NewMar 12-1800IC User manual

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1
P
ERFECT
W
AVE
INVERTER/CHARGER
Inverter/Chargers
Perfect Wave Series
Models:
12-1800IC
12-1801 ICF
24-2200IC
24-2201 ICF
32-2400IC
Guided Wave Series
Model:
12-2500IC
INSTALLATION/OPERATION MANUAL
CONTENTS
Section Topic Page
I) OVERVIEW................................................................................. 2
II) IMPORTANT SAFETY CAUTIONS AND WARNINGS....................... 3
III) INSTALLATION............................................................................ 3
A) Materials Provided........................................................4
B) Location.......................................................................4
C) Mounting..................................................................... 4
D) Case Grounding........................................................... 5
E) Battery Selection and Sizing......................................... 5
F) Battery (DC) Wiring.......................................................6
G) Charging Multiple Battery Banks..................................8
H) Temperature Compensation Sensor.............................. 9
I) AC Input Wiring.............................................................9
J) AC Output Options.......................................................10
K) Remote Panel (optional)................................................ 11
IV) BATTERY CHARGER OPERATION................................................12
A) Battery Capacity Selector..............................................12
B) Charger Output Selector...............................................13
C) Battery Charging Cycle Explained.................................14
V) INVERTER OPERATION............................................................... 17
A) Start-Up/Operation......................................................17
B) Inverter ON/OFF Switch Functions...............................18
C) Inverter Auto-Shut-down Indicators/Causes.................18
VI) SPECIFICATIONS........................................................................ 19
VII) BATTERY CARE TIPS...................................................................21
VIII) REFERENCE APPENDIX.............................................................. 23 M-IC2
OCT 2004

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I) OVERVIEW
Your NEWMAR Inverter/Charger uses 12, 24 or 32 VDC (depending on model) battery power
to produce 120 VAC/60 Hz or 230 VAC/50 Hz power (depending on model) for operating
virtually any AC appliance. It incorporates field-proven technology which provides reliable
service in harsh commercial and recreational marine applications.
The Perfect Wave series produce pure sinusoidal AC to exactly match utility power for
flawless operation of all appliances, including highly sensitive electronics such as comput-
ers, stereos and video displays which are intolerant to any AC wave distortion.
The Guided Wave series produce a quasi-sinusoidal output to match the RMS value of AC
utility power and enables the operation of less sensitive motor loads, such as refrigerators,
dishwashers and power tools.
All units incorporate a built-in three stage battery charger for rapid and safe replenishment
of batteries whenever shore or generator AC power is available.
All models feature numerous circuit and safety protections, such as thermally controlled
cooling fans and ground fault protected duplex outlets, utilize automatic AC transfer relays
and are housed in rugged, rust-resistant powder-coated aluminum cases suitable for perma-
nent bulkhead or horizontal mounting. An optional remote indicator and control panel
(model ICR-2) is available, as well.
In addition, your Inverter/Charger is UL listed (except "ICF" models which are CE marked)
and warrantied for two full years, parts and labor. Careful attention to these instructions
should enable you to enjoy many years of trouble-free service.
Figure 1: Quick Reference Contents
-
+
Temperature Sensor;
Page 9
Remote Panel Option;
Page 11
Battery Input/Output Wiring;
Page 5
Inverter Operation;
Page 17
L.E.D. Status Panel;
Pages 14 & 17
Battery Charger Functions;
Page 14
Case Grounding;
Page 6
AC Input Wiring;
Page 9
Automatic Transfer
Switch (Internal);
Page 17
Hardwire AC Output;
Page 10
Duplex Outlet;
Page 10 (not on ICF
models)
Cooling Fan;
Page 19
30 Amp (Master) "Output Breaker";
Page 10
20 Amp (Duplex Outlet)
"Branch Output Breaker";
Page 10 (not on ICF models)
Battery Charger Control Switches;
Pages 12-13

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II) IMPORTANT SAFETY CAUTIONS AND WARNINGS
CAUTION: Inverters produce hazardous voltages. To avoid risk of harm or fire the unit must
be properly installed. There are no user-serviceable parts inside. Do not remove the inverter
housing.
CAUTION: The inverter should not be mounted in a location that may be exposed to rain or
spray.
CAUTION: The inverter should not be installed in a zero-clearance enclosure.
CAUTION: Damage to the inverter will occur if correct polarity is not observed when installing
the DC input cables.
CAUTION: Damage to inverter will occur if an external AC source is applied to the inverter’s
AC output socket or its hard-wire AC output.
CAUTION: The inverter contains a circuit breaker and capacitor that may produce a spark.
Do not mount in a confined battery or gas compartment.
CAUTION: Working in the vicinity of lead-acid batteries is dangerous. Batteries generate
explosive gasses during operation. There is a risk of acid exposure. There is also a risk of
high current discharge from shorting the battery that can cause fire and explosion.
CAUTION: UL and ABYC specify that the DC input shall be fused no further than 18" from
the battery. This is the responsibility of the installer.
CAUTION: Be sure both the inverter and, if used, the external AC input circuit breaker or
fuse are turned “OFF” during installation.
WARNING: The inverter/charger is not ignition protected so it must not be located in
an area where ignition protected equipment is required.
EXTERNAL CONNECTIONS TO THE INVERTER/CHARGER SHALL COMPLY WITH UL
RECOMMENDATIONS AND/OR UNITED STATES COAST GUARD ELECTRICAL REGULA-
TIONS (33CFR183, SUB-PART I)
THE INSTALLATION AND PROTECTION OF VESSEL WIRING ASSOCIATED WITH IN-
VERTER/CHARGERS SHALL COMPLY WITH ABYC STANDARDS E-8) AC ELECTRICAL
SYSTEMS ON BOATS, E-9) DC ELECTRICAL SYSTEMS ON BOATS, A-20) BATTERY
CHARGING DEVICES AND A-25) INVERTERS.
III) INSTALLATION
IMPORTANT: Do not attempt to begin the installation until you have read and understood
this section completely. If you have any questions regarding the installation of the inverter/
charger, contact NEWMAR’s technical service before proceeding.

