Newcastle Systems PC Series User manual

PC SERIES
ASSEMBLY MANUAL
1 or 2 Battery Setup

PC Series 1 & 2 Battery Systems
with 1000W Inverter/Charger
QUESTIONS? CALL 781-935-3450 2-2-2018 Pg. 1
Standard Contents:
- Cart (Assembled)
- Battery & Hardware
- Wastebasket and
Bracket & Hardware
3. Remove battery from cardboard
box
Standard Contents:
- Cart (fully assembled)
- Battery
- Trashcan holder &
green can
Optional Accessories:
Will either be installed on cart or shipped separately in
box with cart.
**Some accessories may be placed in power cabinet or
trash can for shipping purposes.
Tools Supplied:
(1) 5/32” Allen wrench to remove power box covering
and optional second shelf.
Additional Tools Required:
(1) 10mm insulated wrench (open end or socket) to
tighten battery terminals.
1. If second shelf was purchased, remove it
to gain access to battery box (Allen wrench
required).
Optional second shelf and optional
keyboard tray shown in picture above.
2. Remove (4) screws from the sides of the
battery box (as shown above) with supplied
Allen wrench.

PC Series 1 & 2 Battery Systems
with 1000W Inverter/Charger
QUESTIONS? CALL 781-935-3450 2-2-2018 Pg. 2
7. Place trash can in holder
3. Remove front battery panel by loosening the
thumb screws.
6. Clip nylon straps to
secure battery in cabinet
4. Unplug the power strip from the inverter/charger.
5. Carefully lift the battery box and make
sure cables stay positioned through the
plastic wire grommet.
Place battery box on its side as shown
below.

PC Series 1 & 2 Battery Systems
with 1000W Inverter/Charger
QUESTIONS? CALL 781-935-3450 2-2-2018 Pg. 3
One Battery Setup
(Skip to page 5 for 2-battery systems)
1. Remove battery and hardware from packaging.
2. Carefully place battery on base and
strap down as shown above.
Wire A (red) connects to red
positive (+) battery terminal.
Wire B (black) connects to
black negative (-) battery
terminal.
Wire C (black) connects to
black negative (-) battery
terminal.
Place Battery
here

PC Series 1 & 2 Battery Systems
with 1000W Inverter/Charger
QUESTIONS? CALL 781-935-3450 2-2-2018 Pg. 4
One Battery Setup Cont.
3. Positive Connection: Place lock washer onto bolt
first, then flat washer, then large red wire (A) in order
shown above.
7. Securely tighten terminal bolts with a
10mm wrench.
Wire A (red) comes pre-
connected from remote
battery meter to fuse block.
Wire B (black) connects
remote battery meter to
black negative (-) battery
terminal.
(C has been omitted)
Wire E (red) connects to red
positive (+) battery terminal.
(D & F have been omitted)
Wire G (black) connects to
black negative (-) battery
terminal.
SKIP TO PAGE 8.
5. Pull rubber boot over tightened
terminal.
4. Securely tighten terminal bolt with
10mm wrench.
3. Positive Connection: Take bolt and place flat
washer, small green wire, small red wire and large red
wire onto bolt (as show above); insert bolt through
positive (+) battery terminal; place flat washer, lock
washer, then nut onto bolt and hand-tighten
6. Negative Connection: Place lock
washer onto bolt first, then flat washer, then
small black wire (C), then large black wire
(B) in order shown above.

PC Series 1 & 2 Battery Systems
with 1000W Inverter/Charger
QUESTIONS? CALL 781-935-3450 2-2-2018 Pg. 5
Two Battery Setup
(proceed to page 8 if only 1 battery setup)
1. Remove battery and hardware from packaging.
1. Remove batteries and hardware from packaging.
Place Battery
#1 here
Place Battery
#2 here
2. Carefully place batteries on base (as
shown above) and securely tighten straps.
Battery #1
Battery #2
Wire A (red) connects to red
positive (+) battery terminal of
Battery #1.
Wire B (red) connects to red
positive (+) battery terminal of
Battery #2.
Wire C (black) connects to red
negative (-) battery terminal of
Battery #1.
Wire D1/D2 (black) connects
negative (-) terminal of Battery #1
to negative (-) terminal of Battery
#2. (This wire can be found in clear
plastic bag along w/manual.)
Wire E (black) connects to black
negative (-) terminal of Battery #2.

PC Series 1 & 2 Battery Systems
with 1000W Inverter/Charger
QUESTIONS? CALL 781-935-3450 2-2-2018 Pg. 6
Two Battery Setup Cont.
3. Positive Connection, Battery 1: Take bolt and place
flat washer and large red wire (A) onto bolt (as shows
above); insert bolt into positive (+) battery terminal.
**D1 / D2 battery connector cable can be
found in clear plastic bag w/manual**
4. Securely tighten terminal bolts on Battery
#1 with a 10mm wrench.
5. Pull rubber boot over tightened terminal.
6. Negative Connection, Battery 1: Take
bolt and place flat washer, black connector
wire (D1) and large black wire (C) onto bolt
(as shown above); insert into negative (-)
battery terminal.
Securely tighten terminal bolts with a 10mm
wrench.
Sparking is normal during initial connection.

PC Series 1 & 2 Battery Systems
with 1000W Inverter/Charger
QUESTIONS? CALL 781-935-3450 2-2-2018 Pg. 7
Two Battery Setup Cont.
7. Positive Connection, Battery 2: Take bolt
and place flat washer, large red wire (B) onto
bolt (as shown above); insert bolt into positive
(+) battery terminal.
8. Securely tighten terminal bolts on Battery
#1 with a 10mm wrench and pull rubber
boot over tightened terminal.
9. Negative Connection, Battery 2: Take
bolt and place flat washer, small black wire
(E), and black connector wire (D2) onto bolt
(as shown above).
Securely tighten terminal bolt with a 10mm
wrench.
Sparking is normal during initial connection.
2-Battery Configuration
Fully Connected

PC Series 1 & 2 Battery Systems
with 1000W Inverter/Charger
QUESTIONS? CALL 781-935-3450 2-2-2018 Pg. 8
3. Run charger cord through cable opening
and securely wrap around cord reel holder.
1. Make sure all fittings are tight and that the batteries
are strapped down.
Carefully place the battery box cover on base.
2. Plug the power strip into the
inverter/charger.

PC Series 1 & 2 Battery Systems
with 1000W Inverter/Charger
QUESTIONS? CALL 781-935-3450 2-2-2018 Pg. 9
Testing the Battery Function
1. Turn the unit on by pressing the green power button.
2. Carefully place battery on base and
strap down as shown above
2. Turn the power strip on.
The switch should light red.
3. Reapply the (4) screws to sides of the battery
box with supplied Allen wrench.
3. Run charger cord through cable opening
and securely wrap around cord reel holder
4. Place the front battery panel as shown
above.
5. Tighten (4) battery panel thumbscrews.
Accessory assembly manual can be
downloaded at:
www.newcastlesys.com/accessory-assembly