Mission Critical NEWMAR Sentinel User manual

POWERING THE NETWORK
www.poweringthenetwork.com | 800.854.3906
Costa Mesa, CA
Sentinel Power System
DC Power System
Installation / Operation Manual

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TABLE OF CONTENTS
1. ADMONISHMENTS 2
2. SAFETY 2
3. RECEIVING INSTRUCTIONS 3
3.1. Package Inspection 3
3.2. Equipment Inspection 3
3.3. Handling 3
3.4. Identification Labels 3
4. SCOPE 3
5. SYSTEM OVERVIEW 4
5.1. Power System 4
5.2. Physical Dimensions and Weights 4
5.3. Alarms and Status Indicators 5
5.4. EM4x Features 5
5.5. Rectifier Modules 6
6. INSTALLATIONS 7
6.1. Unpacking & Installing in Frame 8
6.2. AC Cabling 8
6.3. Upstream Over-current Protection 8
6.4. Discrimination 8
6.5. DC Cabling 8
6.5.1. Terminal Block Labeling 8
6.5.2. Terminal Block Max Wire Size/Recommended Torque Specification 9
6.6. Alarm/Ancillary Cabling 11
6.7. Temperature Sensors 11
7. ENERGY MANAGER CONNECTIVITY AND THE WEB UI 11
7.1. Access Levels 11
7.2. Ethernet Port Connection 12
7.3. USB Connection 12
7.4. Energy manager & IO PCB Alarm Output Configuration 13
7.5. EM4x LED Alarm Mappings 13
7.6. EM4x Main PCB Alarm Mappings 14
7.7. EM4x Main PCB Digital Input Alarm Mappings 15
7.8. Circuit Breaker Fail Monitoring 15
8. LVD OPERATION 15
9. MAINTENANCE 16
9.1. System 16
9.2. EM4x Controller 16
9.3. Rectifiers and Converters 17
9.4. Batteries 17
9.5. Ventilation Maintenance 17
10. TROUBLE-SHOOTING AND SERVICING 17
10.1. Servicing 17
11. ESSENTIAL SYSTEM SET-UP PARAMETERS 18
11.1. Systems with Lead Acid Batteries 18
11.2. DC System Lead Acid Battery Commissioning Checklist 21
11.3. Systems with Lithium Batteries 23
Appendix 1 AC INPUT TRANSIENT PROTECTION 24
Appendix 2 RECTIFIER INPUT FUSE CURVES 27
Appendix 3 System Wiring Diagrams 29

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1. ADMONISHMENTS
The admonishments are the symbols and wording used in this manual to alert readers to specific dangers
and instructions. The meanings of the various admonishments are explained as follows:
Warning = risk to life or personal injury and equipment damage
Caution = risk of equipment damage.
= risk of electrical shock potentially causing death or injury.
= alert of risk potentially causing death or injury.
= risk of burn injury from hot surfaces
= an alert that must be understood and undertaken.
= instruction of mandatory reading of product manual.
= risk of electrostatic damage to components. Proper
precautions must be taken.
= access for children prohibited.
= restricted access area.
= tip over hazard.
2. SAFETY
All installation and maintenance must be carried out by suitably qualified personnel.
For your protection, the product manual should be read and thoroughly understood
before unpacking, installing, and using the equipment.
The energy manager contains static sensitive components that require careful handling
and proper precautions to be taken. A grounding strap should be worn.
The equipment is intended only for use in a restricted access area. The equipment is
not suitable f
or use in locations where children are likely to be present.