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A) Materials Provided
The inverter/charger is provided with an installation kit containing the following:
(1 ea.) Hex wrench, 3/8"
(1 ea.) Warning label for AC distribution panel
(1 ea.) Installation/Operation Manual
(1 ea.) Customer satisfaction/warranty card
Please verify that these items have been included with the packaging. For any missing items,
contact the factory. Upon completion of the installation, please fill out the warranty card and
return it to the factory. (Be sure to include the serial number of the unit, located on the top
of the housing.)
B) Location
The inverter/charger should be located as close to the batteries as possible, ideally no more
than about 4-6 feet. The maximum allowable distance is 20 feet. Do not mount the unit
directly over the batteries as battery fumes may cause excessive corrosion. WARNING: The
inverter/charger is not ignition protected so it must not be located in an area containing gasoline
engines or the like, nor in any other area where ignition protected equipment is required. The
area should be well ventilated and free from moisture, exhaust manifolds and battery fumes.
Do not locate the unit where water, spray or condensation can occur, as this will shorten its
life. It should not be located where there is a possibility of dust or debris being drawn into
the unit through the fan. A minimum of 2" clearance around the unit is recommended for
proper cooling.
If the inverter/charger is located in an extreme heat area, such as an unventilated engine
room, and maximum operating temperature is exceeded, an automatic thermal protection
circuit will shut the unit completely off. It will automatically return to service when it has
cooled sufficiently, however this thermal cycling will shorten the life of the inverter/charger,
so if this condition occurs repeatedly, it should be relocated. For optimum performance and
longer life the unit should not be located in an area of high temperature.
C) Mounting
The inverter/charger may be mounted on either a horizontal or vertical surface; performance
will be unaffected by its orientation, however, per UL safety recommendations, when
mounted vertically the front panel controls should be facing downward. It may be mounted
on either a metal or non-metal surface. Four 1/4" screws (wood or machine screws, depend-
ing on mounting surface) with washers are required to secure the unit to the mounting
surface.
For vertical (bulkhead) mounting applications: Note that, in addition to the four permanent
mounting holes in the flanges, there is a hole in each mounting flange which is “keyhole”
shaped. This is provided to ease vertical installation. Make a mark on the wall or bulkhead
where each of the keyhole slots will be located. Then drive a screw about halfway in at each

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of these marks. Hang the inverter/charger onto the bulkhead using the “keyhole” slots.
Doing this will save you from having to support the unit’s weight while you are driving in the
four permanent mounting screws. Note: The “keyhole” slots may be used for additional sup-
port screws but they are not to be used as a permanent mounting points, by themselves.
IMPORTANT: Although the inverter/charger is constructed of materials and in a manner
which makes it resistive to the corrosive effects of the marine environment the unit is not
waterproof. Do not mount the charger where there is a possibility of water entering the unit.
Evidence of water entry into the charger will void the warranty.
D) Case Grounding
The case of the inverter/charger must be properly grounded to ship’s ground*.
*Per ABYC A-20: A DC chassis grounding conductor shall be connected from the case of
the battery charger to the engine negative terminal or its bus, and must not be more than
one size under that required for the DC current-carrying conductors.
For example, if the installed battery wiring (see Wire Size Chart in section F) is 1 AWG, then
the minimum size of the grounding cable is 2 AWG. Use stranded copper wire for case
grounding. A screw compression lug located on the right-hand side of the unit is provided for
attaching the ground wire to the case. The lug accommodates wires up to 1/0 AWG. A flat
blade screwdriver is required to tighten the lug.
E) Battery Selection and Sizing
The inverter/charger should only be wired to deep cycle lead-acid batteries of flooded, gel or
AGM construction. The battery bank should be a dedicated inverter (or house) bank. It
should not be connected to batteries which are designed primarily for engine or generator
starting. Those batteries are not designed for repeated deep discharges which are common
with inverter operation.
There are quite a number of variables which can influence the proper size of a battery system
(expressed as amp-hour capacity) which is used in conjunction with an inverter. Some of
these include:
!Battery type
!Discharge rate
!Intermittent or continuous operation
!Ambient temperature
!Time between recharge cycles
!Depth of discharge
No single formula can practically cover all these variables, however, a general calculation
may be used which assumes no extraordinary variable (such as very high or low tempera-
tures in the battery environment) to make an educated estimation of the proper battery size.
The result can then be adjusted up or down to compensate for unusual circumstances.