NewMar EV-40 User manual

P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
www.newmarEVpower.com
Emergency Vehicle Battery Charger
Model: EV-40
Installation/Operation Manual
Table of Contents
Section Topic Page
QUICK REFERENCE DRAWING………………………………….........….....……......………….......... 2
I) GENERAL INFORMATION…................…..........….………….........…………...............…………… 3
II) IMPORTANT SAFETY INFORMATION…....…......................…………….........………………… 3
III)INSTALLATION……………………………………………………………………................….…....... 4
A) Materials Provided…………………………………………….….............................… 4
B) Location……………………………………………………..................……….......…… 4
C) Mounting………………………………………………………............………..………… 5
D) DC Output Wiring, Battery & Auxiliary Loads…………..…….......................... 5
E) AC Input Wiring............................................................................................................. 7
IV)OPERATION…………………………………………………………………………............................. 7
A) Three Stage Charge Regimen…………………………........................................... 7
B) Time-Out Circuit…………………………………………………....................…............ 8
C) Gel-Cell/AGM/Lead-Acid Selector Switch…………..…................................…. 8
D) Remote Monitor Panel Option………………………………….……………….…… 8
E) Cooling Fan.................................................................................................................... 8
F) Power-On Indicators……………………………………………………………............. 9
V) APPLICATION NOTES………………………………………………..…………………………........ 9
A) Start Up…...……………………………………………..…………………....................... 9
B) Constant Versus Occasional Use……………..…………………………................. 9
C) Proper Load Sizing………………………………….…………………………............... 9
D) Operation with Engine…………………………....…………………………............... 10
E) Operation as a DC Power Supply (stand-alone DC power source)…….… 10
VI) SPECIFICATIONS…………………………………………………………………………………....... 10
VII)TROUBLESHOOTING………………………………………………………………........................... 11
VIII) BATTERY CARE TIPS…………………………………………………………................................ 13
UNIT DIMENSION DRAWING…………………………………………………………………….......... 14
M-EV40
As of April 2011

P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
www.newmarEVpower.com
Quick Reference Drawing: EV-40
AC Plug Input Socket (IEC) Modular
Plug, Cord Provided; Pg. 7
AC Power Indicator
Light (Green); Pg. 9
Remote Meter Plug-in
Connector; Pg. 8
Battery Type Selector
Switch (Gel-Cell/
Lead-Acid/AGM);
Pg. 8
Battery Output Connector Block - 40
Amps Maximum; Pg. 5
Auxiliary Output Connector Block
- 15 Amps Maximum (Air Pump,
Hand Lights, Radios); Pg. 5
Slide-in and Lock
Mounting Plate
(optional); Pg. 5
DC Output Inidcator
Light (Green); Pg. 9
Auxiliary Output Indicator
Light OK (Green); Pg. 9
Auxiliary Output Selector Switch:
A) powered only when AC shore
power connected (battery saver
mode), B) continuously connect-
ed to vehicle battery; Pg. 6
Protective Front Panel Kick Plate
(Optional); Pg. 5
BATT AUX
+ - - +
2
A - B
Optional Accessories
Remote Meter, EVM-12-1
(Optional); Pg. 8

