NewMar PT-24-20W User manual

P.O. Box 1306, Newport Beach, California 92663 • Phone: 714-751-0488 • Fax: 714-957-1621 • E-Mail: techservice@newmarpower.com
www.newmarpower.com
1M-PT-W3-LNGFM
As of Oct 08
Phase Three
Three Stage Smart Charger
Installation/Operation manual
Models: PT-24-20W & PT-40W
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 5
E) Multiple Unit Parallel Wiring 7
F) AC Input Wiring 7
IV) OPERATION 8
A) Three Stage Charge Regimen 8
B) Time-Out Circuit 8
C) Gel-Cell/Lead-Acid Selector Switch 9
D) Remote Panel Option 9
E) Temperature Compensation Option 9
F) Equalize Timing Option 10
G) Cooling Fans 11
H) Output Ammeter 12
I) Power-On Indicator 12
V) APPLICATION NOTES 12
A) Start UP 12
B) Constant Versus Occasional Use 12
C) Proper Load Sizing 12
D) Operation with Engine 12
E) Operation as a DC Power Supply
(stand-alone DC power source) 12
VI) TROUBLESHOOTING 13
VII) SPECIFICATIONS 14
VIII) BATTERY CARE TIPS 14
IX) REFERENCE APPENDIX 15
X) UNIT DIMENSION DRAWING 16

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Quick Reference Drawing
Optional Dripshield
Pg. 4
Permanent
Mounting Holes X4
Pg. 5
Temporary Keyhole
Mounting Holes X2
Pg. 5
Charger Front Cover
Ammeter
Pg. 12
Charger Front Cover
Output Terminals
Pg. 5
AC Input
Pg. 7
1/4 - 20 Chassis
Grounding Stud
Pg. 4
Charger Status LED
Pg. 12
AC Input Fuse
Pg. 7

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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-stage
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 rugged stainless steel
cover coated with a durable white powder coat finish.
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
•Multiple output banks charge independently based on demand
•115/230 VAC, 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
•Automatic high temperature power reduction – allows charger
output in over-temp conditions at reduced output current without
complete shutdown
•Optional temperature compensation sensor fine tunes output
voltage based on battery temperature
• Optional Remote Panel allows remote monitoring of charger
phase status and manual re-initialization of charge cycle
•Internal terminals allow installation of optional equalize timer
connection
•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
•Built to last - rugged stainless steel and aluminum case powder
coated case with marinized internal circuitry; optional-use
dripshield provided
•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 instructions should help
you enjoy years of trouble-free service.
PRODUCT REGISTRATION
If you wish to register your Newmar charger with us and provide
comments or questions, please visit us online at
www.newmarpower.com/product_registration.html or for
immediate response to your questions or comments, please call
tech service at 1-800-241-3897 or
email [email protected].
II) Important Safety Instructions
1. SAVE THESE INSTRUCTIONS – This manual contains important
safety and operating 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) product powered by the battery.
3. CAUTION – To reduce the risk of injury, charge only 6 cell
(12 volt models) or 12 cell (24 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 Phase Three Charger. Refer to the SPECIFICATIONS SECTION to
determine the full load input current of your Phase Three Charger,
and then use the chart below to determine the correct gauge wire
for any extension cord used.
9. Do not operate the charger with a damaged cord or plug;
replace them immediately.
RECOMMENDED MINIMUM AWG SIZE FOR EXTENSION
CORDS FOR PHASE THREE BATTERY CHARGER
AC Input Rating, Amperes Length of Cord, Feet
Equal to or
greater than
but less
than
25 50 100 150
Size of Cord
(AWG)
4 6 16 16 14 12
6 8 16 16 12 10
8 10 16 14 12 10

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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 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
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
Y OUR 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 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
flood 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 high enough to weld
a ring or the like metal, causing a severe burn.
8. Use the battery charger for charging gel-cell 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 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.
GROUNDING AND A.C. POWER CORD CONNECTION
1. The charger should be grounded to reduce risk of electrical
shock.
