winding of the isolation transformer through a ground fault protection device which simultaneously opens both current-carrying shore conductors. Fuses shall not be used in lieu of simultaneous trip devices.
240-Volt branch circuit breakers and switches simultaneously open all current-carrying conductors.
120-Volt branch circuit breakers are permitted to use single-pole breakers in the ungrounded current-carrying conductors.
Polarization of conductors must be observed in all circuits.
The green grounding wire from the shore power inlet is not connected to the isolation transformer shield or case nor to the boat ground.
Figure 4. Electrical Diagram − Method 2
Choosing a Mounting Location for the Transformers
When choosing a mounting location for the PM, placement of the two transformers can be up to 50 feet (15
meters) from the control unit, allowing for the equal weight distribution of the transformers to best balance the
boat. Consideration should also be made for a light audible hum that is present when the transformers are in operation. It is best not to install the transformers adjacent to areas of the boat that are preferred to be kept quiet.
The transformers should be mounted horizontally. Special care should be taken to mount each of the transformers on supports that can sustain a shock load of at least twice the weight of itself. Finally, transformers generate
heat during normal operation. Proper ventilation around the case is important. Allow for 4 inches (10 centimeters) of clearance on all sides of the unit and at least two inches between the back of the unit and the surface it is
mounted on.
Choosing a Mounting Location for the Control Unit
The control unit may be placed in a convenient location, not exceeding 50 feet (15 meters) from each of the
transformers. It too should be mounted horizontally. Inside the control unit are contactors that make a soft
“clanking” sound when the unit is in use. It may be preferable to not place the control unit in or near an area that
should be kept quiet. Special care should be taken to mount the control unit on supports that can sustain a shock
load of at least twice the weight of itself. The control unit will generate heat during normal operation. Proper ventilation around the case is important. Allow for two inches (5 centimeters) of clearance on all sides of the unit.
WARNING − FIRE HAZARD
Do not store equipment on or next to the PM#t. The PM#t transformers, in operation, can reach
high temperatures and must have free airflow to prevent overheating or possible damage to adjacent
materials.
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
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LT-PM3201-1
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Choosing the Appropriate Wire Type and Gauge
All input conductors should be at least 6 AWG, and all output conductors should be at least 4 AWG, stranded,
600 volt rating, UL type AWM, UL 1426 equivalent or better. See ABYC standards for AC electrical systems on
boats for more details on conductor types and sizing.
Choosing Electrical Wiring
The PM is intended to be used as an isolation transformer. In this application, there is no fault current path for
the wiring from the shore power inlet to the PM output connections. For this reason, the wiring should only be
done with a jacketed cable (0.030 inches jacket thickness minimum) such as UL type 1426 boat cable or by using
a marine cable set wire (type SO or equivalent). This wiring should be installed in the boat in a protected area and
routed to avoid contact with sharp edges or hot surfaces.
WARNING − ELECTRICAL SHOCK AND FIRE HAZARD
Strain relief cord grip connectors or another method must be used to prevent wires from chafing on
the metal case and causing an electrical short. See installation instructions for suitable connector
kit. Use wire rated for at least 90 degrees Celsius, and sized on the basis of 75 degrees Celsius rated
wire amperage.
The PM is intended for hard-wiring in a permanent location. Non-metallic strain relief/grip connectors (see
Table 1) are required, and included with the unit, to secure wires or cables going into or out of the PM.
Table 1. Recommended Strain Relief Connectors and Accessories
Description*
Manufacturer
Catalog
Number
Locknut
Charles Number
Cord Range: 1.39 inches (35 millimeters)−1.69 inches (43 millimeters)
Thomas & Betts
2707
145
18-900736-0
0.89 inches (23 millimeters) to 1.09 inches
(28 millimeters)
Thomas & Betts
2702
144
25223
0.66 inches (17 millimeters) to 0.78 inches
(20 millimeters)
Thomas & Betts
2675
142
18-900250-0
Strain Relief Kit − 4 AWG Wire
Charles
N/A
Included
97−001121−A
Strain Relief Kit − 6 AWG Wire
Charles
N/A
Included
97−001120−A
*All strain relief connectors must be of a non-metallic type to conform to UL requirements.
Overcurrent Protection
Overcurrent protection must be provided at the time of installation by a two-pole circuit breaker on each primary
supply (incoming shore power AC) and each secondary (boat system AC power) circuit. Each shore power AC
input breaker should be rated at 50 amps and each boat system AC output breaker should be rated at 100 amps.
Each must be rated 120/240 volts AC, 5,000 Ampere Interrupting Capacity (AIC) and be of the “long delay” type.
A Ground Fault Protector (GFP) must be provided if a shore power grounding conductor is not connected to the
PM input ground (TXFR shield). This should be rated at 20 milliamperes or less and if it is to be combined with
the primary (incoming shore power AC) circuit breaker, it should be rated at 50 amps, 120/240 volts AC, 5,000
Ampere Interrupting Capacity (AIC) and be of the “long delay” type.
WARNING − HIGH VOLTAGE
To avoid serious injury or death from high voltage electrical shock disconnect AC shore power
before opening panel.
While making connections to the PM reference Figure 5.
The wiring installation will depend on the method chosen in the section titled Choosing an Electrical Wiring Method. Follow the procedure below to make the appropriate connections.
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Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
LT-PM3201-1
Issue 1 Print 3
Step
Action
1.
Remove the terminal access cover on the transformer.
2.
Remove the front cover on the control unit.
3.
Install the strain relief connectors.
4.
Undo the chucks and compression grommets from the strain relief connectors.
5.
Slide the strain relief connector chuck and compression grommets down and over the input and output
cables.
6.
Strip back the insulating layers to the appropriate length.
7.
Crimp ring terminals on all wires using the proper tool.
8.
Connect all wiring as shown in Figure 5 and described in Table 2 through Table 4.
9.
Re-assemble and tighten all strain relief connectors.
10.
Re-install the terminal access cover.
