NewMar PM-12-80 Installation instructions

1
P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
PM Series 1kW Power Module
Power Supply/Battery Charger
Models:
PM-12-80, PM-24-40 & PM-48-20
InstallatIon/operatIon InstructIons
M-PM1KW
As Of June 2012
Table Of Contents
Topic Page
QUICK REFERENCE CONTENTS 2
I) OVERVIEW 3
II) AC POWER QUALITY AND EMI COMPATIBILITY 3
A) AC Power Quality 3
B) EMI (Electro-magnetic Interference) 3
C) Other Factors 3
III) INSTALLATION 4
A) Materials Provided 4
B) Mounting 4
C) AC Input Wiring and Voltage Selection 4
D) DC Output Wiring 5
E) Parallel Wiring 6
F) Chassis Grounding 6
IV) OPERATION 7
A) AC Input 7
B) DC Output 7
Regulation
Output Voltage Adjustment
Current Limit Circuit
D.C. Fuses
C) Local/Remote Alarm 7
V) OPTIONS 7
A) DC Quick Connect Kit 7
B) Charger Function Board 8
VI) SPECIFICATIONS 8
VII) TROUBLESHOOTING 9
VIII) WARRANTY AND CONTACT INFORMATION 9

2
P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Quick Reference
The front and rear panel features of the 1 kW Power Modules are illustrated below, along with the page number
where information on each particular feature is locaated.
FIGURE 1: Front Panel (all models):
ON
POWER MODULE
PM-12-80
INPUT:
90 - 264 VAC
16 A @ 115V / 8 A @ 230V
50-60 Hz.
OUTPUT:
13.6 VDC
@ 80 AMPS, CONTINUOUS
NOTE:
NO USER SERVICEABLE PARTS INSIDE. TO BE
SERVICED ONLY BY QUALIFIED PERSONNEL.
NEWPORT BEACH, CA USA
www.newmarpower.com
E-MAIL: [email protected]
TEL: [phone]
FAX: [phone]
POWER MODULE
POWER SUPPLY/BATTERY CHARGER
+
-
OUTPUT
V ADJUST
VOLTAGE
TEST POINTS
AC INPUT
AC INPUT
90 - 264 VAC TEMP
PROBE
EQUALIZE
SHORT PINS
1 & 3
1 2 3 1 2 3
1 2 3
OUTPUT
FAIL = 1 & 3
OK = 2 & 3
INPUT
FAIL = 1 & 3
OK = 2 & 3
(+) POSITIVE
OUTPUT
(-) NEGATIVE
OUTPUT
GND
OPTIONAL
ALARM
CONTACTS:
1 2 3
Ok
Fail
PM "ON" Indicator
Page 7
Input Switch/Circuit Breaker
Page 7
Output Voltage
Test Points
Page 7
Output Voltage
Adjustment Pot
Page 7
FIGURE 2: Rear Panel (all models):
AC Input Socket
Page 4
Output Terminals
Page 4
Chassis Grounding Stud
Page 6
Remote Alarm Contacts
Page 7
C
Output Terminal Cover