2. The Phase Three 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:
Brown AC
Hot (fused)
Blue AC
Neutral
Green AC
Ground (safety/earth)
The charger must be plugged 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 AND/OR UNITED STATES COAST
GUARD ELECTRICAL REGULATIONS (33CFR183, WSUB-PART I)
THE INSTALLATION AND PROTECTION OF VESSEL WIRING
ASSOCIATED WITH BATTERY CHARGERS SHALL COMPLY WITH
ABYC STANDARDS E-11) AC & DC ELECTRICAL SYSTEMS ON
BOATS, AND A-31) BATTERY CHARGERS & INVERTERS.
III) INSTALLATION
A) Materials Provided
The Phase Three charger is provided completely assembled and
ready for installation. Because of numerous installation variables,
the installer will need to provide four suitable _” mounting screws/
washers, as well as DC output wiring and 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, bulkhead or other
suitable mounting surfaces 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.

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Vertical mounting is preferred in order to allow the
dripshield to protect the charger from any moisture which
may fall onto the charger. However, vertical mounting
is acceptable since the charger is forced-air cooled. It
should not be located where there is a possibility of debris
being drawn into the unit through the fans.
If the charger is located in an extreme heat area, such as
an unventilated engine room, and the cooling fans are
unable to maintain proper operating temperature, output
power will automatically be reduced to protect the
charger. For maximum performance, the charger should
not be located in an area of extreme high temperature.
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
The charger may be mounted on either a metal or non-
metal surface*. You will require four screws (wood or
machine screws, depending on mounting surface) with
washers, sized for _” holes, to mount the charger, plus two
temporary holding 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.
This is provided to ease vertical installation.
*To comply with ABYC DC chassis grounding conductor
(ABYC A-20), connect a suitable sized wire to the _”-20
chassis grounding stud near AC cable feed through.
Make a mark on the wall or bulkhead where each of the
keyhole slots will be located. Then drive a screw about
half-way 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.
D) D.C. Output Wiring
Note: Only qualified service personnel should access the
output terminals of the charger.
Whether working with existing battery charger output
wires or installing new ones, make sure the battery(s) is
disconnected from these wires before connecting them to
the charger’s output terminals.
For a secure installation D.C. output wires must be
attached with 1/4” crimp ring lug terminals sized
appropriately to fit wire gauges as listed below.
The D.C. wire size table below may be used to determine
the correct gauge wire, based on the model you have
and the length of the wire run from the charger to the
batteries. Once the output wiring has been attached to
the chargers output posts, install the clear plastic terminal
cover provided with the charger.
FIGURE 1:
Simple D.C. Wiring (Preferred Method)
DC Wire Size Table
Model Distance from batteries, feet
10 15 20
Wire Gauge AWG (mm)
PT-24-20W #10 (6mm) #10 (6mm) #8 (10mm)
PT-40W #6 (16mm) #4 (25mm) #2 (35mm)
* Based on ABYC 3% voltage drop table and NEC minimum
wire size chart
Phase Three
Battery
Charger
AC Input
GND
1 2 3
Battery
Optional
Temperature
Compensation
Sensor
See page 16 for
installation. Use
provided cable
clamps to secure
probe cable.
* Per ABYC A-31: 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 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
Battery
1
Battery
2
Battery
3
TCS

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Note: If batteries are closer to charger than battery
switch, wire directly to battery posts.
It is recommended that DC wiring from the charger
to the batteries be as direct as possible. Line
voltage loss and electronic noise interference of
sensitive electronics are possible if the charging
leads are routed through a central electrical
distribution panel. Any elaborate configurations
are best left to a qualified electrician.
ENSURE THAT LEADS ARE PROPERLY FUSED AT THE
BATTERY. (REFER TO ABYC RECOMMENDATIONS.
SEE REFERENCE APPENDIX AT THE END OF THIS
MANUAL FOR ABYC CONTACT INFORMATION.)
Ensure that your connections are tight and that
correct polarity is carefully observed at all times.
The battery posts should be free of any rust or
corrosion.
IMPORTANT NOTE: EVEN MOMENTARY REVERSE
POLARITY CONNECTION MAY SEVERLY DAMAGE
YOUR CHARGER. THE POSITIVE (+) TERMINAL
MUST BE WIRED TO THE POSITIVE POST OF THE
BATTERY AND THE NEGATIVE OR COMMON
(-) TEMINAL TO THE NEGATIVE POST OF THE
BATTERY OR COMMON BUS.
CAUTION: Do not attempt to increase battery bank
capacity by splitting the output of one of the banks
with a diode-type battery isolator. Undercharging
may occur on the output bank, as a result. If you
wish to add another isolated battery bank, use of
NEWMAR’s Battery Integrator is recommended.