P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
www.newmarEVpower.com
1) General Information
The EV™ Series Battery Charger represents a new phase in
charger design and performance. It’s ideal for application
on emergency and specialty vehicles, utilizing “smart”
switching circuitry which puts batteries through the
optimum three-stage charge process, adapts for gel-cell,
AGM or lead-acid batteries, is rated for continuous duty
and is housed in an aluminum case with an optional
slide-in front access installation bracket.
Following is a brief listing of some of the more important
features/options. Each is fully detailed later in this manual:
• Three step “smart” charging: bulk, absorption, oat
• Gel-Cell/AGM/Lead-Acid switch selects optimum charge/
oat voltages based on battery type
• 90-264VAC, 50-60 Hz input – can be used anywhere in
the world
• Current limited – prevents damage in case of overloading
• Thermally controlled cooling fan allows continuous
operation at full-rated output
• High charge voltage time-out circuit prevents
overcharging during continuous high amperage demand
• Optional Remote Panel allows remote monitoring of
charger status
• Use as a power supply without in-line battery; allows
continued use of DC powered electronics (when AC is
available) in the event that batteries must be taken off-
line or removed
• Auxiliary output for electronics, air compressors, and
hand lights
II) Important Safety Instructions
1. SAVE THESE INSTRUCTIONS – This manual contains
important safety and operating instructions for the EV-40
Battery Charger.
2. Before using this battery charger, read all instructions
and cautionary markings on (1) the battery charger, (2)
the battery, and (3) product powered by the battery.
3. CAUTION – To reduce the risk of injury, charge only 6
cell (12 volt models) gel-cell or lead-acid rechargeable
batteries. Other types of batteries may burst, causing
personal injury and damage.
4. Do not expose charger to rain or spray.
5. Use of an attachment not recommended or sold by
NEWMAR may result in a risk of fire, electric shock or
injury to persons.
6. To reduce the risk of damage to the electric plug and
cord (if plugged into an AC outlet), pull by plug rather
than cord when disconnecting the charger.
7. Make sure the cord is located so that it will not be stepped
on, tripped over, or otherwise subjected to damage or stress.
8. An extension cord should not be used unless absolutely
necessary. Use of an improper cord could result in the risk
of fire and electric shock. If an extension cord must be
used, make sure:
A) That pins on the plug of the extension cord are the same
number, size and shape as those on the plug of the charger.
B) That the extension cord is properly wired and in good
electrical condition.
C) That the wire size is large enough for the AC amperage
rating of the charger. Refer to the SPECIFICATIONS Section,
page 10, to determine the full load input current of your
charger, and then use the chart below to determine the
correct gauge wire for any extension cord used.
25 50 100 150
16 14 12 10
9. Do not operate the charger with a damaged cord or
plug; replace them immediately.
10. Do not operate the charger if it has received a sharp
blow, been dropped, or otherwise damaged; take to a
qualified serviceman.
11. Do not disassemble the charger; take it to a qualied
serviceman when service or repair is necessary. Incorrect
reassembly may result in a risk of electric shock and fire.
12. To reduce the risk of electric shock, disconnect
the charger from AC source before attempting any
maintenance or cleaning.
WARNING – RISK OF EXPLOSIVE GASES
1. WORKING IN THE VICINITY OF A LEAD-ACID BATTERY
IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE
GASES DURING NORMAL BATTERY OPERATION. FOR
THIS REASON, IT IS OF THE UTMOST IMPORTANCE THAT
BEFORE INSTALLING AND USING YOUR CHARGER, READ
THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.
RECOMMENDED MINIMUM AWG
SIZE FOR EXTENSION CORDS FOR
EV BATTERY CHARGER
Length of Cord, Feet
Size of Cord, AWG
3

P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
www.newmarEVpower.com
2. To reduce the risk of battery explosion, follow these
instructions and those published by the battery
manufacturer and by the manufacturer of any equipment
you intend to use in the vicinity of the battery. Review
cautionary markings on these products and on the engine.
PERSONAL PRECAUTIONS
1. Someone should be within range of your voice or close
enough to come to your aid when you work near a lead-
acid battery.
2. Have plenty of fresh water and soap nearby in case
battery acid contacts skin, clothing, or eyes.
3. Wear complete eye and clothing protection. Avoid
touching your eyes while working near a battery.
4. If battery acid contacts skin or clothing, wash
immediately with soap and water. If battery acid enters the
eye, immediately ood eye with running cold water for at
least 10 minutes and get medical attention immediately.
5. NEVER smoke or allow a spark or ame in the vicinity
of the battery or engine.
6. Be extra cautious to reduce the risk of dropping a metal
tool onto the battery. It might spark or short-circuit the
battery or other electrical part and cause an explosion.
7. Remove personal metal items such as rings, bracelets,
necklaces, and watches when working with a lead-acid
battery. A lead-acid battery can produce a short-circuit
high enough to weld a ring or the like metal, causing a
severe burn.
8. Use the battery charger for charging gel-cell or ooded
lead-acid batteries only. It is not intended to supply power
to a low voltage electrical system other than in a starter-
motor application. Do not use the charger for charging
dry-cell batteries that are commonly used with home
applications. These batteries may burst and cause injury
to persons and damage to property.
9. NEVER charge a frozen battery.
PREPARING TO CHARGE
1. Be sure the area around the battery is well ventilated.
2. Clean battery terminals. Be careful to keep corrosion
from coming in contact with eyes.
3. Add distilled water in each cell until battery acid
reaches level specified by battery manufacturer. This
helps purge excessive gas from cells. Do not overfill. For a
battery without cell caps, carefully follow manufacturer’s
recharging instructions.
4. Study all battery manufacturers’ specific precautions
such as removing or not removing cell caps while charging
and recommended rates of charge.
GROUND AND AC POWER CORD CONNECTION
1. The charger should be grounded to reduce risk of
electrical shock.
2. The Charger is provided with IEC certified AC power cord.
If, for any reason, the plug on the cord must be changed or
replaced, observe color coding of the AC wiring as follows:
Black………..................................…AC Hot (fused)
White………….................................AC Neutral
Green……...................…......………AC Ground (safety/earth)
The charger must be plugged or hard wired into an outlet
that is properly installed and grounded in accordance
with all local codes and ordinances.
DANGER: Never alter the AC cord or plug provided, unless
it is absolutely necessary for use with the AC outlet which
conforms to all relevant electrical codes. Any modification
of the cord must only be done by a qualified electrician.
Improper cord/outlet connection can result in a risk of
electrical shock.
EXTERNAL CONNECTIONS TO THE CHARGER SHALL
COMPLY WITH UL RECOMMENDATIONS, NEC, or NFPA
STANDARDS
III) INSTALLATION
A) Materials Provided
The charger is provided completely assembled and ready
for installation. Because of numerous installation variables,
the installer will need to provide four suitable ¼” mounting
screws/washers, as well as DC output wiring and battery
connectors. Proper sizes and gauges for the wire and
connectors are noted in Section III-D following.
B) Location
The charger should be mounted on a wall, vehicle oor,
ventilated compartment or other suitable surface as close
to the batteries to be charged as possible. Do not mount
the charger directly over the batteries as fumes may cause
excessive corrosion. The area should be well ventilated
and free from excessive moisture, exhaust manifolds, and
battery fumes.
For maximum performance, the charger should not be
located in an area of extreme high temperature.
4