Shore Cable − 6 AWG Minimum
See
Table 3
Transformer
*Heavy Cable
50-foot Maximum
(See Table 2)
Side 1
BNC
Output − 4 AWG Minimum
Control Unit
Side 1
Output
Circuit Breaker
Side 2
Output
Output − 4 AWG Minimum
{Side 1 Input
Cat 5 Wire
50-foot Maximum
BNC
Side 2
See
Table 4
Remote Display
{Side 2 Input
Transformer
See
Table 4
*Heavy Cable
50-foot Maximum
(See Table 2)
{Cable/Wire included with the product
Circuit Breaker
See
Table 3 Shore Cable − 6 AWG Minimum
Customer provided
* Ring lugs on each end of the cable are
customer provided
Figure 5. Typical Wiring Connections
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
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Table 2. PM#t Connections from the Transformers to the Control Unit
Side
Connection
Wire
1
T1
Black
1
T2
Red
1
T3
Black with Red Stripe
1
T4
Red with Black Stripe
Case Ground
Ground
Green with Yellow Stripe
2
T1
Black
2
T2
Red
2
T3
Black with Red Stripe
2
T4
Red with Black Stripe
Table 3. Input Connections to the Transformers
Side
Connection
Wire
1
L1
Black
1
N
Neutral
1
L2
Red
2
L1
Black
2
N
Neutral
2
L2
Red
Table 4. Output Connections from the Control Unit
Side
Connection
Wire
1
L1
Black
1
N
Neutral
1
L2
Red
2
L1
Black
2
N
Neutral
2
L2
Red
Securing Covers
After all connections and terminations have been made, the terminal access cover on the transformer and the
front cover to the control unit should be re-installed using all hardware supplied.
Connect the BNC-BNC cables from the transformers to the control unit (see Figure 5).
Installing and Wiring the Remote Panel
The PM remote panel provides a visual display of the operating modes of the unit without having to go physically look at it. Up to two remote panels may be used with the PM. Contact the Charles Marine & Industrial
Group for more information on obtaining a second display unit if desired.
Follow the procedure below to connect the remote panel to the PM.
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Step
Action
1.
Using the template provided with the remote panel, carefully cut out the shaded portion in the desired mounting location.
2.
Using the template provided, drill 4 pilot holes for no.10 self-tapping screws.
3.
Route the cable to the PM control unit using care to avoid chafing and sharp bends.
4.
Strip back approximately 1/2-inch (13mm) of the outer cable jacket (not the wires).
5.
Insert the insulated conductors into the provided RJ45 plug assembly (see Figure 6) and crimp using the proper tool for CAT5 connectors.
6.
Insert the RJ45 plug from step 5 into the socket marked “IN” on the rear of the display. The PM
remote is provided with an additional socket “OUT” for the connection of a second display if desired.
7.
Insert the pre-installed RJ45-plug, provided on the 50-foot Cat 5 cable, into the RJ45-socket located on the right side of the PM control unit.
1 through 8 (see Wire Connection Chart)
Wire Connection Chart
1 2 3 4 5 6 78
Metal
Contacts (up)
RJ45 Plug
Cable
Jacket
Cat 5 Cable
(50 feet provided −
cut to desired lengrth)
Wires
Contactor
Color
1
Green/White
2
Green
3
Orange/White
4
Blue
5
Blue/White
6
Orange
7
Brown/White
8
Brown
Figure 6. Remote Panel RJ45 Plug (Front View) with Wire Connection Chart
Applying Power
Power should only be applied after all connections and terminations have been made and the terminal access
cover is secure. Plug in the shore power AC and turn on the appropriate circuit breakers to apply power. Refer to
the section on Proper Operation.
OPERATING THE PM#t
Proper Operation
The PM is designed to operate in the best possible mode without any user intervention. The PM will select
one of three possible modes of operation automatically: Normal, Separate or Single-Source (Shore Cable 1 or
Shore Cable 2). These modes of operation are described in Table 6 and more fully later in this document. Diagrams of the operating modes are shown in Figure 7. Boosting is available in all except the Manual Override
mode and discussed later in this document.
Note:
When operating in a single souce mode, the source selector switch must be in the position that corresponds to the shore cable being used.
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When power is first applied to Shore Cable 1 (assuming the PM has been disconnected from the power
source at least 15 seconds), there will be no output on the PM. The PM will wait for approximately 25
seconds for a second shore cable to be connected. During this time, the PM will display on the local and remote (if connected) displays the voltage found on the shore cables as referenced in Table 5.
Table 5. Control Unit & Remote Display Examples at Initial Startup
Note:
Typically the Remote Display shows the middle two lines of the Control Unit Display.
CONTROL UNIT
MEANING
− Initial Startup −
Src 1: Found 234V
Src 2: Found 230V
↵= Setup
1. Initial startup indicator.
2. Shore cable 1 connected, the display indicates the input voltage.
3. Shore cable 2 connected, the display indicates the input voltage.
4. Pressing the RETURN key will force the system to enter the setup menu.
REMOTE DISPLAY
Src 1: Found 234V
Src 2: Found 230V
1. Shore cable 1 connected, the display indicates the input voltage.
2. Shore cable 2 connected, the display indicates the input voltage.
CONTROL UNIT
MEANING
− Initial Startup −
Src 1: Found 234V
Src 2:
↵= Setup
1. Initial startup indicator.
2. Shore cable 1 connected, the display indicates the input voltage.
3. Shore cable 2 is not connected or below the minimum operating voltage.
4. Pressing the RETURN key will force the system to enter the setup menu.
REMOTE DISPLAY
1. Shore cable 1 connected, the display indicates the input voltage.
2. Shore cable 2 is not connected or below the minimum operating voltage.
Src 1: Found 234V
Src 2:
The system will begin to analyze power 25 seconds after the initial startup. If the voltage is above the minimum
required, the PM will automatically select one of the three automatic modes.
Table 6. Modes of Operation
Mode
Normal
Description
This mode is available when the 2 shore power AC input cables (Shore Cable 1 and
Shore Cable 2) are connected, functioning and either 0 degrees (in-phase) or 180 degrees (out-of-phase) when compared to each other. The AC load is shared between the
2 shore cables. The total AC amperage is the sum of Shore Cable 1 and Shore Cable
2, up to 100 amps at 240 volts (24,000 VA). (Figure 7)
Note:
Separate
This mode is selected by the PM when the 2 shore power AC cables (Shore Cable
1 and Shore Cable 2) are connected, but phasing cannot be corrected by the PM.
Shore Cable 1 and Shore Cable 2 remain isolated from each other and operate independently. The total AC amperage is up to 50 amps at 240 volts (12,000 VA) for each
output. (Figure 7)
Note:
12
The source selector switch, located in the manual override compartment, can
be set to either the “Source 1” or “Source 2” position.
The source selector switch, located in the manual override compartment, can
be set to either the “Source 1” or “Source 2” position.
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Mode
Description
Shore Cable 1
This mode is selected by the PM when AC shore power is connected to Shore
Cable 1 only, and the source selector switch located in the manual override compartment is set to the “Source 1” position. The total AC amperage of outputs 1 and 2 is 50
amps at 240 volts (12,000 VA). (Figure 7)
Note:
Shore Cable 2
When operating in Shore Cable 1 mode only, adding power to the second
shore cable will cause the unit to restart after a pre-set cycle, allowing the system to switch into Normal or Separate mode if the power is stable.
