NewMar PT-14W User manual

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PhaseThree 
ThreeStageSmartCharger
Installation/Operationmanual 
Models:PT‐14W,PT‐25W,PT‐24‐8W,&PT‐24‐13W
CONTENTS
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SectionTopicPage
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I) GENERALINFORMATION.................................3
II) IMPORTANTSAFETYINFORMATION................4
III) INSTALLATION.................................................6
A)MaterialsProvided..........................6
B)Location..........................................6
C)Mounting........................................6
D)DCOutputWiring............................7
E)MultipleUnitParallelWiring...........9
F)ACInputWiring...............................9
IV) OPERATION.....................................................10
A)ThreeStageChargeRegimen...........10
B)Time‐OutCircuit..............................12
C)Gel‐Cell/Lead‐AcidSelectorSwitch..13
D)RemoteMonitorPanelOption........13
E)TemperatureCompensationOption.14
F)EqualizeTimerOption......................15
G)OutputAmmeter………………….……….16
H)Power‐OnIndicator………………….…..16
V) APPLICATIONNOTES........................................16
A)Start‐Up..........................................16
B)ConstantVersusOccasionalUse......16
C)ProperLoadSizing...........................17
D)OperationwithEngine....................17
E)OperationasaDCPowerSupply......17
VI) SPECIFICATIONS...............................................17
VII) TROUBLESHOOTING........................................18
VIII) BATTERYCARETIPS.........................................20
IX) REFERENCEAPPENDIX.....................................22
lUnitDimensionDrawing.……………..……………....23
M‐PT‐W4
AsofDecember08

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QuickReferenceDrawing
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I)GENERALINFORMATION
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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,featuresprecisevoltagecompensationforvarying
batterytemperature,isratedforcontinuousdutyandishousedinarugged,powdercoatedstainless
steelandaluminumcase.
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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:
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*Threestep“smart”charging:bulk,absorption,float
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*Gelcell/lead‐acidswitchselectsoptimumcharge/floatvoltagesbasedonbatterytype
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*Multipleoutputbankschargeindependentlybasedondemand
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*"Universal"115/230VAC,50‐60Hzinput—canbeusedanywhereintheworld
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*Currentlimitingpreventsdamagefromoverload
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*Coolingfanallowscontinuousoperationatfull‐ratedoutput
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*Highchargevoltagetime‐outcircuitpreventsoverchargeduringcontinuoushighamperage
demands
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*Optionaltemperaturecompensationsensor(modelTCS‐12/24)finetunesoutputvoltagebasedon
batterytemperature
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*Optionalremotepanel(modelRP)allowsremotemonitoringofchargerphasestatusandmanualre‐
initializationofthreestagechargecycle
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*Optionalequalizationcircuitconnection
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*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
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*Ruggedstainlesssteelcasewithdripshield
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*ModelsPT‐14WandPT‐24‐8WcarrytheCEmark
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*AllmodelsignitionprotectedperUSCGCFR183.410
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Inaddition,yourPhaseThreeChargercarriesafulltwoyearwarrantyagainstdefectsinmaterialsor
workmanshipfromdateofpurchase.Carefulattentiontotheseinstructionsshouldhelpyoutoenjoy
yearsoftrouble‐freeservice.
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II)IMPORTANTSAFETYINSTRUCTIONS
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1.SAVETHESEINSTRUCTIONS—Thismanualcontainsimportantsafetyandoperatinginstructionsfor
thePhaseThreeBatteryCharger.
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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(PT‐14WandPT‐25W)or12cell(PT‐24‐8W
andPT‐24‐13W)lead‐acidrechargeablebatteries(flooded,AGM,gelorsealed).Othertypesofbatteries
mayburst,causingpersonalinjuryanddamage.
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4.Donotexposechargertorainorspray.
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5.UseofanattachmentnotrecommendedorsoldbyNEWMARmayresultinariskoffire,electricshock
orinjurytopersons.
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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.
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7.Makesurethecordislocatedsothatitwillnotbesteppedon,trippedover,orotherwisesubjected
todamageorstress.
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8.Anextensioncordshouldnotbeused.Useofanimpropercordcouldresultinariskoffireand
electricshock.
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9.Donotoperatethechargerwithadamagedcordorplug;replacethemimmediately.
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10.Donotoperatethechargerifithasreceivedasharpblow,beendropped,orotherwisedamaged;
takeittoaqualifiedserviceman.
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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.
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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
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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.
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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.

