Newcastle Systems PowerSwap Nucleus MINI User manual

learn more at
newcastlesys.com/powerswap-nucleus
owner’s manual
PowerSwap Nucleus® MINI
Lithium Power System

TECHNICAL SUPPORT +1 [phone] EXT. 3 ii
PowerSwap Nucleus® MINI
Owner's Manual
Document Number: PowerSwap_Nucleus_MINI_00_C
Revision Date: July 31, 2023
Release Date: November, 2019

PowerSwap Nucleus® MINI Owner's Manual | iii
COPYRIGHT
All copyrights to this document are owned by Newcastle Systems, Inc. No part of the contents of this docu-
ment may be reproduced or transmitted in any form or by any means without the prior written consent of
Newcastle Systems, Inc.
NOTICE
Newcastle Systems, Inc. shall not be liable for errors contained herein. Newcastle Systems, Inc. shall not be liable
for any damages whatsoever, including, without limitation, damages for loss of business profits, business inter-
ruption, loss of business information, or other pecuniary loss arising out of the use of this documentation even if
Newcastle Systems, Inc. has been made aware of the possibility of such damages.
Information contained in this document is subject to change without notice. While every effort is made to ensure
that the information is accurate as of the publication date, users are reminded to update their use of this docu-
ment with documents published by Newcastle Systems, Inc. subsequent to this date. Updates may be available at
www.newcastlesys.com or by contacting Newcastle Systems, Inc.
Copyright © 2023 by Newcastle Systems, Inc.
ALL RIGHTS RESERVED
Printed in U.S.A.
Newcastle Systems, Inc.
34 South Hunt Rd.
Amesbury, MA 01913
[phone]
www.newcastlesys.com

TECHNICAL SUPPORT 781.935.3450 EXT. 3 iv
Important
Read and Understand this Manual Before Operation!.......................................................................... v
System Components
Mounting the PowerDock................................................................................................................................. 1
PowerDock MINI PowerCharge MINI & Battery....................................................................................... 2
Operating Guidelines
Storage and Disposal......................................................................................................................................... 3
PowerDock MINI Operating Instructions .................................................................................................. 3
PowerCharge MINI Operating Instructions............................................................................................... 4
Fuel Gauge ............................................................................................................................................................. 5
Preventative Maintenance
Inspection ............................................................................................................................................................... 6
Service/Warnings
Service ..................................................................................................................................................................... 7
Warnings/Precautions....................................................................................................................................... 8
Specifications
Battery Specifications....................................................................................................................................... 10
PowerDock MINI Specifications.................................................................................................................... 11
PowerCharge MINI Specifications ............................................................................................................... 11
Operating, Transportation, and Storage Environment ........................................................................ 11
Transportation Regulation............................................................................................................................... 12

PowerSwap Nucleus® MINI Owner's Manual | v
Read and Understand this Manual Before Operation!
Important
Read and Understand this Manual Before Operation!
The Nucleus MINI battery is specifically designed and optimized for the PowerDock MINI and PowerCharge MINI.
Do not attempt to use a charger or DC load not manufactured by Newcastle Systems, Inc. with this product.
Special precautions and handling instructions are contained in this manual and should be strictly adhered to for
safe and reliable operation. Contact Newcastle Systems, Inc. Customer Service at [phone] or custom-
[e-mail] with any questions regarding this product.

PowerSwap Nucleus® MINI Owner's Manual | 1
Mounting the PowerDock
System Components
Mounting the PowerDock
For mobile power pack-only applications, the PowerDock MINI is shipped with plastic feet installed. The Power-
Dock MINI may be placed securely on a flat level surface.
For mobile cart applications, the plastic feet may be removed and the PowerDock MINI may be fastened securely
to a cart in the following configurations.
LT Series cart:
Will need to be mounted by customer. Use the screws included with the feet to fasten the PowerDock to the
base of the LT Series where holes are pre-drilled.
All other Newcastle Systems carts:
Will be installed by Newcastle Systems before shipping to customer.
Your existing 3rd-party cart:
Place the PowerDock in the desired location and use screws (wood or sheet metal, depending on material) to
attach to the cart’s surface using the (4) eyelets on the corners of the PowerDock.