This mode is selected by the PM when AC shore power is connected to Shore
Cable 2 only, and the source selector switch located in the manual override compartment is set to the “Source 2” position. The total AC amperage of outputs 1 and 2 is 50
amps at 240 volts (12,000 VA). (Figure 7)
Note:
Off
When operating in Shore Cable 2 mode only, adding power to the first shore
cable will cause the unit to restart after a pre-set cycle, allowing the system to
switch into Normal or Separate mode if the power is stable.
Power is still being supplied to the PM, but the outputs are turned off. This mode is
only available for doing maintenance on the PM.
Shore
Cable 1
Shore
Cable 2
Isolation/ Output A
Boost
Isolation/ Output B
Boost
Normal Mode
Shore
Cable 1
Shore
Cable 2
Isolation/ Output A
Boost
Isolation/
Boost
Output B
Shore
Cable 1
Shore
Cable 2
Isolation/ Output A
Boost
Isolation/ Output B
Boost
Separate Mode
Shore
Cable 1
Shore
Cable 2
Source 1 Mode
Isolation/ Output A
Boost
Isolation/
Boost
Output B
Source 2 Mode
Figure 7. Modes of Operation Diagram
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EXPLANATION OF THE DISPLAY INFORMATION
In each of the modes of operation the PM is continually monitoring the system. The modes of operation are
summarized in Table 6 and illustrated in Figure 7.
Note:
The source selector switch, located in the manual override compartment, must be set to the mode that
corresponds to the desired mode of operation.
Normal Mode
When the PM is operating in a Normal mode the control unit will display the output similar to the one shown in
Table 7. The Remote display will rotate the output between the first line and the middle two lines.
Table 7. Control Unit & Remote Display Output in Normal Mode
Note:
The Remote Display unit alternates the display of information two lines at a time.
CONTROL UNIT
MEANING
Mode: Normal 14696VA
1:208V 35A BOOST
The system is running in Normal Mode. Output power is 14696 Volt−Amps.
Shore cable 1 input voltage is 208V. Current draw is 35 Amps. Output voltage
is boosted 15%.
Shore cable 2 input voltage is 206V. Current draw is 36 Amps. Output voltage
is boosted 15%. The input phase is 180 out of phase as compared to shore
cord 1.
Pressing the RETURN key will force the system to enter the setup menu.
2:206V 36A BOOST INV
↵= Setup
Separate Mode
When the PM is operating in a Separate mode the control unit will display the output similar to the one shown
in Table 8. The Remote display will rotate the output between the first line and the middle two lines.
Table 8. Control Unit & Remote Display Output in Separate Mode
Note:
The Remote Display unit alternates the display of information two lines at a time.
CONTROL UNIT
MEANING
Mode: Seprte 9540VA
The system is running in Separate Mode. Both cables, but not power, are combined. Output power is 9540 Volt-Amps.
Shore cable 1 input voltage is 240V. Current draw is 29 Amps.
Shore cable 2 input voltage is 215V. Current draw is 12 Amps. Output voltage
is boosted 15%.
Pressing the RETURN key will force the system to enter the setup menu.
1:240V 29A
2:215V 12A BOOST
↵= Setup
If the PM detects an incorrect shore power AC phase relationship, the PM will not combine the incoming
shore power AC sources. The PM’s outputs will be limited in amperes to their respective shore power inputs.
Separate Mode will continue until both shore power sources are disconnected. Once reconnected, the PM will
attempt to restart following the standard startup sequence.
If the PM has detected a fault on one side (example Shore Cable 1) it will disconnect the output power on the
side with the fault, wait for the source power to stabilize and restart the faulted side following a normal power sequence for a single side. The user is notified of the problem.
Source 1 and Source 2 Modes
When the PM is operating with a single shore cable, either Shore Cable 1 or Shore Cable 2, the control unit
will display the output similar to the one shown in Table 9. The Remote display will rotate the output between the
first line and the middle two lines.
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Table 9. Control Unit & Remote Display Output in Source 1 Mode
Note:
The Remote Display unit alternates the display of information two lines at a time.
CONTROL UNIT
MEANING
Mode: Src 1 11092VA
The system is running in Source 1 Mode. Single cable only. Output power is
11092 Volt-Amps.
Shore cable 1 input voltage is 236V. Current draw is 47 Amps.
Shore cable 2 input is not connected.
1:236V 47A
2:0V 0A NOT USED
HEAVY LOAD
↵= Setup
System warning about heavy load. Reduce load. Pressing the RETURN key
will force the system to enter the setup menu.
The system is operating on an incoming shore power supply. If an error occurs, the PM will disconnect the
power and attempt a restart in approximately 45 seconds.
Should a second incoming shore supply be detected, the system will shut down and restart. Power will be interrupted for a brief period of time during the restart. The system will analyze the shore supplies and switch to either
Normal or Separate mode as appropriate.
Off Mode (Only Available from the Setup Menu)
When the PM is operating in an Off mode the control unit will display the output similar to the one shown in
Table 10. The Remote display will rotate the output between the first line and the middle two lines.
Table 10. Control Unit & Remote Display Output in Off Mode
Note:
Typically the Remote Display shows the middle two lines of the Control Unit Display.
CONTROL UNIT
MEANING
Mode: Off
1:212V 0A
2:219V 0A
The system is turned off. There is no voltage on the output. Output power is 0.
Shore cable 1 input voltage is 212V. Current draw is 0 Amps.
Shore cable 2 input voltage is 219V. Current draw is 0 Amps.
Pressing the RETURN key will force the system to enter the setup menu.
0VA
↵= Setup
Isolation
All modes listed in Table 6 have 4000 VRMS isolation from the source side to the output side.
Compatibility
The PM will accept shore power AC input on either Shore Cable 1 or Shore Cable 2 within the following
range:
Voltage: 185 to 260 Volts AC (recommended maximum)
Frequency: 50 Hz or 60 Hz
Shore power Load: 0 to 50 Amps per input (55 Amps maximum)
Thermal Protection
The PM is equipped with a built-in thermal cutout that is embedded in the transformer windings. In the event
of sustained overload or overheating, this device will disable the transformer and shut down. When this occurs all
AC power being supplied from the transformer to the outputs will be disconnected and the manual override may
not function. A red light on the transformer will indicate that the unit has been disabled due to overheating.
Reduce all AC loads and allow the unit to cool down. The thermal cutout will automatically reset and the PM
will re-energize and resume normal operation.
Note:
It may take a significant amount of time for the PM#t to cool down depending on the ambient temperature.