3
P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
I) Overview
The PM Series Power Module is a uniquely adaptable
communication equipment power source which
functions as either power supply or battery charger
for 12, 24 or 48 volt d.c. systems positive, negative or
floating ground. Power Modules may be employed
singly or in combination, enabling the installer to
scale the system output from 1000 to 6,000 watts per
rack. Units may be paralleled for N + 1 redundancy
and alarm contacts allow local or remote monitoring.
An optional d.c. wiring quick connect kit allows easy
replacement of modules while the system as a whole
remains up and running (see section V-A).
Power Modules may be used separately as a power
source, or they may be integrated with NEWMAR’s
Power Function Manager (model PFM-400; rated to
400 amps maximum) to greatly expand the system
capability with other functions such as digital output
monitoring, multiple load distribution and low
voltage disconnect. (Contact the factory for complete
information regarding the PFM-400.) Note: If the Power
Module is being installed as part of an integrated
system with the PFM-400 refer to the manual which
comes with that unit for all d.c. wiring instructions and
functional descriptions.
II) AC Power Quality and EMI Compatibility
A) AC Power Quality
Reliability is of prime concern when designing an
AC-DC power system for communication sites. Poor
AC input power quality can seriously impede system
reliability. In particular, transient disturbances on the
power lines can severely weaken or cause failure of
semi-conductors in power supplies and communication
gear. It is important that you know the input power
quality when installing the PM. Following is some basic
information on the subject:
Causes
Transients are characterized as a voltage pulse of high
energy and very short duration impressed upon the AC
wave form. These over voltage pulses can range from
1 to 100 times the normal AC voltage level and can
last for a fraction of a cycle to a few cycles.
Transient disturbances can be placed into two
categories:
- Lightning generated
- Equipment generated
A direct lightning hit on a utility power line will cause
a high energy voltage transient to travel in both
directions along the power line. This disturbance can
affect equipment hundreds of miles from the strike
point.
Equipment generated transient sources include utility
fault conditions and load switching as well as on-site
equipment such as pumps and air conditioning loads,
motors, phase control equipment.
Recommendations
All PM models requirements for transient withstand
capability. The AC power source should conform to this
specification to ensure reliable power supply operation.
If the power source quality is suspect or unknown, it
is recommended that an AC power quality survey be
conducted by a power quality consultant or power
conditioning firm. Corrective measures may include
lightning suppressors, line conditioners and filters.
An AC transient suppressor is recommended for
installations in third world countries and sites that
are subject to nearby lightning strikes or transients
caused by nearby motor contactors, air conditioning
compressors, etc.
B) EMI (Electro-Magnetic Interference) Considerations
The PM Series Power Modules employ switch-mode
technology to convert AC to DC. They are designed
to produce minimal EMI levels when operating
(compliant to International Standards EN55022
(CISPR22) EN61000-3-2,3. Although the level of
EMI produced may be acceptable for most radio
applications, some installations may not even tolerate
what little EMI is produced.
Analog microwave and other extremely sensitive radio
sites may require additional input/output filtering and
careful installation. In some cases linear power supplies
(also available from NEWMAR) should be considered,
as they emit lower EMI (although they are more
susceptible to “brown-outs” or voltage sags and high
input voltage).
C) Other Factors
Some of the various factors which must be considered
when discussing electrical interference include the
following:
- RF Signal strength
- Ground loops
- Power and signal cable routing proximity
- Power supply and radio mounting locations
- Antenna, signal, and power grounds

4
P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
III) Installation
A) Materials Provided
Prior to installation, check to ensure that each of
the following items have been included with the
packaging. For any missing items please contact the
factory or warehouse.
(2) ea. Mounting brackets for 19” rack mounting
(# 13917-0)
(6) ea. 6-32 X 3/8” pan head Phillips screws
(2) ea. 3 position pluggable connector (Alarm Contacts)
- installed on rear panel
(1) ea. 115V NEMA 5-20P AC input power cord
(1) ea. Installation/Operation manual
(1) ea. Plastic output terminal guard (#15645-0)
(2) ea. 6-32 x 7/16" pan head Phillips screws
(mount guard)
B) Mounting
The PM is provided with one set of mounting ears for
19" rack mounting (# 13917-0). Six # 6-32 x 3/8” pan
head Phillips screws are provided for attaching the ears
to the PM chassis. Note: For 23" rack mounting, please
contact Newmar and request a pair of P/N: 699-3918-0,
23" rack ears.
Note there are three sets of a triangular pattern of
6-32 tapped holes on each side of the PM. When rack
mounting (two posts) the PM it is recommended that
the ‘center mount’ holes (6” set back from the PM’s
front panel) be used. The set of holes nearest the front
panel and the set nearest the rear panel are normally
used when installing the optional Universal Mounting
Bracket (UMB).
For four post mounting, please contact the factory for
a second set of ears (specify 19” or 23” and the model
no.), mount one pair of ears to the front holes and the
second pair of ears to the center or rear most tapped
holes. Adjust your cabinet rail front to back distance so
it matches the mounting holes on the PM.
Note: Due to the weight of the Power Module, we
do not recommend flush mounting the PM with the
mounting ears attached to the forward most mounting
holes unless rear support is provided.
C) AC Input Voltage, Current, and Wiring
1) Input Voltage: These Power Modules operate from 90
to 264 VAC, universal input. No switch position changes
or jumpers needed. They will operate from 115 or 230
VAC on initial start-up without any adjustments.
2) Input Currents @ Full Load:
115 VAC = 13 Amps
230 VAC = 7 Amps
3) Input Wiring: These models are provided with an IEC
power cord (in the installation kit) with a NEMA 5-20
plug (115 VAC, 20 Amp) attached for use with a 115
VAC, 20 amp outlet and one end with a molded socket
that mates with the chassis mount IEC C-19 connector
on the rear of the PM. If the 5-20 plug is not suitable
for the available AC outlet at site, two choices are
available:
A) Obtain an IEC cord with appropriate plug and IEC
C-19 mating socket or
B) Cut off the 5-20 plug, obtain correct plug for the
available outlet and attach to the provided IEC
power cord (plug should be rated at 20 Amps). When
replacing the plug, pay careful attention to the AC
plug terminal wiring as follows:
BLACK......................AC Hot (over-current protected/
Line 1 (230 VAC split phase i.e. North America)
WHITE......................AC Neutral/Line 1 (115 VAC North
America) or AC Hot/Line 2 (230 VAC split phase i.e.
North America)
GREEN or GREEN w/YELLOW stripe.......Ground (safety,
earth)
Important: Although the internal AC wiring is
protected by the front panel mounted double pole
circuit breaker, the wiring to the PM must also be
protected by plugging into an appropriate over-
current protected three prong outlet or routed through
a separate dedicated fuse or circuit breaker on an AC
distribution panel with proper safety/earth chassis
ground in accordance with all applicable codes and
ordinances.
Distribution Panel AC Fuse/Circuit Breaker Values
115 VAC = 20 amp
230 VAC = 10 amp
D) DC Output Wiring
IMPORTANT: Ensure that AC input to the PM is
switched off before working with DC wiring. The output
terminals are “hot” whenever the unit is switched on.
1) 1/4"-20 thread output terminals and washers for
hard-wiring of DC output are located on the rear
panel of the PM. Terminate wires with 1/4” ring lug
connectors and use the provided 1/4" hardware for a
secure installation.