TECHNICAL SUPPORT +1 [phone] EXT. 3 2
PowerDock MINI PowerCharge MINI & Battery
PowerDock MINI PowerCharge MINI & Battery
1. PowerDock MINI Station (PWD1M): This may be installed on a Newcastle cart. See “Mounting the PowerDock”
on page 1 to view your cart configuration.
2. PowerCharge MINI Station (PWC1M): This is used to charge PSNU1.8M batteries.
3. 18 AH/230 WH LiFePO4 (PSNU1.8M): 1 to 2 units, based on your order.
Make sure batteries are fully charged prior to powering equipment.
3
12
120V model shown

PowerSwap Nucleus® MINI Owner's Manual | 3
Storage and Disposal
Operating Guidelines
Storage and Disposal
Storage Instructions:
• DO NOT SHORT TERMINALS.
• This battery should be stored in a cool, dry, and well-ventilated area. Sustained elevated temperatures are
the primary reason for premature failure of batteries. Charge batteries at room temperature. In warm cli-
mates, keep chargers in air conditioned rooms for best performance.
• Although our batteries have good self-discharge characteristics, batteries should be stored for long term
storage in a fully charged condition.
• It is always a good idea to submit the battery to a discharge/charge cycle from time to time during storage.
• Do not store batteries in temperatures above 140oF/60oC or below -40oF/-20oC. Do not store in direct sun-
light or near heating equipment.
Disposal Instructions:
• DO NOT INCINERATE. DO NOT DISASSEMBLE.
• Disposal must be in compliance with applicable regulations which vary depending on national, state/provin-
cial and local basis. This battery contains recyclable materials so recycling is strongly recommended.
PowerDock MINI Operating Instructions
Step 2: Place fully charged batteries
in PowerDock MINI Station. Make sure
battery is fully engaged and the LED
lights on the battery are lit. *Batter-
ies should be inserted firmly, but never
slammed into place.
Step 3: Turn PowerDock MINI
Station on (-) (switch located as
shown). LED should light green.
When unit is not in use, turn the PowerDock MINI OFF. Batteries will continue to drain if unit is left on.
Tip: Monitor battery status with the LED meter on battery. When batteries become low, alarm will sound and bat-
tery should be swapped with a fully charged one.
Step 1: Confirm your device(s) is
plugged into the AC outlet(s).
(120V model shown)

TECHNICAL SUPPORT +1 [phone] EXT. 3 4
PowerCharge MINI Operating Instructions
PowerCharge MINI Operating Instructions
Step 1: Connect charge cord to rear of charge dock and plug in at wall outlet.
Step 2: Place discharged battery in PowerCharge MINI Station. Make sure battery is fully engaged. *Batteries
should be inserted firmly, but never slammed into place.
Step 3: Confirm LED changes color from green to orange during charge. Note: LED will turn green once fully
charged.
Charging time of the PWC1M takes approximately 3 hours to charge fully depleted batteries.
Replaceable Fuse: This is located on the front of the PowerCharge MINI to protect from DC overload. The AC
fuse is internal and non-replaceable. If DC fuse blows, replace with equivalent, fast-acting, 125 V, 15A rated 5 mm
x 20 mm glass fuse. CAUTION: Installing non-rated fuses could cause equipment damage and void your warranty.

PowerSwap Nucleus® MINI Owner's Manual | 5
Fuel Gauge
Fuel Gauge
The following graphics illustrate the amount of battery power and corresponding LED lighting sequence.
Illustration of Fuel Gauge LEDs Battery Fuel
5 81-100%
4 61-80%
3 41-60%
2 21-40%
1 solid 11-20%
1 flashing 1-10%