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Voltage Boosting
All modes will automatically boost (with the exception of the Manual Override mode) the output voltage 15% over
the shore power AC voltage when it is less than optimal. This helps to prevent harm to voltage sensitive motors
and electronics on the boat. Voltage boosting is done automatically by the PM and follows these simple rules:
1. Upon power up, if the source voltage is less than 220 volts, the PM will boost the output voltage
by a factor of approximately 15% over the shore voltage.
2. If the shore voltage is or rises above 220 volts, the PM will remove the boost and provide a 1:1
shore voltage to output voltage ratio.
3. Should the shore voltage drop below 210 volts, the PM will again implement the boosting of the
output voltage by approximately 15% over the shore voltage.
Important notes about voltage boosting:
During voltage boosting, the usable current on the output side is reduced by 15% to prevent
overloading shore circuit breakers.
Shore Cable 1 voltage boosting is independent of Shore Cable 2 voltage boosting and vise versa.
When switching in and out of boost, the output voltage is not interrupted. However, the output voltage
may be reduced during the transition.
Input to output conversion is approximate. Due to varying loads, boost percentages vary slightly.
Power Interruptions and Recovery
The PM is designed with a momentary power black-out detector. If a momentary loss of power is
detected by the PM computer, the system will attempt a quick restart once the power situation
has passed. This feature minimizes the time the boat will experience a power loss once the dock
power has been restored.
If the power loss is greater than a few seconds, when the power returns, the system will restart using
the procedure described in section Proper Operation above.
Safety
The PM will display three types of warnings on the remote display to indicate to the user that the limits of the
system are being reached. The warnings are below.
Low Voltage warning: When the input voltage on the shore cables falls below 200 volts, the system
will display a warning message on the remote display informing the user of low shore cable voltage.
The user should consider disconnecting the shore cables to prevent damage to motors and other
systems on the boat.
High Voltage warning: When the input voltage on the shore cables rises above 252 volts, the system
will display a warning message on the remote display informing the user of high shore cable voltage.
The user should consider disconnecting the shore cables to prevent damage to motors and other
systems on the boat.
High Current warning: When the current draw on a shore cable reaches 46 amps, the system will
display a warning message on the remote display informing the user of excessive current draw. The
user should immediately reduce the load on the system by turning off some electrical appliances or
systems to prevent a system shutdown if the current rises to the shutoff limit.
The PM design is self-protecting and also protects the AC systems it powers. To do so, the PM has several safety features.
16
Low Source Voltage: If the shore power AC input voltage drops below 185 volts, The PM will shut
down. There is a built-in time delay to allow for large motor starting that may drag the voltage below
the threshold for a minimal period of time.
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Over Load Condition: If the PM detects an overload condition of 110% of the maximum current
draw of each input for an extended period of time, the system will shut down to protect the system’s
internal components. (i.e. 55 amps per shore cable or 110 amps total if both shore cables are
connected in Normal Mode)
Phasing: Normal Mode is only available when the Shore Cable 1 source and Shore Cable 2 source
are either 0 degrees or 180 degrees out of phase (typically, a source 180 degrees out of phase is due
to incorrect wiring on the shore). If the phasing of the source cannot be determined, or is not 0
degrees or 180 degrees out of phase, the PM will revert to Separate Mode.
External AC Voltage on the outputs: If the PM detects another AC power source (such as an AC
generator) on the outputs during startup, the PM will not allow shore power AC to be connected to
the outputs until the external AC voltage source is removed from the outputs. This feature prevents
potential damage to AC systems on the boat (such as an AC generator).
Extreme Temperature: Should the PM detect excess temperature internally (usually caused by
overloading), the PM will immediately shutdown and the red LED, “Over Temperature”, located on
the transformers will turn on.
Integrated wire protection: If the wiring becomes shorted between the transformer and the control unit
the circuit breakers located in the affected transformers will trip.
Incorrect wiring: If the wiring between the transformer and the control unit is incorrect or missing, the
PM will shut down and indicate the location of the fault when it attempts a system startup.
Isolation: 4000 VRMS isolation is designed to prevent a shock hazard from boat to shore.
Remote Display Warning Messages
Should any of the messages in Table 11 appear on the remote display, follow the suggested action and take precaution to avoid a recurrence of the condition.
Table 11. Remote Display Warning Messages
REMOTE DISPLAY
MEANING
Heavy Load WARNING
Reduce Load
1. The PM is close to maximum power. Consider reducing the load.
Shore Cable WARNING!
Voltage very low!
1. Shore cable voltage is nearing the minimum voltage needed for PM to
operate properly.
Shore Cable WARNING!
Voltage very high!
1. Shore cable voltage is nearing the recommended maximum voltage for
PM . Consider switching the a generator to prevent damage to other AC
systems on the boat.
**** FAILURE ****
**** Detected ****
1. Indicates the PM has stopped because of some reason. Often it’s due to
shore cable problems.
**** SYSTEM ****
**** HALTED ****
1. Indicates the PM has been turned off. Usually this is due to a second
shore cable that has been detected.
2nd Cable Detected
Waiting for restart
1. Cable has been plugged in and the system has detected it.
2. Waiting for cable to stabilize before restarting.
System will attempt
a restart in 15 sec
1. System will restart in the displayed number of seconds.
If any of the fault conditions triggers the PM to shutdown (other than over temperature), the local and remote
displays will describe the condition and the possible methods to remedy the problem. In addition, the system will
try to restart after approximately 45 seconds.
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Manual Override
Manual override is for emergency situations only, and is not intended for normal use. When operating in manual
mode, the user should pay particular attention to the input voltage and load on the system as not to damage the
PM or systems that rely on the PM for power. Of particular concern is extremely low or high input voltage
which may damage devices in the boat.
Table 12. Manual Override Mode
Mode
Description
Manual Override
To be used when the PM control unit has malfunctions or the operation of the
PM is necessary when voltage is outside of the normal operating limits. During
the operation in manual override, isolation is maintained.
Note:
Display voltage and boost not available.
Use the following procedure to enter the manual override mode.
Action
Step
1.
Disconnect all shore cables.
2.
Remove the manual override access cover on the PM control unit and switch the manual override switch to ”override mode”.
3.
Connect one or both of the shore cables to power. If connecting only a single cord, shore cable 1
must be connected to the power source. The system will operate as in SEPARATE mode described
earlier with the following exceptions:
a.
The computer and all displays are disengaged and off.
b.
c.
d.
Four LEDs located in the manual override switch compartment are off.
Boost is not available. The system only operates in non-boost mode.
All the computer controlled safety shutdown mechanisms are disabled
except over-temperature.