5
P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
2) Use the chart below to determine minimum gauge
for wires depending on the particular model and the
length of the run from the PM to the load or distribution
DC Wire Size Table:
Model Minimum Wire Size per N.E.C. AWG (mm)
PM-48-20 #14 (2.5 mm)
PM-24-40 #8 (10 mm)
PM-12-80 #4 (25 mm)
To minimize line loss at lengths greater than 5 feet, it is
recommended to increase wire size one gauge for each
additional 5 feet of cable run.
Note: When the PM is used in a parallel n+1 redundant
configuration, output current is derated by 10 % due
to current sharing tolerances (see SPECIFICATIONS
section).
Typical single PM wiring schemes are illustrated
in Figures 3-4.
FIGURE 3: Single Power Module, negative ground, with battery
FIGURE 4: Single Power Module, positive ground, with battery
(-) Negative to Load
or Ground Bus Bar
(+) Positive to Load
or Distribution Panel
BATTERY
* Typical; Fuse per
N.E.C or local code
* Typical; Fuse per
N.E.C or local code
(+) Positive to Load
or Ground Bus Bar
(-) Negative to Load
or Distribution Panel
BATTERY

6
P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
E) Parallel Wiring
The internal oring/isolation diode of the PM allows
parallel n+1 redundant wiring with no modification or
other external isolation devices required. Figures 5-6
illustrate some typical parallel wiring schemes.
IMPORTANT: When wiring two or more units in parallel
d.c. wires for all units should be identical in gauge and
length and the output voltage of each module should
be adjusted (as outlined below) in order to facilitate
droop load sharing.
Parallel Load Sharing Adjustment Procedures
Method 1:
1) Shut off all but one of the Power Modules and apply
a load equivalent to 1/2 of the rating for that unit (e.g.,
for model PM-12-80 apply a 40 amp load).
2) Connect a digital voltmeter to the test points on the
front of the power module at the “V OUT” and (+) and
(-) positions.
3) Verify that the output voltage is at the correct factory
setting (see Specifications section) or at the desired
system voltage. If adjustment is necessary, use a small
flat tip screwdriver to turn the “OUTPUT VOLTAGE
ADJUST” potentiometer on the front panel until the
voltmeter reads the desired system output voltage.
4) Shut off the PM, turn on the next unit in the system,
and repeat steps 2 through 4 until all PM’s in the system
have the identical “V OUT” output voltage.
Method 2:
1) With all Power Modules powered up, apply the
typical operational DC system load.
2) Using a clamp-on ammeter, measure the output
current of each PM in the system. If there is an out-
put current differential of greater than 5 % between
any two PM’s, attach the ammeter to the PM with
the highest output current and turn the “OUTPUT
VOLTAGE ADJUST” potentiometer on that unit slowly
counterclockwise, until the output current of that unit
reduces slightly.
3) Repeat step 2 until there is less than 5% current
output differential between all PM’s in the system.
F) Chassis Grounding
If grounding of the PM chassis is required for the
installation, use the provided 1/4” grounding stud on
the rear panel for this purpose (see Figure 2).
FIGURE 5: Parallel (two to six Power Modules)
and N+1 redundancy, negative ground
FIGURE 6: Parallel (two to six Power Modules)
and N+1 redundancy, positive ground

