NewMar Phase Three PT-7 User manual

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INSTALLATION/OPERATION MANUAL
Model:
PT-7
CONTENTS
Section Topic Page
I) GENERAL INFORMATION.................................... 2
II) IMPORTANT SAFETY INFORMATION.................. 2
III) INSTALLATION.................................................... 5
A) Materials Provided................................. 5
B) Location................................................ 5
C) Mounting............................................... 5
D) d.c. Output Wiring................................. 6
E) a.c. Input Wiring.................................... 7
F) Gel-Cell/Lead-Acid Selector Switch....... 8
IV) OPERATION........................................................ 9
A) Three Stage Charge Regimen.................9
B) Start-Up................................................ 10
C) Constant Versus Occasional Use............ 11
D) Proper Load Sizing................................. 11
E) Operation with Engine........................... 11
F) Operation as a d.c. Power Supply........... 11
V) SPECIFICATIONS................................................. 12
VI) TROUBLESHOOTING........................................... 13
VII) BATTERY CARE TIPS.......................................... 15
VIII) REFERENCE APPENDIX.......................................17
M-PT7
As ofAPR 2003

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I) GENERAL INFORMATION
Your Phase Three Series Battery Charger represents a new phase in charger design and
performance, employing "smart" switching circuitry which puts batteries through the
optimum three-step charge process, adapts for gel-cell or lead-acid batteries, is rated for
continuous duty and is housed in a rugged stainless steel case.
Following is a brief listing of some of the more important features/options of your Phase
Three Charger. Each is fully detailed later in this manual:
* Three step “smart” charging: bulk, absorption, float
* Gel cell/lead-acid switch selects optimum charge/float voltages based on battery
type
* Dual output banks charge independently based on demand
* "Universal" 115/230V a.c., 50-60 Hz input—can be used anywhere in the world
* Charger Status indicator light—changes color according to output
* Current limiting prevents damage from overload
* Load activated cooling fan allows continuous operation at full-rated output
* Use as a power supply without in-line battery; allows continued use of d.c. powered
electronics (when a.c. is available) in the event that batteries must be taken off-line
or removed.
* "Float" selector switch protects batteries when charging under continuous load
* Rugged stainless steel case with drip shield
* Carries the CE mark.
* Ignition protected per USCG CFR 183.410
In addition, your Phase Three Charger carries a full two year warranty against defects in
materials or workmanship from the date of purchase. Careful attention to these instruc-
tions should help you to enjoy years of trouble-free service.
II) IMPORTANT SAFETY INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS — This manual contains important safety and operat-
ing instructions for the Phase Three Battery Charger.
2. Before using this battery charger, read all instructions and cautionary markings on
(1) the battery charger (2) the battery, and (3) any product powered by the battery.

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3. CAUTION — To reduce the risk of injury, charge only 6 cell lead-acid rechargeable
batteries (flooded, AGM, gel or sealed). Other types of batteries may burst, causing per-
sonal 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 a.c.
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 other-
wise subjected to damage or stress.
8. An extension cord should not be used. Use of an improper cord could result in a risk of
fire and electric shock.
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 other-
wise damaged; take it to a qualified serviceman.
11. Do not disassemble the charger; take it to a qualified 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 a.c. 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 UTMOST IMPORTANCE THAT BEFORE INSTALLING AND USING YOUR
CHARGER, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.
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 all cautionary markings on these products.
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.

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3. Wear complete eye protection 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 flood the eye with running cold water for at
least 10 minutes and get medical attention immediately.
5. NEVER smoke or allow a spark or flame 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 current
high enough to weld a ring or the like to metal, causing a severe burn.
8. Use the battery charger for charging gel-cell, AGM or flooded lead-acid batteries only.
Do not use the charger for charging dry-cell batteries that are commonly used with home
appliances. These batteries may burst and cause injury to persons and damage to prop-
erty.
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 manufacturer’s specific precautions such as removing or not removing
cell caps while charging and recommended rates of charge.
GROUNDING AND a.c. POWER CORD CONNECTION
1. The charger should be grounded to reduce the risk of electric shock.
(For marine applications only) EXTERNAL CONNECTIONS TO THE CHARGER SHALL
COMPLY WITH UL RECOMMENDATIONS AND/OR UNITED STATES COAST GUARD
ELECTRICAL REGULATIONS (33CFR183, SUB-PART I)
(For marine applications only) THE INSTALLATION AND PROTECTION OF VESSEL
WIRING ASSOCIATED WITH BATTERY CHARGERS SHALL COMPLY WITH ABYC
STANDARDS; E-8) AC ELECTRICAL SYSTEMS ON BOATS, E-9) DC ELECTRICAL SYS-
TEMS ON BOATS, AND A-20) BATTERY CHARGING DEVICES.

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III) INSTALLATION
A) Materials Provided
The PT-7 charger is provided completely assembled and ready for installation. The in-
staller must provide mounting hardware, as well as d.c. output wiring and connectors.
Proper sizes and gauges for the hardware, wire and connectors are noted in sections C
and D following. A warranty registration/customer satisfaction card has been included
in the packaging. Upon completion of the installation, please fill out this card and return
it to the factory. You will be contacted promptly if you have any problems with or ques-
tions about your Phase Three charger.
B) Location
The charger should be mounted on a wall, bulkhead or other suitable mounting surface
as close to the batteries to be charged as possible. Do not mount the charger directly
over the batteries as battery fumes may cause excessive corrosion. The charger is igni-
tion protected so it is acceptable to locate the unit in an area where ignition protected
equipment is required. The area should be well ventilated and free from excessive mois-
ture, exhaust manifolds and battery fumes.
Vertical mounting is preferred. However, horizontal mounting is acceptable where abso-
lutely necessary. Do not mount the charger where water, spray or condensation can occur, as
this will shorten charger 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
charger is recommended for proper cooling.
If the 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 charger off. Although it will return to service automatically after
cooling sufficiently, thermal cycling will shorten the life of the charger. If this condition
occurs repeatedly, the charger should be relocated. For optimum performance and longer
life the charger should not be located in an area of extreme high temperature.
C) Mounting
The charger may be mounted on either a metal or non-metal surface*.
*Per ABYC A-20: A d.c. 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 d.c. current-carrying conductors, and not less than 16 AWG.
Four # 10 screws (wood or machine screws, depending on mounting surface) with wash-
ers, are required to mount the charger.
IMPORTANT: Although the charger is constructed of materials and in a manner
which makes it highly resistive to the corrosive effects of moisture in the environ-