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AC SURGE SUPPRESSION - If these systems are used in outdoor cabinet
applications, the fitment of a
Type 2 AC Surge Suppression Device is mandatory (see
Appendix
2). If a Type 2 SPD is NOT fitted, the warranty is void.
3. RECEIVING INSTRUCTIONS
Newmar provides all equipment to the delivering carrier securely packed and in perfect condition. Upon acceptance of the
package from Newmar, the delivering carrier assumes responsibility for its safe arrival. Once the equipment is received, it is
the recipient’s responsibility to document any damage the carrier may have inflicted, and to file the claim promptly and
accurately.
NOTE: the period to make a claim against damage by a transport carrier can be short, a matter of days, and varies by
transport method, the transport contract, and local laws.
3.1. Package Inspection
Examine the shipping crate or carton for any visible damage: punctures, dents, and any other signs of possible internal
damage.
Describe any damage or shortage on the receiving documents and have the carrier sign their full name.
3.2. Equipment Inspection
Open the crate or carton and inspect the contents for damages. While unpacking, be careful not to discard any equipment,
parts, or manuals. If any damage is detected, call the delivering carrier to determine the appropriate action. They may
require an inspection.
NOTE: Save all the shipping materials for the inspector to see.
After the inspection has been made, if damage has been found, contact Newmar. We will determine if the equipment should
be returned to our plant for repair or if some other method would be more expeditious. If it is determined that the equipment
should be returned to us, ask the delivering carrier to send the packages back at the delivering carrier’s expense.
If repair is necessary, we will invoice you for the repair so that you may submit the bill to the delivering carrier with your
claim forms.
It is your responsibility to file a claim with the delivering carrier. Failure to properly file a claim for shipping damages may void
warranty service for any physical damages later reported for repair.
3.3. Handling
Handle the equipment with care. Do not drop or lean on front panel or connector. Keep away from moisture.
3.4. Identification Labels
Model number and serial number are clearly marked on all equipment. Please refer to these numbers in all correspondence
with Newmar. Ideally provide a photograph of the product label for reference.
4. SCOPE
This manual covers essential information for the installation and commissioning of the 1USentinel Rectifier
System
System set-up for the rectifiers, alarms etc., are provided in separate manuals for the SM35/6supervisory module and
RM648 rectifier.
All installation and maintenance must be carried out by suitably qualified personnel.
Note 1: The 1U Sentinel Rectifier System is factory default set with positive earthing (fixed). Anoption is available for
isolating DC output from AC earth – see section 7.2 ‘Isolated System’ for information.
Note 2: Please understand the following nomenclature applies:“Live” = -48 VDC
“Common” = +48 VDC

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5. SYSTEM OVERVIEW
The Sentinel Rectifier System can hold three rectifier modules and have a maximum poweroutput of 1.8kW, producing
a maximum current output of 33.3A at 54 VDC. Peak current is 37.5A @ 48 VDC.
The system is intended to be a complete power system in a box, so no connections need to bemade internally. AC
connection is via rear exiting lead with all the DC (Load and Battery) connections are made at the front of the unit. Alarm
connections are accessible from the front.
5.1. Power System
The system is designed to be extremely simple to install and set up.The following is a
summary of the system:
-Up to 3 RM648 series rectifiers - may be packaged separately
-SM36 supervisory module (fully integrated in the system)
-Battery Low Voltage Disconnect fitted as standard (80A rating).
-Up to 2*x 30A Battery Circuit Breaker, this may be specified as different values at time oforder.
-Up to 4x Load Circuit Breaker, this may be specified as different values (6, 10, 15, 20 or30A) at time of order.
-Single phase or split phase lead supplied for input termination (phase, neutral and earth orphase, phase, and
earth), 110 or 220 VAC.
-Front or rear cable access
5.2. Physical Dimensions and Weight
Model
Sentinel
Depth (Total)
280mm/11”
Width (Total)
483mm (19” mount)
Height
44.5mm (1U)
Weight without rectifiers
3.6kg/8 lbs.
Weight with max. rectifiers
5.6kg/12.3 lbs.