7
P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
IV) Operation
A) AC Input
The PM will operate on any AC voltage in the following
range: 90-264 VAC, 50-60 Hz.
AC input is protected against over-current and internal
short circuit conditions by the circuit breaker/input
power switch on the front panel. When this switch is
in the on position and DC is available at the output
terminal, the “ON” indicator L.E.D. on the left side of the
front panel will illuminate green.
If AC power is connected and the input power switch
is on but AC Input indicator is red, a fault has occurred
within the Power Module.
B) DC Output
The PM produces 12, 24 or 48 VDC nominal output,
depending on model. The ground reference may
be positive, negative or floating. Chassis is isolated
from DC. A 1/4" chassis ground stud is provided for
grounding the chassis to DC pos. (+), or neg. (-) if
desired
Regulation: Regulation at the output terminal is
within ± 2 % of rated voltage, under all line and load
conditions. Ripple is within ± 1 % of rated voltage with
or without batteries on-line.
Output Voltage Adjust: Factory-set voltages (as
measured at the output terminal) and approximate
adjustment ranges are specified below. Adjustment
is made at the “OUTPUT VOLTAGE ADJUST” pot on
the left side of the front panel using a small flat tip
screwdriver (see Figure 1). Output voltage test points
provided beside the voltage adjust pot for ease of
monitoring while making this adjustment. Use of a
digital multimeter is recommended when making this
adjustment. If the PM has had the charger function
board installed, output voltage adjustments are
automatic and this adjustment pot has limited range.
Output Voltage Table
Factory Set “V OUT” “V OUT”
Model Output Voltage Adjustment
Range
PM-12-80 13.6V DC 12.2 - 15V DC
PM-24-40 27.2V DC 24.4 - 30V DC
PM-48-20 54.4V DC 48.8 - 60V DC
Current Limit Circuit: The PM is rated for continuous
duty at the current level indicated by model
number, e.g., PM-24-40 is rated at 40 amps con-
tinuous duty. To prevent overload when recharging
severely discharged batteries, current is limited at
approximately 105-115% of the continuous duty rating.
DC Fuses: d.c output wiring is protected by an internal
DC output fuse. The current limiting circuit of the PM
should prevent this fuse from blowing under normal
operating conditions. If the d.c fuse blows, this may
indicate a reverse polarity hook-up or an internal short.
Always disconnect AC to the PM before checking fuses.
To replace the DC fuse, the cover must be removed.
The DC fuse is an HBO type mounted near the rear
panel . Be sure to replace with the same type and
value as indicated on the fuse.
If the battery is connected to the PM output with
backwards polarity, the fuse should blow to protect
DC wiring. However damage to internal components
may also have occurred. If the replacement fuse blows,
return the PM to the factory for a thorough inspection.
C) Local/Remote Alarm
A loss-of-output relay and loss of input relay (both
form “C”) are wired to the pluggable output connectors
on the rear panel. When wired to an external alarm
or remote indicator lamp it will alert the operator in
the event of any condition which causes a loss of DC
output.
The alarms may be wired with the relay “normally
open” or “normally closed”, as needed. See FIGURE 2
for the contacts position during input or output failure
and normal operating condition.
Relay contact rating for all models is 2A @ 30V DC.
V) Options
A) DC Quick Connect Wiring Kit
Note: This option is available only for systems which
incorporate the NEWMAR Power Function Manager.
For complete information on this product, please
contact the factory.
A DC wiring harness quick connect kit is available
from NEWMAR which simplifies parallel wiring
installation of multiple Power Modules with the Power
Function Manager and facilitates “hot change-out” of
modules for repair or replacement.