TECHNICAL SUPPORT +1 [phone] EXT. 3 6
PowerDock MINI PowerCharge MINI & Battery
Preventative Maintenance
Damaged connectors, contacts and cables may present hazards, resulting in inefficient battery and charger op-
eration. To avoid these problems, conduct the following maintenance checks at least once annually. If you see any
of the following problems, take corrective action immediately.
Inspection
Check contact surfaces for signs of “pitting” caused by dirt or disengaging connectors under load. One badly
pitted contact, particularly in a connector attached to a battery charger, can lead to pitting on surfaces of other
contacts. If not corrected, this can result in an epidemic of bad connectors throughout a fleet of batteries and in
chargers and batteries.
Check to see if batteries are being disconnected while the charger is still on. This may cause the contacts to arc
at the tips, resulting with progressive pitting and silver removal from tip to crown. If this practice is occurring,
discontinue it now to avoid major repairs in the future.

PowerSwap Nucleus® MINI Owner's Manual | 7
Service
Service/Warnings
Service
In the event the Nucleus battery fails to deliver acceptable performance, it must be returned to
Newcastle Systems, Inc. No other facility is qualified and equipped to service the Nucleus battery and calibrate
the electronic components and sensors. Any attempt by the user or any other unauthorized persons may result
in improper calibration of the electronic components causing severe battery damage and/or safety hazards,
including potential personal injury and/or damage to property. Any such attempt will void any/all warranties.

TECHNICAL SUPPORT +1 [phone] EXT. 3 8
Warnings/Precautions
Warnings/Precautions
1. NEVER attempt to service this battery. Incorrect assembly may result in electric shock or fire. If there is a
problem, send this battery only to Newcastle Systems, Inc. for evaluation.
2. NEVER attempt to open this battery. The electronic circuits inside the battery can be damaged, causing
malfunction and/or potential hazard to person and property.
3. NEVER attempt to replace the cells in this battery - it cannot be rebuilt or refurbished. At the end of its useful
life, contact Newcastle Systems, Inc. Customer Service at [phone] or customerservice@newcastlesys.
com.
4. It is recommended that you return the Nucleus battery interface to a qualified dealer for any service or repair.
5. To reduce risk of electric shock, unplug the DC input (battery) and AC input (charge cord) before attempting
any maintenance or cleaning.
6. To reduce risk of damage to electric plug and cord, pull by plug rather than cord when disconnecting anything
from the unit.
7. The use of an extension cord is not recommended. If an extension cord is used, make sure that it has a 3-prong,
male plug and 3-prong female receptacle. The size of the current carrying conductors should be such that they
are able to carry at least 5.0A for the length of the extension.
8. Place components in an area that will allow air to flow freely around them. DO NOT block or obstruct vent
openings or install the unit in an enclosed compartment.
9. Keep the unit away from moisture and water.
10. Never operate two or more units in parallel.
11. WARNING: To avoid risk of electric shock, the charge dock must only be connected to a supply mains with
protective ground.
12. WARNING: No modification of this equipment is allowed.
13. Do not expose this battery to extreme high (above 140oF /60oC) or low (below 32oF/ 0oC) temperatures. This
includes storage in direct sunlight, in cars in hot or cold weather, or in close proximity to heating/cooling devices.
This may cause electrolyte leakage, impaired performance and shortening of battery service life.
14. When not using the battery for prolonged periods, the Nucleus battery should be fully charged.
15. ALL BATTERIES have a finite life. If the battery exhibits noticeably shortened run-time, the battery should be
replaced immediately. Shortened run-time is indicative of at least one cell which has reached end of life. UNDER
NO CIRCUMSTANCES should one attempt to “recondition” this battery by repeated charging and discharging.
16. This battery contains specialized electronic circuits, which are designed to protect the cells from overcharge,
over discharge and over current. Redundant protection devices are designed to operate if the battery voltage is
abnormally high or low and if the temperature of the battery exceeds operating specifications. These electronic
devices can be damaged if the battery is subject to abuse or damage. Do not use a battery that has been
subjected to excessive mechanical shock or water damage.
17. Do not drop, puncture or crush this battery. Do not use the battery if the case is damaged or broken. Do not
open or attempt to service this battery if damaged.

