Newcastle Systems PP Series User manual
PP Series
Power Package
Assembly Manual
34 South Hunt Rd. ●Amesbury, MA ●01913 ●USA ●781.935.3450 ●www.newcastlesys.com
ITEM # QTY. DESCRIPTION
1 1 Battery Box Cover
2 1 Battery Box Bottom
3 4 Battery Box Stop Angle
4 3 Rivet, .143D X .267L
5 4 Pem Nut, #10-32
6 4 Screw, 10-32 X 1/2"
PP Series
Cabinet Assembly
Drawings
1 Battery Set-Up
(for 350 watt inverter & separate charger)
(+) on Charger to (+) on Battery: 29” Long 14 AWG, Red Wire
(-) on Charger to (-) on Battery: 29” Long 14 AWG, Black Wire
(+) on Inverter to (+) on Battery: 14 AWG Wire, Black Wire, Red Tape
(-) on Inverter to (-) on Battery: 14 AWG Black Wire
Feed volt meter wire down mast and through middle opening
(+) on Volt Meter to (+) on Battery: 18 AWG Red Wire
(-) on Volt Meter to (-) on Battery: 18 AWG Black Wire
A
B
C
A
B
C
Battery
D
E
E
Volt Meter
F
-
+
Inverter
F
** Please note:
Make sure all fittings are tight and charger & battery are strapped down in cabinet**
Power
Cabinet
Charger
D
F
Feed cord from
power strip in mast
through middle
opening and plug
into inverter
Red cord will plug into
back of charger and
feed out through the far
right opening; cord is
used to plug into wall
to recharge the unit
E
A
E
F
1 Battery Set-Up
For Stand Alone Power Pack &
Mobile Powered Cart
(+) on Inverter to Rear Fuse Block: 11” Long 2 AWG, 5/16 Ring Both, Red Wire
(-) on Inverter to (-) on Battery: 16” Long 2 AWG, 5/16 Ring Both, Black Wire
(+) on Battery to Front Fuse Block: 16” Long 2 AWG, (2) 5/16 Ring Terminals, Red Wire
Integrated Powerstrip Plug (located in mast): Plug into cord from side of inverter
Grey RJ45 Cable from Inverter: Plug into Remote Volt Meter located at top of mast
Charger Cord
A
B
C
A
B
C
Battery
E
-
+
Inverter
** Please note: Make sure all fittings are tight and battery is strapped down in cabinet**
Ground
Wire
D
B
C
D
D
E
Fuse
Block
E
F
F
(+) on Inverter to Rear Fuse Block: 11” Long 2 AWG, 5/16 Ring Both, Red Wire
(-) on Inverter to (-) on Battery #1: 16” Long 2 AWG, 5/16 Ring Both, Black Wire
(+) on Battery #1 to Front Fuse Block: 16” Long 2 AWG, (2) 5/16 Ring Terminals, Red Wire
(+) on Battery #2 to Front Fuse Block: 16” Long 6 AWG, (2) 5/16 Ring Terminals, Black Wire & Red Sleeve
(-) on Battery #1 to (-) on Battery #2: 16” Long 6 AWG, (2) 5/16 Ring Terminals, Black Wire
Grey RJ45 Cable from Inverter: Plug into Remote Volt Meter at top of mast
Integrated Powerstrip Plug (located in mast): Plug into cord from side of inverter
Charger Cord
** Please note: Make sure all fittings are tight
and batteries are strapped down in cabinet**
B
C
A
B
C
Battery #1
D
E
E
Fuse Block
D
Battery #2
F
F
G
G
+
-
-
+
2 Battery Set-Up
For Power Pack and
NB Series Mobile Cart
-
A
B
C
D
E
GF
H
H
Fuse Block
Inverter
G
Ground Wire
Assembly Instructions for PP Series Power Packages
Main Components:
1. PP Series cabinet and cover
2. Battery 40, 100 amp or (2) batteries hour sealed
3. Inverter / Charger 1,000 watt peak inverter w/ built in smart charger 20 amp
or 350 watt inverter with separate 10 amp charger
4. Battery status meter
5. Nylon straps
6. Wire harness
7. Fuse block & fuse
Step 1: Remove the cover of the cabinet. Insert the nylon strapping into the slots in the base to hold the
battery and inverter / charger down. These can be tightened later.
Step 2: Please refer to Battery Set-Up Document shown on previous pages
Step 3: Make sure the inverter is set to the automatic mode on the rear of the unit. Place the power
pack cover on and secure in place with (4) #10-32 screws.
Turn inverter off if not been used for several days as it will drain the battery.
The charger will not work if voltage in battery is below 11 volts.
Tools required: 1/8 Allen wrench, preferably one with a long handle.
Thanks you for choosing Newcastle Systems to meet your mobile equipment requirements.
or comments.
Tips to Extend
Battery Life
34 South Hunt Rd. ●Amesbury, MA ●01913 ●USA ●781.935.3450 ●www.newcastlesys.com
1. Charge the battery before using it to ensure it is fully charged.
2. Monitor the battery status meter on the cart.
3. Batteries SHOULD NOT be discharged below 11.5 volts as this will shorten
the life of the battery.
4. Batteries SHOULD NOT be stored in a discharged state for more than 1
or 2 days. They should be charged as soon as possible after each use
(otherwise it can void the warranty). If a battery has been left in a
discharged state for a period of time it may no longer take a charge.
5. Avoid exposing battery to heat, service life is shortened at ambient
temperatures above 85F.
6. Batteries should always be charged in a secure but ventilated enclosure.
7. When powering equipment on the cart one can have the charger plugged in if
necessary. In this case, the AC power will pass thru the charger and power
your equipment directly.
8. When not in use, the system charger can be plugged into the AC power to
ensure the battery remains in an optimal state or turn inverter to off position.
9. Charging system is a trickle charger so leaving it plugged in will NOT damage
the battery.
10.Make sure that the terminals on the battery are tight as are the set screws
holding the wire inside the inverter / charger.
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