8
P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
The kit consists of two wiring harness; one for positive
and negative DC output wiring, another for alarm
contact wiring. Wires are pre-cut to proper length, all
necessary connectors are installed and the bundles
are neatly tie-wrapped into proper position for a simple
and professional installation.
For more information, or to order the quick connect kit,
please contact the factory and specify the number of
PM’s (2-6) in the system being installed.
PM DC Quick Connect Wiring Kits Model Numbers
PM Model 2-3 PM Wire
Harness
4-6 PM Wire
Harness
PM-12-80 QCK-3A QCK-6A
PM-24-40 QCK-3 QCK-6
PM-48-20 QCK-3 QCK-6
B) Charger Function Board
The Chager Function option (model CFCB, works on
12, 24, and 48 VDC models) is available for installation
at the factory or purchased later for field installation.
The charger function option provides smart three-
stage temperature compensated charging of GEL and
FLOODED lead acid batteries as well as a manually
triggered "Equalize" timer for flooded-lead acid
batteries.Contact Newmar or your distributor for more
information.
If this option was factory installed, there will be a
Temp Probe and Equalize connnector installed at
the rear panel and you should receive a Charger
Function Operation Manual. If you wish to install the
charger function option, contact Newmar or your local
distributor for ordering information. Installation and
operation instructions will be provided.
With the charger function board installed, each of
the following installation/performance options are
available:
1) Three stage “smart” charging: Bulk, Absorption, Float
2) Selection of ideal charge regimen for either gel-cell
or flooded lead acid batteries
3) Installation of an optional temperature compensation
sensor for optimal charging in high/low temperature
environments
4) Installation of an equalize timer for periodic
equalization of battery plates (for use with
flooded-type batteries only)
VI) Specifications: All Models
Input: 90 - 264 VAC (universal), 50 - 60 Hz.
Power Factor: 0.95 - 0.98
Regulation (with internal or-ring diode): ± 2%
Ripple P-P: 1%
Efficiency: 86% @ full load
Output Voltage Adjustment Range: ± 10 %
Temperature Rating: -20° to +70° C derate linearly from
100% load @ 50° C to 50% load at 70° C
Altitude Operational Rating: Full output to 5,000 feet;
reduce output current 4% per 1,000 feet
above 5,000 feet; 10,000 feet maximum
Individual Model Specifications
Model
Input Amps
@ F.L.
115/230V
Output
Voltage
Output
Amps
Cont.
PM-12-80 16/8 13.6 80
PM-24-40 16/8 27.2 40
PM-48-20 16/8 54.4 20
Protection
Output fuse for reverse polarity
Current limit and foldback
Input circuit breaker
Over-temperature shut-down, automatic recovery
Over-voltage protection
Case Size (all models):
Dimensions: 3.5” H x 17” W* x 20.5” D
* 19” mounting brackets provided
Weight: 15.2 Lbs.

9
P.O. Box 1306
Newport Beach
California 92663
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
VII) Troubleshooting
Condition Possible Cause Solution
A. No Output 1. PM not receiving AC input
voltage or is not receiving correct
input voltage
2. PM limiting its output due
to overload or high ambient
temperature codition.
3. Blown output fuse possible
reverse battery polarity
4. Defective Power Module
1. Using a voltmeter, confirm
AC input voltage. Check input
connections.
2. Reduce DC load and/
or determine cause of over
temperature condition.
3. Clear blown fuse (See section IV-
B, DC Output - DC Fuse)
4. Return to place of purchase for
repair/replacement or contact
NEWMAR for return authorization
B. PM repeatedly trips input circuit
breaker with no battery or load
connected
1. Internal short 1. Return to place of purchase for
repair/replacement or contact
NEWMAR for return authorization
C. Reverse polarity battery
connection to PM has cause and
PM to stop charging
DC output fuse and possibly other
components blown
Replace output fuse. If fuse blows
again, return to place of purchase
for repair/replacement or contact
NEWMAR for return authorization
D. Batteries connected to PM
overcharging
Output voltage adjusted too high Lower output voltage (See section
IV-B, DC Output - Output Voltage
Adjust) to battery manufacturer's
recommended charging levels
VIII) Warranty and Factory Contact Information
Newmar warrants that the Power Module be free from defects in material and workmanship for two years from
date of purchase. If you have a problem with your Power Module, or have any questions about the installation
and proper operation of the unit, please contact NEWMAR’s Technical Services Department:
Phone: [phone] - From the hours of 7:30 a.m. to 5:00 p.m. weekdays, P.S.T.
Fax: [phone]
E-mail: [e-mail]