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5.3. Alarms and Status Indicators
•Status LEDs:
◦Red LED Urgent alarm state.
◦Orange LED Non-Urgent alarm
◦Green LED DC power is connected to the unit; Energy Manager is functioning
NOTE:The LED mapping can be user modified.
•The energy manager is fitted with an audible buzzer which can be configured to alert to any alarm depending on the alarm
mapping.
NOTE:To disable the buzzer when active, tap any button.
•Micro-USB Connector: can independently power the EM4x and provides access to the Web UI
Note: when there are multiple alarms raised the Active Alarm display cycles through the list. The complete list can be
viewed by tapping Alarms.
•Tap the buttons to navigate through the menus.
Note: the EM4x-01 has the option to PIN lock function change through the front screen interface. See the EM4x manual
for details.
5.4. EM4x Features
The EM4x microcontroller-based DC system energy manager provides the control and monitoring functions for all Newmar
Energy’s power systems. With an appropriate communications connection third party lithium battery can also be managed.
The EM4x monitors all power system conditions including DC voltage, rectifier current, battery current, battery temperature,
distribution failure and battery pack status. It has an in-built web-based configurator allowing setup of system parameters,
monitoring, updating and download of logs using a web browser as well as a front panel interface through which key
parameters are also configurable. Visual notification of alarm conditions is given by LEDs and a display mounted on the front
of the EM4x, with remote notification being enabled by relay contacts, RS232, or TCP/IP (using SNMP).
The EM4x utilizes a USB communications port which allows for local monitoring of system operations as well as pre-
commission and power down configuration of the Web UI.
The EM4x also incorporates the following features:
• Support for third-party external batteries, both lead-acid and lithium based
• Support for AC-DC rectifiers (24V and 48V Outputs)
• Network connectivity (web access)
• System voltage metering for primary system DC supply. (e.g., 48V primary DC output)
• Load, battery and rectifier current metering and alarms
• Active rectifier current share
• Automatic system voltage control
• Effectively unlimited alarm thresholds as standard, for use with multiple DC outputs
• Advanced monitoring, display and logging of battery packs, and system performance data
• Advanced hybrid site control and monitoring with patented anti-stall feature for generators.
• Phase balance controls for multi-phase and single-phase AC input management
• Sophisticated programmable logic control
• For lead-acid external batteries -
◦Battery and room temperature metering and alarms (when fitted with optional temperature sensors)
◦Temperature compensation of float voltage (when fitted with optional temperature sensors)
◦Manual equalize charging to prolong the life of the batteries
◦Periodic equalize charging to prolong the life of the batteries
◦Fast charging after battery discharge
◦Battery capacity remaining indication
◦Battery testing facility

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◦Battery current limit
• Six user defined General Purpose Inputs (“GPIPs”) which can be software configured as either digital or analogue inputs*
(up to 10 may be made available under special circumstances)
• Six relay outputs*
5.5. Rectifier Modules
6. Installations
WARNING - All upstream AC, Load and Battery breakers must be switched OFF prior to installation. The
system must be completely de-powered.
All circuit breakers in a Newmar power system must be in their OFF position prior to installation.
WARNING - Use extreme care when fitting batteries & their connections. Remove all
conductive materials from yourself such as watches, jewelry, and rings prior to commencing the
installation. DO NOT short terminals when working on them.
CAUTION - Avoid resting cables on sharp edges (cold-creep)
The energy manager contains static sensitive components that require careful handling and proper
precautions to be taken. A grounding strap should be worn.
6.1. Unpacking and Installing in Frame
Upon unpacking, check that the unit is not damaged, and that you have the required number ofrectifiers.
Remove the transport bracket supplied attached to the top of the system.
The unit fits into a standard 19” rack. Use the mounting hardware (#12-24 or #10-32) provided with the rack.
Please note the complete system weight is 12.3 lbs. Ensure the 19” mounting rails can withstand mounting of the system. The
supplied transport bracket can be utilized in cabinets with 19” mounts at the rear of the cabinet to increase the system
mounting rigidity if required.
6.2. AC Cabling
The AC cables are clearly labelled at the rear of the system (see Fig 3). The AC cable provided is 14AWG cables and a
115 VAC/20 Amp NEMA 5-20 plug is fitted.
AC connection internally is via .25” QC tabs. Longer cables can be easily fitted by replacing theexisting cable. Ensure that
the AC color coding is correct for the country of fitment:
Status LEDs
Lock/Unlock
Fan Cooled