Use the following procedure to exit the manual override mode.
Action
Step
1.
Disconnect all shore cables.
2.
Flip the manual override switch on the PM control unit to automatic mode.
3.
Replace the manual override access cover.
POST INSTALLATION VERIFICATION
Post installation verification should be done after installing the PM and making all the final connections, or
after servicing the PM to verify that the connections in the boat and to the control unit and transformers are
functioning properly.
Note:
The remote display (and optional second display if present) should be installed prior to performing the
Post Installation Verification.
Voltage Boosting
During the testing sequence, depending on the shore power voltage, the PM may automatically turn on the
voltage boost mechanism. If this occurs, there may be a momentary reduction in the power and the remote display (if present) will indicate “BOOST” after the shore voltage. Likewise, if the voltage reaches a point where
boost is not needed, there may be a momentary reduction in the power as it is removed. The post installation verification is not intended to verify voltage boosting, and therefore the voltage boost mechanism should be ignored.
The PM’s voltage boosting function is set and pre-tested at the factory prior to shipment.
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Phase Inverting
During testing, depending on the phase of the shore power, the PM may invert the shore input that is 180
degrees out of phase. The remote display (if present) will show “INV”. The post installation verification is not intended to verify phase correction, and therefore this should be ignored. The PM’s phase inverting function is
set and pre-tested at the factory prior to shipment.
Digital Multi-Meters
Often a digital multi-meter will display stray voltage on a circuit that is open and not connected. The meter, because of its high input impedance, is actually detecting stray induced power on the open wire. This stray power is
not useable nor does it pose a danger to the user. However, this fact should be taken into consideration when
making measurements. Consult the user manual for the digital multi-meter to determine how to reduce
incorrect readings.
WARNING
It is possible to have back voltage on an unused shore cable if a wiring error has been made during
the installation of the PM#t. Take appropriate precautions to prevent injury during the testing. The
Post Installation Verification procedure checks for wiring errors, removing any chance of back voltage
on an unused shore cable.
Testing Procedure
Before beginning the testing procedure the following should be readily available:
Volt Meter capable of measuring 120/240VAC
Estimated 15 minutes time to perform tests
Required Connections: Two 50-amp 240VAC shore power inputs with phasing that is 0 or 180
degrees apart. Do not test with shore power that has 120 degree phasing (split phasing off, a
three-phase connection is not acceptable.)
At least 6 amps of load is available to load the PM down properly.
Follow the procedure below after the PM is installed and wired, shore power is available, and when sufficient
wiring of the AC circuits on the boat are complete to provide at least 6 amps of load. (i.e. lighting, motors, etc.).
Each mode of operation in this test procedure must be performed in the order shown, which are:
1. Source 1 Mode
2. Source 2 Mode
3. Normal Mode
4. Manual Override Mode
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1. Source 1 Mode
Use the following steps to perform the Post Installation Verification in Source 1 Mode.
Step
Action
Result
1.
Connect Shore Cable 1 (only) to the
supply voltage. Switch the source selector switch in the manual override
compartment to Source 1.
The remote display and the display on the control unit should
power up indicating that Source 1 is found along with the input
voltage. After approximately 25 seconds, the PM will engage the outputs. The remote display will indicate that Source
1 is functioning by showing the input voltage. The remote display will indicate that Source 2 is not used.
2.
Verify the following:
−The output on Side 1 is operating
−The output on Side 2 is operating
−Shore Cable 2 should have no power
Verification complete.
3.
Disconnect Shore Cable 1
Cable disconnected, no power.
4.
Verify the following:
The output on Side 1 is off
The output on Side 2 is off
Output on Side 1 and Side 2 is off.
2. Source 2 Mode
Use the following steps to perform the Post Installation Verification in Source 2 Mode.
Step
Action
Result
1.
Connect Shore Cable 2 (only) to the
supply voltage. Switch the source selector switch in the manual override
compartment to Source 2.
The remote display and the display on the control unit should
power up indicating that Source 2 is found along with the input
voltage. After approximately 25 seconds, the PM will engage the outputs. The remote display will indicate that Source
2 is functioning by showing the input voltage. The remote display will indicate that Source 1 is not used.
2.
Verify the following:
−The output on Side 1 is operating
−The output on Side 2 is operating
−Shore Cable 1 should have no power
Verification complete.
3.
Disconnect Shore Cable 2
Cable disconnected, no power.
4.
Verify the following:
The output on Side 1 is off
The output on Side 2 is off
Output on Side 1 and Side 2 is off.
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3. Normal Mode
Use the following steps to perform the Post Installation Verification in Normal Mode.
Step
Action
Result
1.
Connect Shore Cable 1 to the supply
voltage. Switch the source selector
switch in the manual override
compartment to Source 1.
The remote display and display on the control unit should power up indicating that Source 1 is found along with the input voltage. Within 25 seconds, connect Shore Cable 2 to the supply
voltage. The remote display should show that Source 1 and
Source 2 have been found along with the input voltage. After a
brief time delay, the PM will engage the outputs. The remote display will indicate that Source 1 and Source 2 are functioning by showing the input voltage.
2.
Verify the following:
−The output on Side 1 is operating
−The output on Side 2 is operating
Verification complete.
3.
Disconnect Shore Cable 2
Cable disconnected, no power.
4.
Verify the following:
−The output on Side 1 is off
−The output on Side 2 is off
−Shore Cable 2 has no power
Verification complete.
−The remote display and local display
on the control unit indicates a fault
condition
5.
Disconnect Shore Cable 1
Shore Cable is disconnected.
4. Manual Override Mode
Use the following steps to perform the Post Installation Verification in Manual Override Mode.
WARNING
Both Shore Cables must be off (non-powered) prior to switching the manual override switch, or system
damage may occur.
Step
Action
Result
1.
Uncover the PM and toggle the
Manual Override switch, located on
the lower right front of the control unit,
to “Manual”.
The PM is in Manual Override mode.
2.
Connect Shore Cable 1 and Shore
Cable 2 to the supply voltage
The PM will engage a select number of relays to provide
“limp home” power only. Neither the main computer nor the
remote display will power up. Boost is not available in manual
override mode.
3.
Verify the following:
−The 4 LED’s in the manual override
switch compartment are off
−The output on Side 1 is operating
Verification complete.
−The output on Side 2 is operating
4.
Disconnect Shore Cable 1 and Shore
Cable 2
Shore cables are disconnected.
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Action
Result
5.
Toggle the manual override switch
back to automatic mode
The PM resumes automatic mode.
6.
Replace the cover
The PM is intact.