PowerSwap Nucleus® MINI Owner's Manual | 9
Warnings/Precautions
EU Waste Electrical and Electronic Equipment (WEEE) Directive
Figure 1: WEEE symbol – crossed out wheeled bin
For private households: Information on Disposal for Users of WEEE:
This symbol (Figure 1) on the product(s) and/or accompanying documents means that used electrical and
electronic equipment (WEEE) should not be mixed with general household waste. For proper treatment, recovery
and recycling, please take this product(s) to designated collection points where it will be accepted free of charge.
Disposing of this product correctly will help save valuable resources and prevent any potential negative effects
on human health and the environment, which could otherwise arise from inappropriate waste handling.
Please contact your local authority for further details of your nearest designated collection point.
Penalties may be applicable for incorrect disposal of this waste, in accordance with your national legislation.
For professional users in the European Union:
If you wish to discard electrical and electronic equipment (EEE), please contact your dealer or supplier for further
information.
For disposal in countries outside of the European Union:
This symbol is only valid in the European Union (EU). If you wish to discard this product, please contact your local
authorities or dealer and ask for the correct method of disposal.
ENVIRONMENTAL HAZARD
Contains Lithium-Ion.
Disposal: DO NOT dispose of the Nucleus components and its associated components and/or
accessories in municipal waste at the end of their expected service life. Consult Newcastle Systems, Inc.
Customer Service for information on disposal/recycling of the Nucleus battery interface and its
associated components and/or accessories.
FCC NOTICE
This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part
15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate
radio frequency and, if not installed and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct the interference at their own expense. This
equipment has been approved by one or more agencies. All changes and/or modifications not expressly approved
by Newcastle Systems, Inc. could void the users’ warranty and authority to operate this equipment. There are no
serviceable parts in this equipment.
Li-Ion

TECHNICAL SUPPORT +1 [phone] EXT. 3 10
Battery Specifications
Specifications
Battery Specifications
Output Voltage 12.8 V Nominal
10.0 V - 14.6 V Operating
Capacity 18 Ah
Chemistry Lithium Iron Phosphate (LiFePO4)
Maximum Discharge Rate 12.0 A
Cut-off Charge Current 2000 mA
Typical Run-Time
(Assuming Constant Load)
@ 10W 20 hrs
@ 26W 8 hrs
@ 41W 5 hrs
@ 69W 3 hrs
Weight 6 lbs (2.7 kg)
Size 6” L x 11” W x 3.375” H
(152 x 279 x 86 mm)
Operating Temperature 32-104oF (0-40oC) Discharge
32-131oF (0-55oC) Charge
Regulatory Approvals
Li-ion

PowerSwap Nucleus® MINI Owner's Manual | 11
PowerDock MINI Specifications
PowerDock MINI Specifications
PWD1M PWD1Mi
Voltage 120 VAC ± 3%
Pure Sine
230 VAC
Pure Sine
Current 1.0 A 0.5 A
Frequency 60 Hz ± 1% 50-60 Hz
Regulatory Approvals
PowerCharge MINI Specifications
PWC1M PWC1Mi
Power Input 115 VAC/60 Hz 2.5 A 230 VAC/50-60 Hz 1.2 A
Output 7.5 A DC 7.5 A DC
Charge Time 3 hrs 3 hrs
Regulatory Approvals
Operating, Transportation, and Storage Environment
Temperature Range 32 to 104oF (0 to 40oC)
Relative Humidity 20-70% non-condensing
Pressure 985 hPa to 1040 hPa
Device intended for indoor use only.
Never use flammable or combustible solvents around batteries or chargers.
PowerDock & PowerCharge MINI Specifications

TECHNICAL SUPPORT +1 [phone] EXT. 3 12
Transportation Regulation
Transportation Regulation
Transportation Regulation
Requirements for shipping Lithium-Ion batteries in the US are located in 49CFR173.185. Please refer to local,
state, and/or Federal regulations before offering Lithium-Ion batteries for transport.

34 South Hunt Road
Amesbury, MA 01913 / USA
+1.781.935.3450
www.newcastlesys.com
owner’s manual