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Connections should allow for a maximum single phase AC supply of 16.5A (@ 110VAC) (seenext section).
The AC earth is internally bonded to the system chassis.
DC Common (+48VDC) is connected to the AC earth through the placement of the PCB connecting the backplane to the
distribution. Alignment depends on required earthing connection. Please see the DC earthing section of this manual
(Section 7) for more detail.
Note: Please refer Appendix 2 for AC Input Transient Protection.
6.3. Upstream Over-current Protection
There are two considerations to consider when selecting an appropriate fuse/circuitbreaker.
-The upstream protection should protect the downstream cable from overload situations.
-Discrimination should be maintained with the downstream device fuses.
Cable Rating
The maximum current drawn by the DC power system is 16.5A (5.5A per rectifier at a minimum input voltage of 110VAC
and full output power). The upstream protection device must be able tosupply this load under all conditions without tripping.
Therefore, typically at least 20% headroom is allowed for in the protection device, making its minimum rating 20A.
Note: The current carrying capacity of cables is dependent on the type of cable used. Pleasecheck with your local
supplier and local regulations for appropriate sizing.
For convenience, the system is supplied with 6 feet long, 3-core, 14AWG flex alreadyattached with a NEMA 5-20, 110
VAC, 20 Amp plug. This cable has a current carryingcapacity of 20A.
6.4. Discrimination
Discrimination ensures that the upstream circuit breaker or fuse does not blow if a rectifier inputfails (short circuit).
Therefore, it is important to ensure the upstream protection discriminates withthe internal fuse of the rectifier. The fuse used
in the RM648 is a slow blow 10A fuse. The tripping curve for this is shown in Appendix 1 at the rear of this manual.
A minimum circuit breaker to use for this system is a 20A, D-curve (note, a 20A C-curve breakerwill not discriminate with the
rectifier fuse). Therefore, when used with the 14AWG cable supplied, a 20A, D-curve breaker should be used.
Alternatively, a 32A C-curve breaker, or greater, can be used. However, AC cable provided mayhave to be replaced for a
larger cable.
Note:A larger breaker may be used even though in theory it may appear that the 14AWG wire is not fully protected. In fact,
it is protected on two accounts. Firstly, it is protected by the rectifier input fuse (which is only a short distance away).
Secondly, the rectifiers are power-limited on their input. Therefore, they can never be overloaded. As a result, the wire can
never beover-loaded by the rectifier – it can only see fault current. As a result, depending on local authorities, only fault
current protection may be catered for by the upstream protective device.
White Wire
Black Wire
Live (Black
Neutral (White)
Earth (Green)
Green Wire
Fig 2, AC Cable Detail

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15mm, Strip
If a fuse is used upstream, then any BS88 or NH g style fuse, of 20A or greater rating willdiscriminate.
6.5. DC Cabling
CAUTION: Use extreme care when fitting batteries & their connections. Remove all jewelry and rings from oneself prior to
commencing the installation. Always use insulatedtools when fitting batteries and take extreme care not to
short terminals when working on them.
All DC Load cables terminate to the connectors at the front of the unit as shown in Figure 5. These terminals
are all 10AWG maximum wire size. Load connections are of a ‘push in’ design and cables can be simply pushed into the
connector for termination after stripping to theappropriate length.
Removal requires a small screwdriver to be inserted into the rectangular hole above theconnector whilst pulling on
the cable.
Connector designators are available on the pull-out guide. See Figures 3, 4 and 5 for detail.
Fig 3 & 4, DC Connector detail and pullout guide
The battery cabling connects through the SB50 style power-pole connectors. From here it goesdirectly to the appropriate
circuit breaker, then via a Low Voltage Disconnect relay and current shunt to the internal live bus. This can be seen in the
appropriate wiring diagram as the rear ofthis manual.
6.6. Alarm/Ancillary Cabling
5/8”, Strip Length
Connector layout for Rectifier Shelf
Fig 5, DC Connector detail