MAINTAINING THE PM#t
WARNING − HIGH VOLTAGE
To avoid serious injury or death from high voltage electrical shock, disconnect the AC shore power
before attempting any maintenance or cleaning.
No adjustment or maintenance is required for the PM other than periodic cleaning of the outside cabinet with
a dry cloth and inspecting all connections for tightness and corrosion by a qualified service person.
WARRANTY AND SERVICE
Warranty
The CHARLES Marine & Industrial Group warrants the PM will be free from defects in materials and workmanship which cause mechanical failure for one (1) year, as set forth in the Limited Warranty. Review the enclosed warranty carefully for information on what is covered by its terms. Complete and return the warranty registration card within ten (10) days of purchase to establish proof of ownership and validate the warranty coverage.
You must provide notice of any alleged defect in material or workmanship within thirty (30) days of discovering the
problem, and within the warranty period. Follow the procedure outlined below to obtain warranty service.
Service and Repair
If the unit fails to operate properly after following all the instructions in the manual, or if the PM requires service, contact the Service Center directly to purchase a Service and Repair manual.
Note:
Do not attempt to service the PM#t . Contact the Service Center.
Service Center and Correspondence
To contact the Service Center via telephone directly:
800.830.6523 (Voice)
217.932.2473 (FAX)
Correspondence can be sent to Corporate Headquarters via the address below:
Charles Industries, Ltd.
Marine & Industrial Group
5600 Apollo Drive
Rolling Meadows, IL 60008-4049
USA
www.charlesindustries.com
Correspondence can be sent to the Service & Repair Center via the address below:
Charles Industries, Ltd.
Marine & Industrial Group
400 S.E. 8th Street
Casey, IL 62420-2054
USA
22
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
LT-PM3201-1
Issue 1 Print 3
SPECIFICATIONS
The operating specifications of the PM are listed in Table 13.
Table 13. PM#t Operating Specifications
Specification
Feature
Total Power
24 KVA
Power per Shore cable
12 KVA
Nominal Input Voltage
240 VAC
Minimum Input Voltage
185 VAC
Maximum Input Current
100 Amps (50 Amps per cord)
Operating Frequency
50/60 Hz
Nominal Output Voltage
240 VAC
Maximum Output Current
100 Amps (50 amps with a
single shore cable) Non-boost
mode)
Ambient Operating Temperature
−25° C to +55° C
(−13° F to +131° F)
The physical specifications of the PM control unit and transformer are listed in Table 14 and Table 15.
Control Unit
Table 14. PM#t Control Unit − Physical Specifications
Specification
Feature
Approximate Weight
62 pounds (28 kilograms)
Length
18.0 inches (45.7 centimeters)
Width (including mounting feet)
15 inches (38.1 centimeters)
Width (excluding the mounting feet)
13.0 inches (33.0 centimeters)
Height (with the mounting feet)
12.0 inches (30.5 centimeters)
Air space around unit
2 inches on all sides
Control Unit Display
4 line X 20 character
Keypad
12 keys
Transformer
Table 15. PM#t Transformer − Physical Specifications
Feature
Specification
Approximate Weight
244 pounds (111 kilograms)
Length
18.0 inches (45.7 centimeters)
Width (including mounting feet)
15 inches (38.1 centimeters)
Width (excluding the mounting feet)
13.0 inches (33.0 centimeters)
Height (with the mounting feet)
12.0 inches (30.5 centimeters)
Air space around unit
2 inches on the back and top. 4
inches on the sides.
The system specifications of the PM are as follows.
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
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LT-PM3201-1
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The distance between the control unit and transformer must not exceed 50 feet
A high-speed microprocessor controls the Control Unit
A keyboard is located on the front of the control unit for diagnostics
An RJ-11C Telephone interface is available for remote debugging (United States compatible
telephone systems only)
Emergency operational mode (Manual Override).
For the remote display units:
A maximum of two remote display units can be connected to the system
One display unit is provided, the second is optional.
The second remote display unit may be up to 50 feet from the first display unit
Cable is provided.
The power and control cabling with the PM includes the following:
The cabling required between the control unit and transformer is provided
Up to 100-foot 5 conductor 6 AWG jacketed cable
(2) BNC-BNC control cables
All strain reliefs are included.
The customer is required to provide:
3 conductor minimum 6 AWG for input connection to power source (recommended)
3 conductor minimum 4 AWG for output connection to distribution source (recommended)
The PM meets the following regulatory specifications.
24
Marine UL
CE
FCC Class A: This device complies with part 15 of the FCC Rules. Operation is subject to the
following two conditions: 1.) This device may not cause harmful interference, and 2.) this device must
accept any interference received, including interference that may cause undesired operation.
FCC Telephone ID: US: DWEMM00BXE2430G
Ringer Equivalent: 03B
Assembly location: United States of America
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
LT-PM3201-1
Issue 1 Print 3
APPENDIX A − SENSORS
Current Sensor
1C
T1
Variable
Voltage Sensor
1A
Fixed
Voltage Sensor
1E
T2
Fixed
Voltage Sensor
1F
Current Sensor
1D
Side 1
T3
T4
Case Ground
(Boat Ground)
L1
N
Side 1
L2
Fixed
Voltage Sensor
1B
4 Position Terminal
Block − 50 Amp Service
Capability
(IN from Transformer)
PM
Central
Switching
System
3 Position Terminal
Block − 100 Amp
Service Capability
(OUT to Boat)
Current Sensor
2C
T1
Variable
Voltage Sensor
2A
Fixed
Voltage Sensor
2E
T2
Fixed
Voltage Sensor
2F
Current Sensor
2D
Side 2
T3
T4
L1
N
Side 2
L2
Fixed
Voltage Sensor
2B
Sensor
Type
1A
Variable Voltage Sensor (measures voltage level)
1B
Fixed Voltage Sensor (only checks for voltage present)
1C
Variable Current Sensor (measures current level)
1D
Variable Current Sensor (measures current level)
1E
Fixed Voltage Sensor (only checks for voltage present)
1F
Fixed Voltage Sensor (only checks for voltage present)
2A
Variable Voltage Sensor (measures voltage level)
2B
Fixed Voltage Sensor (only checks for voltage present)
2C
Variable Current Sensor (measures current level)
2D
Variable Current Sensor (measures current level)
2E
Fixed Voltage Sensor (only checks for voltage present)
2F
Fixed Voltage Sensor (only checks for voltage present)
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
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LT-PM3201-1
Issue 1 Print 3
Sensor
26
Phase Relationship
1A
Reference for 1B,2A
1B
Phase Compared to 1A
1C
None
1D
None
1E
Reference for 1F
1F
Phase compared to 1E
2A
Reference for 2B, Phase Compared to 1A
2B
Phase Compared to 2A
2C
None
2D
None
2E
Reference for 2F
2F
Phase compared to 2E
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
LT-PM3201-1
Issue 1 Print 3
APPENDIX B − SAMPLE OF NON−VOLATILE ERROR MEMORY
CONTROL UNIT
MEANING
Last Error #1 ↵= Exit
Last Mode: Normal
Err: Output
Input Phase: 180 deg
Error report for most recent shutdown (page 1).