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PERSONALPRECAUTIONS
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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.
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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.
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5.NEVERsmokeorallowasparkorflameinthevicinityofthebatteryorengine.
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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.
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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.
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8.Usethebatterychargerforcharginggel‐cell,AGMorflooded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appliances.
Thesebatteriesmayburstandcauseinjurytopersonsanddamagetoproperty.
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9.NEVERchargeafrozenbattery.
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PREPARINGTOCHARGE
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1.Besuretheareaaroundthebatteryiswellventilated.
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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sealed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.
GROUNDINGANDACPOWERCORDCONNECTION
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1.Thechargershouldbegroundedtoreducetheriskofelectricshock.
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(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SYSTEMSONBOATS,ANDA‐20)BATTERYCHARGINGDEVICES.
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III)INSTALLATION
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A)MaterialsProvided
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ThePhaseThreechargerisprovidedcompletelyassembledandreadyforinstallation.Theinstallermust
providefoursuitable1/4"mountingscrews/washers,aswellasDCoutputwiringandconnectors.
PropersizesandgaugesforthewireandconnectorsarenotedinsectionDfollowing.
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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ignition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moisture,exhaustmanifoldsandbatteryfumes.

Verticalmountingispreferred.However,horizontalmountingisacceptablewhereabsolutely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

ImportantPre‐InstallationNote:ThewiringaccessportforACinputislocatedonthebottomofthe
charger.Ifthefactory‐installedACcordmustbechangedforanyreason,thisshouldbedonebefore
mounting,asaccesswillbedifficultafterwards.

Thechargermaybemountedoneitherametalornon‐metalsurface*.
*PerABYCA‐31: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,andnotlessthan16AWG.

Fourscrews(woodormachinescrews,dependingonmountingsurface)withwashers,sizedfor1/4"
holes,arerequiredtomountthecharger.Anadditionaltwotemporaryholdingscrewswilleasevertical
installation.Theprovideddripshieldisinstalledusingtheuppertwomountingscrews.

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.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ofthesemarks.Hangthe
chargerontothebulkheadusingthekeyholeslots.Doingthiswillsaveyoufromhavingtosupportthe
charger’sweightwhileyouaredrivinginthefourpermanentmountingscrews.Note:Thekeyholeslots
maybeusedforadditionalsupportscrewsbuttheyarenottobeusedaspermanentmountingpoints
bythemselves.
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environment,thechargerisnotwater‐resistant.


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)DCOutputWiring

Note:Onlyqualifiedservicepersonnelshouldaccesstheoutputterminalsofthecharger.

Theinstallerwillneedtoprovideoutputwires.Usethetablebelowtodeterminethecorrectgauge
wire,basedonthelengthofthewirerunfromthechargertothebatteries.

Model  LengthofWirefromChargertoBatteries(infeet)
10' 15' 20'
MinimumWireGaugeAWG_____
PT‐24‐8W #18 #16 #14
PT‐24‐13W #16 #14 #12
PT‐14W #12 #10 #10
PT‐25W #10 #8 #6

*BasedonN.E.C.MinimumWireSizeChartandABYC3%VoltageDropChart
ENSURETHATLEADSAREPROPERLYFUSEDATTHEBATTERY.(REFERTOABYC
RECOMMENDATIONS.)

TypicalDCwiringconfigurationsareillustratedinFIGURES1and2.

FIGURE1:SimpleDCWiring(PreferredMethod)


*PerABYCA‐31:ADCchassisgrounding
conductorshallbeconnectedfromthecaseof
thebatterytotheenginenegativeterminalor
itsbus,andmustnotbemorethanonesize
underthatrequiredfortheDCcurrentcarrying
conductorandnotlessthan16AWG.

Note:Thisdiagramdoesnotillustratea
completesystem.RefertoABYCstandardsE‐11
AC&DCelectricalsystemonboats.

IMPORTANT:Installfusesatbatteries
perABYCrecommendations.










FIGURE2:WiringwithBatterySwitch



*PerABYCA‐31:ADCchassisgroundingconductorshallbeconnectedfromthecaseofthebatteryto
theenginenegativeterminaloritsbus,andmustnotbemorethanonesizeunderthatrequiredforthe
DCcurrentcarryingconductorandnotlessthan16AWG.

Note:Thisdiagramdoesnotillustrateacompletesystem.RefertoABYCstandardsE‐11AC&DC
electricalsystemonboats.

IMPORTANT:Installfusesatbatteries
perABYCrecommendations.

AnImportantNoteabouttheDCOutputFuse:DCoutputwiringisprotectedbyaninternallymounted
ATCblade‐typeoutputfuse.Thefuseholderislocatedtothebottomrightofthemeteronthelarge
circuitboard.Toremovethefuseforcheckingorreplacing,removedripshield,thencoverandsimply
pinchthefusebetweenthumbandforefingerandpullfirmlydownward.