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Alarm and communication cables terminate directly into the connectors of the SupervisoryModule, SM36, which
terminals are assessable by pulling the monitor forward to expose connections (see Fig 6 & 7). Cables can be routed
through the front of the system via the cable exit indicated. When routingthe cables, ensure they are kept away from
the AC and DC
power cables
when possible.
Relays 1- 6 can be used for normally open or normally closed states by jumper selection. The relay states labelled NO or
NC are for their de-energized state. If an alarm is programmed for the relay to be normally energized (as may be required in
the case of a low voltage alarm whereloss of power will put the alarm into its active state), then be sure to connect the
remote wiring appropriately.
For full monitor functionality and operation information, refer to the appropriate monitor manual.
6.7. Temperature Sensors
Uncoil the battery temperature sensor and place in the middle of the middle battery string. If thelead is not long enough,
ordinary 2-core copper (approx. 18AWG) wire can be used as an extension. The purpose of the battery temperature
sensor is to monitor the ambient temperature of the batteries over long periods of time and adjust the rectifier output
Fig 6. For removal, pull monitor forward to release the ball catch
Fig 7. SM3x cable access

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(float) voltage accordingly. As a result, it is not necessary to have the temperature sensor touching the batteries. If the
Battery Temperature Sensor is removed a “battery temp fault” alarm is generated.
7. ENERGY MANAGER CONNECTIVITY AND THE WEB UI
The energy manager is configured via a web browser-based user interface (Web UI).
There are two methods to access the Web UI:
•Ethernet connection from the J305 ethernet connector
•Front panel micro-USB local connection
7.1. Access Levels
There are 3 access levels for the Energy Manager Web UI:
enaguest : can only view status of system
enabasic : reduced privilege, can view settings and system status
enaadvanced : this user has normal full control access of the system
The default password for all levels = ena123
7.2. Ethernet Port Connection
The energy manager contains static sensitive components that require careful handling and
proper precautions to be taken – an electrostatic discharge protection device must be worn.
Figure 16: Energy Manager Ethernet Port
1. Connect the communicating device to the J305 Ethernet port inside the energy manager.
2. Open an internet browser such as Edge, Chrome, Firefox or similar on the device.
3. Enter the Ethernet default IP address into the internet browser.
Note: the energy manager IP address can be located from the front panel LCD menu under: Settings>Networking>Ethernet.
4. The energy manager log in page appears.
5. Enter the user name and password. See 7.1 Access Levels.
Ethernet Port

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7.3. USB Connection
Figure 17: 1U EM4x-01 Front Panel micro-USB
1. Connect the communicating device to the micro-USB port on the front of the energy manager. See Figure 17.
A driver installation prompt appears.
2. Double-click the appropriate USB driver (32bit or 64 bit).
3. Follow the installation wizard instructions to install the driver.
4. Open an internet browser such as Edge, Chrome, Firefox or similar.
5. Enter the USB default IP address into the internet browser: 172.31.250.1
6. The energy manager log in page appears.
6. Enter the username and password. See 7.1 Access Levels.
Note: USB connection to the energy manager is possible without AC, battery or other external power supply. The EM4x
operates drawing power through the USB port. However, USB supply does not power the IO Board. In this scenario there is a
set of alarms that display depending on the system configuration relating to the nonoperation of the IO board.
For example:
For information on the use of the energy manager Web UI please refer to the Energy Manager Installation and Operation
Manual.
7.4. Energy manager & IO PCB Alarm Output Configuration
For full EM4x functionality and operation information, refer to the EM4x Installation and Operation Manual.
7.5. EM4x LED Alarm Mappings
Refer to the Alarm Configuration>Alarm Configuration page of the Web UI to see the priority setting of each alarm.
Refer to the Relay/Output page Configure Relay section of the Web UI to understand the how the Alarm Configuration is
mapped to the EM4x LEDs.
Micro-USB