Contact the factory for details. Be sure to replace
the clear plastic terminal cover to prevent
accidental shorting of the output terminals in the
future.
An Important Note about the DC Output Fuse(s):
internal DC wiring is protected by the internal DC
output fuse(s). The current limiting circuit of the
Phase Three Charger should prevent these fuses
from blowing under normal operating conditions.
If the DC fuse(s) blow, this may indicate a reverse
polarity hook-up or an internal short.
Always disconnect AC to the charger before
checking fuses. To check or replace the DC fuse,
the cover must be removed. To do this requires
removal of four screws from the front of the unit
and three screws on each side. The DC fuse is
mounted on the main circuit board. Be sure to
replace with the same type and value as indicated
on the fuse.
If the battery was connected to the charger
backwards, the fuse should blow to protect DC
wiring, however damage to internal components
may also have occurred. If the replacement
fuse blows, return the charger to an electronics
service professional or to the factory for a thorough
- Buss
Master
Battery
Switch
Phase Three
Battery
Charger
AC Input
GND
1 2 3
Battery
Optional
Temperature
Compensation
Sensor
See page 16 for
installation. Use
provided cable
clamps to secure
probe cable.
* Per ABYC A-31: 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 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
Battery
1
Battery
2
Battery
3
TCS
+ Buss
Loads
FIGURE 2: Wiring With Battery Switch

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inspection. Note: The internal fuses do not provide protection if
there is a short in the wiring between the charger and the battery.
The battery is itself a power source and charging leads should be
fused at the battery per ABYC standards.
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 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 itself.
F) AC Input Wiring
NOTE: (For marine applications) THE INSTALLATION AND
PROTECTION OF VESSEL WIRING ASSOCIATED WITH BATTERY
CHARGERS SHALL COMPLY WITH ABYC STANDARDS E-11) AC
& DC ELECTRICAL SYSTEMS ON BOATS, AND A-31) BATTERY
CHARGERS & INVERTERS
These models are provided with an IEC certified AC cord which
may be plugged into the charger and a proper outlet. If the plug
is not suited to the available outlet, 1) obtain an IEC cord with
appropriate plug or 2) obtain the correct plug for the outlet and
install it on the provided IEC cord. When installing the plug, pay
careful attention to the pin wiring as follows:
Brown……………….……………………….……AC Hot (fused)
Blue………………………………………………...AC Neutral
Green (or Green with Yellow Stripe…AC Ground (safety/earth)
As shipped from the factory, the charger is set up for 230 VAC
input. For 115 VAC applications, you must:
1) Slide the recessed 115/230 input select switch located on the
left hand side of the charger to the proper position. Positions are
identified on the front of the charger.
2) Replace the input fuse as explained in section
3) Input Fuse Replacement. The correct fuse for 115V applications
is the ABC-12 and it is attached to the hang tag on the BATT. 1
terminal of the charger. If it is missing, see the INPUT/OUTPUT
FUSE VALUE table in the SPECIFICATIONS sections of this manual to
determine the correct fuse value. Warning: Do not replace the gray
slotted cap of the fuse holder without a fuse installed. It will not be
retrievable. If this occurs, contact factory
A power cord cable clamp has been provided to prevent
accidental disconnect of the AC cord. After the plug has been
inserted into the charger, snap the pre-formed clamp around the
AC input cable as close to the insertion point as practicable and
use a screw to fasten the clamp tightly to the wall or bulkhead on
which the charger is mounted.
Hard-wiring AC Input
If desired, the AC input to your charger may be hard-wired
directly to the AC distribution panel. Install the charger end of the
provided input cord as described above, then cut off the plug and
splice onto three conductor marine-grade cable with crimp but
connectors, observing color codes and fuse/circuit breaker ratings
as above. For all models, use minimum 16 AWG cable.
All charger wiring should be made in accordance with UL, U.S.
Coast Guard and/or ABYC regulations and recommendations,
as well as all relevant local codes. See REFERENCE APPENDIX for
sources.
AC input for the charger must be plugged 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 local codes and ordinances.
CAUTION (230 VAC applications only): If AC input is derived from
a source consisting of two HOT leads (phase-to-phase 230 VAC
input voltage), an external fuse or circuit breaker must be used to
protect the unfused (formerly NEUTRAL, now HOT) lead.