Operating in NORMAL mode prior to shutdown.
Cause of the shutdown was an output voltage error.
Input voltage phase is inverted at shutdown.
Last Error #1 ↵= Exit
1: 195V MAX 249 MIN 192V
Error report for most recent shutdown (page 2).
Shore cable 1 Shutdown at 195 volts. Highest voltage recorded is 249 volts
during the time the system was running. Lowest voltage is 192 volts.
Sensor 1A
2: 208V MAX 245 MIN 200v
Shore cable 2 shutdown at 208 volts. Highest voltage recorded is 245 volts
during the time the system was running. Lowest voltage is 200 volts.
Sensor 2A
At the time of shutdown Shore Cable 1, Current Sensor 1C is 20 Amps.
Shore Cable 2, Current Sensor 1D, is 21 Amps. Shore Cable 2, Current
Sensor 2C is 19 Amps. Shore Cable 2, Current Sensor 2D is 18 Amps.
1: 20 21 2: 19 18 Amps
Last Error
Sensor 1B:
Sensor 2B:
Sensor 1E:
#1 ↵= Exit
Present
Reversed
Missing
Error report for most recent shutdown (page 3).
Sensor reporting voltage.
Sensor reporting voltage but with inverted phasing.
Sensor reporting no voltage.
Last Error
Sensor 1F:
Sensor 2E:
Sensor 2F:
#1 ↵= Exit
Missing
Present
Missing
Error report for most recent shutdown (page 4).
Sensor reporting no voltage.
Sensor reporting voltage.
Sensor reporting no voltage.
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
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APPENDIX C − Troubleshooting
TROUBLESHOOTING
If there is a problem with the PM, first check all connections and retest. If all connections are good, see if the
problem is covered in Table 16. If the problem is not covered in Table 16, or if the PM still malfunctions after
performing the solution given, contact the Charles Marine & Industrial Group for technical assistance.
Table 16. Troubleshooting Suggestions
Item
1.
Condition
No display on the
PM controller.
Solution
If the green LED indicator is NOT illuminated on either of the PM
transformers:
1. Check the dockside circuit breakers
2. Check the inlet circuit breakers.
If the green LED indicator IS illuminated on both PM transformers:
1. Check the PM transformer circuit breaker.
2. Check the PM controller manual override switch.
3. Check the wiring polarity between each transformer and
PM controller.
4. Remove the PM controller cover and check all connections to
the control PC board assembly.
If only one AC shore power cord is used and the green LED indicator
IS illuminated on only one of the PM transformers:
1. Check the PM transformer circuit breaker
2. Check the PM controller position of the shore cable source
switch.
Check the PM controller manual override switch. Set in Auto mode.
2.
The dockside circuit breaker
“trips”
If the dockside circuit breaker immediately trips:
1. Check the plug for physical damage.
2. Turn off the inlet circuit breaker and attempt to turn on the
dockside circuit breaker.
If the dockside circuit breaker still trips then the cord-set may need repair or replacement.
If the dockside circuit breaker does not trip, then turn on the inlet circuit
breaker.
If the circuit breaker immediately trips again, check the PM transformers and input wiring for physical damage.
If the dockside circuit breaker trips shortly after the PM system is
powered up:
1. Ensure that both shore power cords are connected and all
breakers are on.
2. Reduce the AC loads applied on the boat, then re-apply power.
3.
The PM isn’t boosting the
incoming shore power AC.
4.
There is no AC power on the
Check the AC circuit breaker that must be installed after each of the
boat but the PM display in- PM outputs.
dicates there is power available.
28
The shore power is within the normal non-boost range.
Boost is not available in Manual Override mode.
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
LT-PM3201-1
Issue 1 Print 3
Item
Condition
Solution
5.
Shore power AC is available
but the PM will not enable
the outputs.
The PM will not enable the outputs if there is insufficient shore
power AC.
The output load is exceeding limits. Reduce the load.
An external AC power source is detected. Turn off all powering systems (i.e. generator) on the boat before enabling the PM.
System is waiting in a reset timeout. Wait 45 seconds for a reset
System has overheated due to overload condition. Wait for the system
to cool off. This may take some time.
6.
The PM was operating but
stopped.
Check to see if a failure is being displayed and use that as a guide to
correct the error.
Check the circuit breakers and transformers.
If there is no display available, check the shore power AC circuit breaker(s) and/or the required inlet breaker on the boat.
7.
The circuit breakers that supply shore side AC power to
the PM are tripping.
The PM may be in the Separate Mode or Single Mode, thus reducing each AC output bus to a maximum of 12KVA(50Amps) or less.
The combined total of AC amps demanded may be exceeding the
PM’s current limits and the available shore side AC current. Reduce
the amount of amps required (turn off some of the AC powered devices) and reset the affected shore side AC breakers.
8.
The Remote Display does not
function.
The Remote Display is not connected to the PM.
If the remote display was just connected, wait 30 seconds for the system to acknowledge the display.
Check all connections for a loose wire.
Incorrectly wired. Input to the remote display is the center connector.
The side connector is output to an additional remote display.
More than 2 remote displays are daisy-chained. The system is designed for up to a maximum of 2 remote displays.
The remote display should have no more than 50-feet of cable.
9.
The PM is operating in
Separate mode.
The PM operates in Separate mode whenever the phases of the
power are incompatible.
The shore power is from a 3-phase system.
10.
The power “dims” when going
into/out of boost.
Normal condition.
11.
The PM will not power up
with only a single shore cable
connected.
Check that the source selector switch, in the manual override compartment, is set to the appropriate source.
Check the breakers in the transformers.
The transformers have overheated. Allow sufficient time to cool.
12.
One of the over-temperature
You must wait for the transformers to cool down before the system reindicators on the PM trans- starts. The cooling period might take some time.
formers are on.
Ensure there is adequate airflow around the transformer.
Reduce the load on the PM by turning off non−essential systems in
the boat.
13.
The circuit breakers in the
transformers keep tripping.
Generally this is caused by a faulty wiring system either between the
PM transformers and the control unit or in the boat itself. Have the
wiring system checked.