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EM4x Yellow LED non-Urgent Alarm Mapping
7.6. EM4x Main PCB Alarm Mappings
Alarms can be mapped to any of the voltage free output relays fitted to the EM4x. Output states of either Normally Open or
Normally Closed can be selected (NO and NC states are for the de-energized relay). A jumper is fitted to nominate the
required output state, ensure the jumper is placed in the correct configuration for installation requirements.
If an alarm is programmed for the relay to be normally energized (such as a low voltage alarm where loss of power will put the
alarm into its “active” state), then be sure to connect the remote wiring appropriately.
Table 2 lists alarm assignment for the EM4x controller as matches the relay outputs shown in Figure 18.
Figure 18: EM4x Relay Outputs
EM4x Red LED Urgent Alarm Mapping
(
For reference only. Actual system alarm mapping may vary)
(
For reference only. Actual system alarm mapping may vary)

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Table 2: IO Board 1 Relay Alarm Assignments
Relay
Output
Relay Label
(In NewMar Config.)
Alarms Mapped to Relay/Output
(All multiple states “OR-ed”)
Relay 1
CPU Fail
Relay 2
Non-Critical Alarms
Orange LED
Relay 3
Critical alarms
Red LED
Relay 4
Spare
Relay 5
Spare
Relay 6
Spare
Buzzer
Red LED
7.7. EM4x Main PCB Digital Input Alarm Mappings
General purpose inputs allow the Commander II & II+ system to monitor any external equipment that includes relay or
auxiliary outputs. The GPIP inputs are activated by connecting the system positive (common) to the input terminal
(configuration setup in the EM4x can allow activation by connecting to system live).
General purpose inputs can also be configured as analogue inputs for purposes such as battery midpoint monitoring and
voltage monitoring.
These inputs may be assigned to contribute to alarm states within the monitor. The state mapping is defined in the
configuration file. Alarm mapping should be completed using the EM4x software. Please refer to the EM4x manual for detailed
information.
The inputs are normally activated by connecting system positive (usually system common) to the input.
7.8. Circuit Breaker Fail Monitoring
Comment: Main circuit breakers (MCBs) are monitored electronically via a diode to a digital input on the EM4x. The digital
input will trigger an alarm when it is pulled to the system common (positive) rail. The Breaker Fail alarm will only operate if a
load is connected to the output to provide a return circuit for the sense wire. Therefore, for breakers that do not have a load
connected, the breaker can remain in an OFF position without causing a false alarm.
The battery circuit-breakers, however, use voltage sense to detect tripping or whether they are turned off. This is because
when a battery breaker is tripped, there may be very little voltage difference across the breaker, making electronic fail
Relay Outputs 1
-
6

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detection problematic. Hence, if no battery is connected, the breaker must be ON to clear the Battery Breaker Fail alarm.
8. LVD OPERATION
The primary Low Voltage Disconnect contactor is in the battery side of the DC distribution. A secondary Load Low Voltage
Disconnect can be optionally included in a section of the load side of the DC distribution.
The LVD contactor is a bi-stable, magnetically latching contactor. This means that failure of power or removal of the EM4x
from a live system will not cause the contactor to change state. Periodic pulsing of the LVD control signal allows the monitor
to ensure the contactor remains in the correct state. The contactor is monitored by the EM4x to allow an alarm to be
generated when the contactor is open.
8.1. DC EARTHING OPTIONS
8.1.1. Dedicated Positive Earth System
The 1U Sentinel system is a positive earth system where the positive DC output is tied to ACearth as shown in figure
8.
8.1.2. Isolated System
For systems that require no connection to earth, the PCB can be cut as indicated in figure 9 toisolate DC output from
AC earth.
9. MAINTENANCE
As NewMar power systems are state of the art electronic systems, little routine maintenance is required.
9.1. System
• During normal operation the cable entries to the MCBs may loosen over time due to movement in the cable strands. To
avoid damage to the MCB’s and cable entries due to heat build-up and arching, it is recommended that the retaining
torque is periodically checked at least annually.
• MCB’s should be maintained at a torque of 2Nm.
• All other connections should also be checked at this time.
9.2. EM4x Controller
• The controller can give a good indication of the condition of the system. Alarm logs can show issues with the system and
rectifiers and should be regularly checked.
+ve Earth
Fig 8, +ve earth option
+ve Earth
Fig 9, isolated earth option