3) Input Fuse Replacement
The AC input of your charger is protected by an input fuse. The
input fuse holder is located near the bottom of the unit on the left
side. The proper value for the input fuse is indicated on the lower
left corner of the front panel (230V, ABC-6A FB; 115V, ABC-12A
FB). If the input fuse needs replacing, it must be replaced with the
proper type and value. Use standard or fast-blow fuses. Never use
a slow-blow fuse.
Caution: Ensure that AC power to the charger has been
disconnected before attempting to open the fuse holder. To remove
the fuse for replacement, insert a flat tip screwdriver into the fuse
holder cover and turn clockwise until the spring-loaded cover
releases. To replace the fuse holder cover, depress it fully into the
fuse holder and turn it clockwise until it locks into position (about
quarter turn). Warning: Do not replace the gray slotted cap of the
fuse holder without a fuse installed. It will not be retrievable. If this
occurs, contact factory.
All charger wiring should be made in accordance with UL, U.S.
Coast Guard and/or ABYC regulations and recommendations,
as well as all relevant local codes. See section IX) REFERENCE
APPENDIX for sources.

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IV) OPERATION
A) Three Stage Charge Regimen
The Phase Three Battery Charger features 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.
This three stage regimen is initiated each time AC is first applied,
when drained batteries are most likely to be encountered. (This
also occurs when the reinitialize button on the optional Remote
Panel is activated – see section IV-D – Remote Panel Option). The
regimen proceeds as follows:
1) Bulk Charge – 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 them. It is during this stage that charging current
is maintained at a high level as battery voltage increases. Bulk
charging continues until battery voltage reached the “charge”
voltage level (where batteries are at about 75-80% of capacity).
A current limit circuit prevents charger overload during this
maximum output stage
2) Absorption Charge – During this second stage of the charge
cycle, battery voltage is maintained at the “charge” voltage level.
Output current begins to taper off as the battery plates become
saturated. Charge voltage is maintained until the current sensing
circuit detects that output current has tapered to about 5-15% of
charger rating*. At this point, the batteries are at about 95% of full
charge and the Phase Three charger switches to the third and final
stage of the charge cycle.
*Note: The absorption phase may also be ended by the time-out
circuit. See section B following for a complete explanation of the
purpose and functioning of the time-out circuit.
3) Float Charge – For extended battery life, the Phase Three
then automatically switches to a lower float voltage level.
This float charge keeps batteries at peak condition without
overcharging. The charger may be left in this stage for months
without attention (though periodic checks of electrolyte level in
flooded batteries is recommended.) FIGURE 3: Typical Charger
Output Graph (into battery without load)
FIGURE 3: Typical Charger Output Graph
(into battery without load)
B) Time-Out Circuit
Batteries have a tendency to lose their electrolyte and may be
damaged if they are maintained for long periods of time in the
elevated voltage of the absorption phase. Therefore, the Phase
Three Charger employs a special time-out circuit. This circuit is
initialized each time AC is first applied to the charger (or when the
re-initialize button on the optional remote panel is activated) and
runs for a pre-set interval before forcing the charger to go into the
float (lower voltage) mode. The functioning of the charger during
this interval is as follows:
If the current demand of the batteries/load falls below 5-15 percent
of the charger’s output capacity prior to the circuit timing-out, the
charger will automatically switch to the float mode. (For instance,
with model PT-40W, the charger will drop into float mode at
about 2-6 amps output.) If demand rises to about 10-20 percent
of capacity (4-8 amps with PT-40W, for instance), the charger
will return to the elevated output of the absorption phase. This
switching back and forth between modes may occur until the
circuit times-out (8-10 hours after AC is first applied), after which the
charger will remain at float voltage, until the circuit is re-initialized,
either by turning the charger off and then on again or by pressing
the re-initialize button on the remote panel.
Note: The Phase Three Charger is able to deliver its full rated
output current while in float mode.
Installation Note: The time-out circuit of the Phase Three Charger
has been set at about 8-10 hours, which is appropriate for battery
systems within the capacity range specified on the front of the
panel of the charger. If the charger is used with a battery system
with a capacity near (or outside) the upper or lower ranges of
the specified range of the charger, adjustment of the time-out
circuit may be recommended. If the installer wishes to make
this adjustment at the time of installation, the procedure is as
follows (Caution: Ensure AC input has been disconnected before
proceeding):
1) Remove the four screws on the front of the panel and two screws
on each side of the unit.