ThecurrentlimitingcircuitofthePhaseThreechargershouldpreventthefusefromblowingunder
normaloperatingconditions.Ifthefuseblows,thismayindicateareversepolarityhook‐uporan
internalshort.Ifthebatteryisconnectedtothechargerbackwards,thefuseshouldblowtopreventa
dangerousshortcircuit,howeverdamagetotheinternalcomponentsispossible,aswell.If,after
replacingthisfuse,itblowsagainuponapplicationofpower,returnthechargertoanelectronicsservice
professionalortothefactoryforathoroughinspection.Alwaysreplacethefusewithanotherofthe
sametypeandvalue.ThevaluesfortheDCoutputfusesarelistedinthetableonthenextpage:






DCOutputFuseTable

ModelFuseValue
PT‐14W ATC20amp
PT‐25W ATC30amp
PT‐24‐8W ATC15amp
PT‐24‐13W ATC20amp

E)MultipleUnitParallelWiring

Ifincreasedpowerorsystemredundancyisrequired,asecondchargermaybewiredinparallel.The
unitisdiodeprotectedsoitwillnotbedamagedbyfeedbackfromthesecondunitandcurrentlimiting
willpreventoverloadinginthecaseofafailureofoneoftheunits.

Observethefollowingguidelineswhenwiringaparallelunit.

1)Useonlyanotheridenticalchargermodel.Donotuseadifferentcharger
model,eitherfromNEWMARorfromanothermanufacturer.

2)Wirelengthandgaugeandwirelugsizemustbeidenticalforeachchargerto
ensureproperloadsharing.

3)Wiregaugeforeachchargermustbethesameusedasifasinglechargerwere
wiredintothesystembyitself.

F)ACInputWiring

FortheconvenienceoftheinstalleranACpowercordhasbeenfactoryinstalled.Itisathree‐conductor
strandedtype,16AWG.ThecordisterminatedwithaplugsuitableforstandardUSAoutletsanduses
standardUSAcolorcodingofconductors.
ACinputis"universal".ModelsPT‐14WandPT‐24‐8Woperateinarangeof85‐264VAC,47‐63Hz.No
switchsettingisrequiredforeither115VACor230VACapplications.ModelsPT‐25WandPT‐24‐13W
operateinarangeof90‐132or180‐264VAC,47‐63Hz.Inputvoltageselectionforthesemodelsismade
viaaslideswitchontherighthandsideofthecharger.Itisfactorysetfor115V.For230VAC
applicationsuseaballpointpenorsimilartooltoslidetheswitchupintothe230Vposition.For
reference,theswitchisdownfor115Vandupfor230V.

ACinputforthechargermustberoutedthroughfuseorcircuitbreakeronanACdistributionpanelwith
propersafety/earthchassisgroundinaccordancewithallapplicablelocalcodesandordinances.Caution
(230Vapplicationsonly):IfACinputisderivedfromasourceconsistingoftwoHOTleads(phase‐to‐
phase230VACinputvoltage)anexternalfuseorcircuitbreakermustbeusedtoprotecttheunfused
(formerlyNEUTRAL,nowHOT)lead.
ColorcodingoftheinstalledACcordisasfollows:
Black.................................ACHot(fused)
White.................................ACNeutral
Green................................ACGround(safety,earth)

Ifthefactory‐installedcordmustbereplaceduseacordofequalorlargerAWGratingwithstranded
(notsolid)conductors.RemovetheACinputterminalcoverbyremovingthethreePhillipsheadscrews


securingit.Loosenthestrainrelieftoslidethecoverassemblydownthecordforterminalaccess.Note
theconfigurationofterminalblockwiringasfollows:

FIGURE3:ACInputWiring(asviewedfrombottomofcharger)



(Inmarineapplications)AllchargerwiringshouldbeinstalledinaccordancewithUL,U.S.CoastGuard
and/orA.B.Y.C.regulationsandrecommendations,aswellasallrelevantlocalcodes.SeeREFERENCE
APPENDIXattheendofthismanualforsources.

AnoteabouttheACinputfuse:TheACinputofyourchargerisprotectedbyaninputfusewhichis
locatedinsidetheunit.Duetothecurrentlimitingcharacteristicofthecharger,itishighlyunlikelythat
thisfusewillblowunlessthereissomeothermalfunctionwithinthecharger.Thisfuseisnotuser‐
replaceable.Replacementoftheinputfusemustbeperformedbyaqualifiedserviceperson.

IV)OPERATION

A)ThreeStageChargeRegimen

ThePhaseThreeBatteryChargerutilizesthethreestagechargeregimenwhichiswidelyrecommended
bybatterymanufacturersforallowingthefastestpossiblerechargetimewithoutlossofbatteries’
electrolyte(gelorliquid)whichmaybecausedbysustainedchargingathighervoltages.WhenACpower
isappliedtothecharger,thegreenpower‐onlightwillilluminate.

ThisthreestageregimenisinitiatedeachtimeACisfirstapplied,whendrainedbatteriesaremostlikely
tobeencountered,andproceedsslowlyorquicklythrougheachstagedependingonthebattery’s
relativestateofcharge.(Thisalsooccurswhenthereinitializebuttonontheoptionalremotepanelis
activated;seeRemotePanelOptionsectionformoreinformation).Thechargeregimenproceedsas
follows:

1)BulkPhase:Whenbatteriesaresignificantlydischargedthechargerrespondsinitiallybydeliveringa
highamountofDCcurrent,atornearthecharger’smaximumratedoutput,inordertorapidlyreplenish