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
29
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Issue 1 Print 3
Setup and Diagnostic Systems
The PM is equipped with an on board setup and diagnostic system that will facilitate trouble shooting of the
system.
CAUTION
Some parts of the diagnostic system require that all systems that the PM#t is providing power to be
turned off. Take this into consideration when using the diagnostic systems.
R
www.charlesinductries.com
− Initial Startup −
Src 1: Found 234V
Src 2: Found 230V
↵= Setup
PM
3
1
2
3
4
5
6
7
8
9
MASTER CONTROL SYSTEM
Figure 8. Display Panel on the Control Unit
The keys used for the diagnostic system and their meaning are described below.
Description
Key
1−9
Option Keys: Even though an option may not be listed on the screen at the current
time, the key is still valid.
Example: The SETUP menu has 9 options. Only a few are shown on the screen at one
time, yet all are valid entries. Note: some menu screens do not use all 9 option keys.
Scroll Keys ( ↑,↓ )
Moves the display up or down through the options and messages.
Return Key ( ↵ )
Return to the previous menu or enter the initial setup.
To enter the diagnostic system, do the following.
Action
Step
1.
Result
Press ↵ on the keypad
The first few lines of the setup menu will be displayed.
Setup Menus
The Setup Menu is primarily used for setup and diagnostic systems. The setup menu has the available options
listed below.
Key
Option
Description
1
Power Down
Turns off the output power.
2
Automatic mode
Starts the automatic startup sequence for powering the system. Depending on
the cables connected and the phasing, this may either be Normal mode, Separate mode or Shore Cable 1 mode.
3
Separate mode
Forces the system to start in Separate mode. In this mode, shore cable 1 supplies output 1. Shore cable 2 supplies output 2. Shore cable 1 and shore
cable 2 are not interconnected.
4
Source 1 mode
Forces the system to start using only shore cable 1.
Note:
30
Selecting this mode disables the “restart if a second shore cable is
found.”
Charles Industries, Ltd. All rights reserved. Printed in the United States of America.
LT-PM3201-1
Issue 1 Print 3
Key
5
Option
Source 2 mode
Description
Forces the system to start using only shore cable 2.
Note:
6
System Diagnostics
Selecting this mode disables the “restart if a second shore cable is
found.”
Runs a self test on the PM to assist in determining problems. The test will
halt on the first error found, display the suspected problem and allowing for
troubleshooting of the system. To run this test, the system must be in Power
Down mode, both shore cables connected, and all systems that the PM
supplies with power disconnected. Generally, this is simply accomplished by
turning off the breakers in the boat’s distribution panel.
Note:
Using this option could possibly damage systems connected to the
PM#t. For this reason it is extremely important for the PM#t’s output
to be disconnected from all loads. This is explained in the menu listing.
Press the arrow keys to read all the warnings in this menu prior to engaging the diagnostic routines.
7
Sensors display
All the PM sensors are displayed along with their relationships for phase
control. Use the arrow keys to scroll through the sensors. Appendix A shows
the location of the sensors in the system. To obtain the best sensor information, the system should be in Normal mode or Separate mode, but is not required.
8
Relay Test
This option consists of two menus that allows the user to individually select
each relay one at a time. Only one relay may be energized at a time and there
is a slight delay after selecting a relay to energize so the system may turn off
any relays that have been previously turned on. Use the arrow keys to scroll
through the list. The system must be in Power Down mode to use this option.
The boost relays are in the transformer modules. Boost relays are special as
both relays in a single box are on for about half of a second. Exiting this menu
turns off all relays in the control unit and returns the system to a non-boost
mode.
9
Next menu
Switches to setup menu 2
↵
Exit
Exits Setup Menu 1 and returns the displays to their normal operation.
Setup menu 2 has the following options available.
Mode
Option
Description
1
Display Last Error
Each time the system successfully starts, it records the mode the system
started up with. In addition, if an error occurs (other than loss of power on
shore cable 1), the system records important information about the system into
non-volatile memory. Each time a record is made, the previous error is pushed
down one storage slot. So error in slot 1 is moved to slot 2, and slot 2 is
moved to slot 3, etc. The information in the last slot is lost.
Reference Appendix B for a representation of errors. The arrow keys can be
used to scroll through the information while viewing.
When the system is successfully running, the first slot only shows the mode the
system is in. All the other information is invalid.
After the system is reset to factory defaults, the mode of operation is reported
as Power Down on all used error slots.
2
Factory Defaults
Selecting this option and following the on−screen display will return the system
to factory defaults. It will also erase all the non−volatile error memory. Use
with caution. Generally, this option is not needed.
3
Version
Displays the version of the PM’s software.
9
Previous menu
Switches to setup menu 1
↵
Exit
Exits Setup Menu 2 and returns the displays to their normal operation.
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Modem Interface
The PM is equipped with a modem interface to allow remote operation and diagnostics of the PM. When
the modem interface is active, a remote user can operate the PM as if the user is pressing the keys on the
keypad. In addition, the remote user can see the local and remote displays on their computer terminal.
A low speed, 2400 baud modem is used (2400 baud, 8 bits, no parity, 1 stop bit) is used to provide the remote
connection. The low speed modem has the distinct advantage of being able to connect when telephone lines are
less than perfect.
CAUTION
The modem interface is only designed for systems compatible with telephone systems used in the
United States. Using the modem with any other type of telephone system is at the users own risk.
Note:
It is highly recommended that all answering machines, computers, or faxes be disconnected from the
telephone line as they may interfere with the operation of the PM#t modem interface if they answer the
telephone at the same time as the PM#t.
To access the modem port, remove the cover label ”Telephone Interface” and plug a standard phone cable into
the system. Provide the remote user the telephone number of that phone line being used to connect with the
PM. The remote user will then call the PM. The PM will act similar to an answering machine, answering the phone on the first or second ring. After about 30 seconds, the modems will connect and the remote user
can operate the system.
The information on the remote user’s system is updated every 3 to 4 seconds. Since the system uses a low
speed modem, the update is somewhat delayed. However, this does not affect the performance of the system.
The keyboard on the remote users computer becomes the keypad on the system. The following computer keys
translate to the keypad.
PM#t Keypad
Remote Computer Keys
1−9
1−9
↑
u
↓
d
↵
Enter
Note:
Remote computer entry is not case sensitive.
Pressing either the PM’s keypad or the computers keyboard accomplish the same effect and update both displays. In addition, selecting functions on the PM’s keypad will cause the display on the remote computer to
update.
The remote user may disconnect the connection by hanging up the phone.
WARNING
For security reasons, it is generally not a good idea to keep the PM#t connected to the phone line
any longer than is needed to remotely operate the system.
32
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