2) Remove the front cover and locate the potentiometer on the
small “charger function” plug-in printed circuit board which is
labeled “TIMER ADJ.”
3) Using a small flat tip screwdriver, turn the potentiometer
clockwise to increase the amount of time the charger remains
in the absorption mode before timing out, or counter clockwise
to decrease the amount of time. The approximate ranges are
illustrated below.
FIGURE 4: Adjusting the Time-out Circuit
BULK PHASE
ABSORPTION PHASE
FLOAT PHASE
AMPS
AMPS
VOLTS
VOLTS
TIME
*Approximately 10 hours maximum at factory setting.
Note: Once the time-out circuit has put the
charger into float mode, the charger will
remain in this mode. Since the Phase Three
Charger is well regulated, it is able to deliver
its full rated output current in this mode and
battery discharge will not occur (provided load
current does not exceed charger rating and
output wiring is properly sized).

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C) Gel-Cell/Lead Acid Selector Switch
According to most battery manufacturers, the ideal charging
regimen for gel-cell and wet or flooded lead acid batteries differs
somewhat.
The gelled electrolyte in a sealed battery may be lost or damaged
by high voltage and, once lost, cannot be replaced as it can
with a wet lead acid battery. Manufacturers of gel-cells usually
recommend an ideal charge voltage which is slightly lower for a
gel-cell than a lead acid battery.
However, when the charger is in the float voltage mode over
lengthier periods of time, gelled electrolyte in a sealed battery
is not susceptible to evaporation, as is the non-immobilized
electrolyte of a wet lead acid battery. This evaporation can be
accelerated by the applied voltage. Consequently, the ideal float
voltage is slightly higher for a gel-cell than a lead acid battery.
The ideal charge/float regimen has been programmed into the
Phase Three Charger for either sealed gel-cell or flooded lead acid
batteries. Simply make the proper selection for your battery type
via the slide switch on the right side of the charger. The switch
positions are indicated on the front panel (up for Gel-Cell batteries,
and down for Lead-Acid/AGM type batteries). Use a ball point
pen or similar object to slide it into the correct position. The charger
is shipped from the factory set for Lead-Acid/AGM batteries.
Note: A wide variety of batteries are available which do not
conform to conventional descriptions as “gel-cell” or “lead-acid”.
You are advised to consult the manufacturer of your particular
battery as to proper charging regimen, and use the battery
type selection switch setting which most closely conforms to the
recommended voltages.
See the SPECIFICATIONS section for the actual preset charge and
float voltages for each battery type/charger model.
D) Remote Monitor Panel Option
A Remote Monitor Panel is available from NEWMAR (model RP)
which will enable you to monitor the charger’s status at-a-glance
from a remote location. Red and green L.E.D.’s indicate whether
the charger is in the bulk, absorption or float phase of the charge
cycle. In addition, the panel features a re-initialize button, which,
when pressed, will cause the charger to restart the three phase
cycle. This resets the time-out circuit (see section B, Time-Out
Circuit, above). Note: The charger may not stay in the bulk or
absorption mode after pressing the re-initialize button. If batteries
are at or near full charge, the charger will quickly revert to the
float mode.
The panel comes pre-wired with 30’ of cable and 4 mounting
screws. Simply install the panel at the desired location and insert
the plug on the end of the cable into the remote panel jack
which is located on the right side of the charger. (See FIGURE
5) The remote panel jack is identified on the front panel. Note:
Inadvertently putting the remote panel plug into the temp
compensation jack (or vice versa) will not harm the charger.
If additional cable length is required, additional cable is
commonly available from most electronics supply retailers such as
Radio Shack/Tandy. Request a 6 conductor modular-to-modular
line cord (part number 279-422, 25 feet long) and a 6 pin modular
in-line non-reversing coupler (part number 279-423).
E) Temperature Compensation Option
Because low battery temperature increases resistance to charging
and high battery temperature reduces impedance, requiring
a lower charge voltage, the ideal charging voltage will vary
depending on the temperature of the battery’s environment when
it is being charged.