P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
www.newmarEVpower.com
IMPORTANT: Although the charger is constructed of
materials and in a manner which make it highly resistive
to the corrosive effects of moisture in the environment, the
charger 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.
C) Mounting
Charger only (not using optional Slide-in Bracket
Assembly.)
The charger may be mounted on either a metal or non-
metal surface. You will require four (4) screws (wood or
machine screws, depending on mounting surface) with
washers, sized for ¼” holes, located on the tab end panel.
For extreme vibration installations, use optional High-Vibe
Mounting Kit (model Kit-L).
Optional Slide-In Bracket
For installation in hard to access locations such as under
a seat or in storage compartments, an optional “slide-in”
bracket assembly is available (P/N: 444-52790-0), which
permits total front access only removal and re-installation.
The system consists of a base mounting plate which is
secured to the vehicle, and a slide plate which attaches
to the bottom plate of the battery charger. This slide plate
has pins that slide in and engage with the base mounting
and are secured in place by front panel screws. The slide-in
plate can be oriented to the rear of the assembly or facing
out, at installers discretion. Reference Figure 2.
Figure 2: Optional Slide-In Bracket
Slide-in and Lock Mounting System Description
The Slide-in and Lock mounting plate system is designed
to ease installation and removal of the EV-40 charger in
hard to access areas such as under seats and in small
compartments:
• Charger is secured to the slide-in and lock plate
via 4 stud mounts.
Note charger can be oriented either direction
on the plate to meet desired location of front
panel wiring.
• The Vehicle mounting bracket is secured in its
desired location via 6 fasteners.
• Charger with plate attached the slides on to the
vehicle mounting bracket and is captured via
two insertion pins at one end and secured in
place via stainless steel fasteners and compression
angle bracket at other end.
Kick Plate
To protect wiring on the charger end panel, an optional
Kick Plate is available, (P/N: 444-5280-0)
It installs using the front end panel screws. Loosen the two
(2) screws shown in Figure 3, and attach the kick plate to
the battery charger case. Re-tighten screws.
Figure 3: Kick Plate
D) DC Output Wiring To Battery
Secure battery wiring to the output terminal block observing
proper polarity and wire gauge per the table on the
following page. Strip wires 1/2”, insert in barrel terminal
and secure in place by tightening the screw. Note, wire
terminals are not necessary. See Figure 4.
EV-40 Charger
Slide-in and
Lock Plate
Vehicle Mounting Bracket
Insertion Pins To
Retain Charger To
Vehicle Mounting
Bracket
Plate Screws
5
Studs Secure
Charger to
Plate