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• As a minimum, check that the float voltage and load current is as expected.
• If the batteries are fully charged, check the battery current is zero or near to zero amps, and check that the amp-hours
remaining is 100%.
9.3. Rectifiers and Converters
• During normal operation some dust will build-up on the front of the rectifiers. This should be kept to a minimum by
regularly wiping the rectifiers to avoid accumulation within the rectifiers and blocking the airflow to the units. The
positioning of the system and surroundings will determine the regularity of this requirement.
• In extremely dusty positions it is recommended that the units are removed and cleaned with compressed air to prevent
airflow blockages.
• Check the air flow front and back to the rectifiers is unimpeded by cables or otherwise.
• Check nothing has entered the rectifiers such as insects or geckos.
9.4. Batteries
• Battery maintenance depends on the individual manufacturer’s specification, please contact the battery supplier for
recommendations.
• Periodic discharge tests may be beneficial to ensure reliable system operation and may be recommended by the battery
manufacturer.
CAUTION - The user must be aware of the consequences of battery State of Health (SoH) with regards their
specific load requirements and implement their own policy regards the end of life of the batteries.
9.5. Ventilation Maintenance
Check that there has been no change in the required airflow space or environment that impacts the ventilation.
10. TROUBLE-SHOOTING AND SERVICING
If the red LED is alight:
•Unplug the rectifier and re-engage.
•Check AC power to the rectifier.
•Check for rectifier alarms in the monitor Urgent Alarm list.
•If symptoms persist, contact a service agent.
If the yellow LED is alight:
•Check the monitor Non-Urgent Alarm list.
10.1.Servicing
DANGER - Do not operate the rectifiers, converters, or other power modules if the covers are damaged or
removed in any way.
WARNING - The rectifiers, converters or other power modules contain voltages that may be lethal even
after the input supply has been removed.
WARNING - The rectifiers, converters or other power modules contain components at high temperature
that may burn if touched
To isolate a rectifier or converter from the power supply, unplug it from the shelf.
The power modules contain no user serviceable components. Do not disassemble the modules.
If a power module has an operational fault or is damaged in any way, an authorized service center should service it

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immediately.
11. ESSENTIAL SYSTEM SET-UP PARAMETERS
The following steps are system settings that must be checked at the time of commissioning for each system installed. You
can print this section and fill it out for each site commissioned.
Note: these steps are battery chemistry dependent. Follow the appropriate section.
11.1.Systems with Lead Acid Batteries
Failure to correctly follow the items below may cause incorrect system functionality and, in some cases, ruin your battery
(without the ability to claim battery replacement under warranty).
NOTE: Any values shown below are indicative only. If the values in your system differ from those
shown here, write in the values relevant to your system.
Refer to the EM4x energy manager manual for more details.
Check the Battery Type
The system MUST be
configured to the correct
battery type.
EM4x Web UI page
Battery>Battery Settings
/ 
Check/Set Float Voltage
Consult battery manufacturer’s data for proper setting.
The Float voltage is for 25°C reference temperature in NewMar systems.
EM4x Web UI page: Control
Example:
Site Setting:
/ 
Set Battery Temperature Compensation
Toggle temperature
compensation On.
EM4x Web UI page:
Battery>Battery Settings
You must consult the battery manufacturer’s data to obtain the correct Slope
setting.
Note that in many Hybrid applications where the battery is constantly being
cycled, having temperature compensation enabled may not be necessary as
the voltage on the battery is constantly changing anyway.
EM4x Web UI page: Battery>Battery Settings
Example:

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Site
Settings:
/ 
If you choose not to enable Temperature Compensation, then set the Rectifier Float
Voltage to that required by the battery manufacturer for the average long-term
temperature you anticipate your system to operate at.
Set Battery Capacity
Consult the battery manufacturer’s data for correct battery capacity settings.
For the EM4x to set the correct Battery Current Limit current, it is essential
that this is filled out correctly. These figures are also used for estimating the
Battery Time Remaining during a discharge.
For Telecom applications, the 10-hour rate is usually the name-plate rating of
the battery. However, once again, check the battery manufacturer’s data
sheets as some manufacturers state the 20-hour rate (which is usually a little
more “optimistic”).
The second rate is required specifically for the time-remaining algorithm. A
4-hour rate is usually a good one to use. This information is available from
the battery manufacturer’s data sheet.
The Battery SoC adjust can be used at the time of installation (or for testing
purposes) in case the installed battery is not initially fully charged. If you
think the battery is only 80% charged, then simply enter that value. The
value displayed here will correct itself once the battery has been on charge
for some time or gone through a few charge/discharge cycles.
Battery Recharge Efficiency considers the ohmic and any other losses in the
battery charge/discharge cycle. The effect is that more energy (Ah) needs to
be put back into the battery than was taken out. With the efficiency set to
96%, then 4% more Ah is needed to be returned to the battery before the
EM4x will register that the battery is at 100% SoC (State of Charge).
The Battery Discharge Threshold is a buffer to prevent false triggering of
discharge notification and is usually related to the size of the battery shunt. A
larger shunt requires a larger discharge threshold.
EM4x Web UI page: Charge
Example:

18
Site
Settings:
/ 
Set Battery Current Limit
Consult battery manufacturer’s data for maximum battery recharge current
settings.
The Battery Current Limit is set as a percentage of the 10-hour rate entered
above.
It is recommended this value is set at the highest rate allowable to ensure the
battery is recharged as fast as possible.
In some systems, especially larger systems, this may require limiting further
because of the number of rectifiers available, rather than the maximum
setting.
EM4x Web UI page: Battery>Battery Settings
Enable Battery Current Limit by clicking on the tick icon beside the field.
Example:
Site Settings:
/ 
For telecom settings, this limit is often set to 10% (or 0.1C10, i.e., a 10A current limit
for a 100Ahr battery). This is more typical of a design parameter than the need for the
setting to be at this level but a setting higher than this level should be considered to
enable the fastest recharge possible without exceeding the battery manufacturer’s
maximum value.
Ensure sufficient rectifier capacity is available to cover battery recharge and load
requirements.

19
Low Voltage Disconnect Settings
The LVD disconnect set points are usually a customer generated setting.
As the discharge time increases, the higher the end voltage should be set.
For a discharge of <1hr, this may be as low as 1.75Vpc (42.0V for a “48V”
battery), or for an 8-hour discharge, it may be 1.85Vpc (44.4V for a “48V”
battery).
Note: that if only one LVD is fitted, LVD2 and LVD3 thresholds are set
outside of possible tripping voltages. This avoids any confusion over which
LVD signal is being used by the EM4x energy manager.
EM4x Web UI page: IO Configuration>IO Boards
Toggle LVD latching On
Example:
Site Settings:
/ 
11.2.DC System Lead Acid Battery Commissioning Checklist
This section is for a more detailed commissioning process than the Essential Set-up Parameters. It
may be printed out separately and filed for record keeping.
DC System Lead Acid Battery Commissioning Checklist
Site Name:
Date:
Tests Without Batteries Connected
Value
Results
Check Float Voltage
Meter:
V
/ 
Check Load Current
Meter:
A
/ 
Voltage thresholds can either be checked using an external power supply, or by
adjusting the EM4x float voltage 0.1V above (or below for the low voltage alarms). It is
recommended to have the batteries disconnected.
1. Adjust the supply/float voltage to 55.7V & observe the “High Float” alarm.
2. Adjust the supply/float voltage to 57.7V & observe the “High Load” alarm.
3. Adjust the supply/float voltage to 52.7V & observe the “Low Float” alarm.
4. Adjust the supply/float voltage to 46.9V & observe the “Low Load” alarm.
High Load Volts (urgent)
57.6V
V
/ 
High Float Volts (non-urgent)
55.6V
V
/ 
Low Float Volts (non-urgent)
52.8V
V
/ 
Low Load Volts (urgent)
47.0V
V
/ 