If a charger has a fixed output voltage which is ideal at, say 72_
F that same output may cause a battery charged in consistently
high temperature environment to be overcharged, resulting
in excessive loss of electrolyte. Conversely, if the batteries are
in a consistently cool environment, they may be chronically
undercharged, resulting in sulfation of the battery plates. Either of
these two conditions will shorten battery life.
Therefore, the Phase Three Charger is designed to utilize an
optional remote sensor (available from NEWMAR, model TCS-
12/40) which provides automatic temperature compensation. The
remote sensor will signal the charger to fine tune its output voltage
so that it is properly matched to the temperature of the battery/
battery environment. The adjustment rate is approximately -3mV
per cell per _C. (Note: The temperature compensation option is
strongly recommended for sealed, valve-regulated or gel-cell
batteries.)
The remote sensor is provided with 30’ of cable (model TCS-12/24-
40 is provided with 40’ of cable). One end of the cable is plugged
into the temperature compensation jack which is located on the
right side of the charger. (See FIGURE 5.) The temp sensor jack is
identified on the front panel. If additional cable length is required,
additional cable is commonly available from most electronics
supply retailers as Radio Shack/Tandy. Request a 6 conductor
modular-to-modular line cord (part number 279-422, 25 feet long)
and 6 pin modular in-line non-reversing coupler (279-423).
The sensor itself should be mounted on the inside of the battery
box, or more ideally, mounted onto one of the batteries using a
clamp or a small amount of silicon-type adhesive. The sensor has
a hole in the center which will accommodate a #6 screw. If you
have access to the exterior of a wall of the battery box, you may
drill a hole in the wall of the box and run the screw through to
mount the sensor onto the interior wall. Use caution when drilling
so that you do not accidently puncture the case of any battery
inside the box.
Important note: When wiring multiple units in parallel (see section
III-E) and using the temperature compensation option, you must
use a separate sensor for each charger, and the sensors must be
mounted close together in the same battery box or on the same
battery for proper operation.
FIGURE 5: Gell-Cell/Lead Acid Selector

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FIGURE 5: Temperature Compensation Sensor
and Remote Panel Installation
To give some idea of the effect of the temperature compensation
sensor, the chart on the following pages list the charge/float output
voltages of the charger when no sensor is installed (or when
batteries are at 72_ F), and at cold (50_ F) or hot (90_ F) battery
temperature with temp sensor installed:
F) Equalize Timing Option
Not for sealed Lead-Acid (maintenance free), Gel, or AGM – for
Flooded Lead-Acid Only. Some manufacturers of flooded lead-acid
batteries recommend a charging process known as equalization
for extended battery life. This process involves occasionally
charging a wet lead-acid battery life at a very high voltage for a
short period of time in order to completely de-sulphate each of the
battery plates, essentially equalizing their voltage. The installer of
the Phase Three Charger may choose to wire in this option at the
time of installation.
Note: The equalization process is not recommended for sealed
valve-regulated or gel-cell batteries.
The equalize terminals (located inside the PT charger) should be
wired through a manual or electric timer which provides a closed
contact when engaged and an open circuit when timed out (SPST
– Single Pole Single Throw). Do not use a manually operated switch
for the equalize timer. This is because unless the charger is reverted
to a safe float voltage in a timely manner, the batteries will almost
certainly be damaged or destroyed. The timer should be a 0-12
hour type, capable of carrying a minimum of 100 mA at 5 VDC.
CAUTION: Do not install the timer in an area requiring ignition
protected equipment unless it has been certified to meet ignition
protection requirements.
The equalization circuit of the Phase Three Charger boosts output
voltage to approximately 8% above float voltage. Refer to the
battery manufacturer’s instructions when deciding the appropriate
time period setting for this voltage to achieve proper equalization,
while ensuring batteries are not damaged by increased battery
temperature. This installation should only be performed by a
qualified technician.
Installing the timer requires a mating connector with dual wires
which are plugged into a jack on the internal charger function
circuit board. The connector/wire assembly is available from
NEWMAR. Request part number 873-3716-0, CFB Equalize 2 pin
assembly. Proceed with the installation as follows:
(Caution: Ensure AC input has been disconnected before
proceeding.)
1) Remove the charging leads (if already attached)
2) Remove the charger cover assembly (as previously described)
3) Locate the two-pin header labeled “J2” just over the cut-out on
the top of the vertically oriented charger function circuit board.
Insert the mating connector and route the two-control wires
through one of the air vents on the bottom of the charger beside
the “COMM” terminal. Connect the wires to the timer.
4) Replace the cover assembly. Reconnect the charging leads and
AC input.
* Factory pre-set voltages without temperature compensation option installed
Battery Temperature
Output V DC: 12 Volt Models Output V DC: 24 Volt Models
Charge Float Charge Float
°F °C Gel-Cell Lead Acid Gel-Cell Lead Acid Gel-Cell Lead Acid Gel-Cell Lead
Acid
50 10 14.4 14.6 14.0 13.8 28.8 29.2 28.0 27.6
72 22.2 14.0* 14.2* 13.6* 13.4* 28.0* 28.4* 27.2* 26.8*
90 32.2 13.7 13.9 13.3 13.1 27.4 27.8 26.6 26.2
Temperature Compensation Chart

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G) Cooling Fan
To maximize the life of the internal components and to allow
continuous operation at full rating, the Phase Three Charger
employs two automatic integral cooling fans. The fans draw air
through the bottom of the unit and expel it out the top to improve
cooling and reduce the possibility of drawing in water drops (an
optional dripshield is provided for extra protection). These fans
operate whenever load and/or ambient temperature cause a rise
in the heat sink temperature. Their speed automatically increases/
decreases in response to load and/or ambient temperature
increases/decreases. Note: Under most circumstances, the fans will
be in operation when the charger is on. However, they may stop
completely under no load and/or ambient temperature conditions.
Fan Replacement
If a fan(s) fails to operate when the charger is on and a load is
applied, it may be in need of replacement. Replacement fans are
available from NEWMAR. (Specify part number 999-1208-0. Refer
to Replacement Fan with PCB connector.)
1) Disconnect the charger from the AC power source.
2) Referring to Photo 1, remove the top cover screw and the 2
panel screws as shown and carefully remove the fan panel.
3) Referring to Photo 2A & 2B, unplug the 2 fan connectors noting
their orientation as shown. Note the orientation of the wires as
shown in Photo 2.
4) Invert the fan panel and remove the 4 screws securing the fans
as shown in Photo 3.
5) Install the new fans in the reverse order using the 4 screws and
refer to Photos 2 and 3 for orientation.
6) Plug in the fan connectors to the circuit board – the notch in the
fan connector faces upwards.
7) Replace the fan panel and secure it with the three mounting
screws.
8) Once unit is back in service, verify that the fans are blowing air
out of the unit through the vent slots in the fan panel. If the fans are
drawing air into the unit through the vent slots, they are installed
backwards and need to be corrected (repeating Fan Replacement
Procedure).
It is important that both fans are installed correctly or the charger
will not cool properly and overheat.
H) Output Ammeter
This will indicate total charging output current for all battery banks
connected.
Photo 1 Photo 2A
Photo 3
Photo 2B

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I) Power-On Indicator
This green LED will glow whenever the charger is receiving AC
power.
V) Application Notes
A) Start Up
1) Before powering up your charger, check for tight electrical
connections to each battery in your system. Switch off any DC
loads on the batteries. Apply AC power. Observe the DC ammeter
on the front panel. This meter displays the total DC output of the
charger, through all banks. It will give some indication of the
overall state of charge of your batteries. If the meter is reading
mid-scale or higher, it is an indication that the batteries are in
a relatively low state of charge. The charger, sensing this, is
supplying high current to the batteries. If the meter needle is at
or near the bottom of the scale the batteries are at or nearing full
charge.
2) Apply a load to the charger by switching on some lights, a
pump, or some other DC appliance. Observe the charger meter. It
should read approximately the same as the expected current draw
of the appliance. As current is demanded from the battery system,
the charger will automatically increase its output in response
to the increased load demand. When load current exceeds 10-
20% of the charger’s rated capacity, the charger will go into the
absorption mode and remain there until current drops below 5-15%
of capacity or until the time-out circuit cycle is complete.
Note: The Phase Three charger is self-limiting and will rarely blow
an input fuse. If the input fuse should blow upon first application
of power, disconnect AC power to the charger and consult the
TROUBLESHOOTING section of this manual.
If the input fuse does need replacing, be sure to replace it with
the same type and value for continue protection. The fuse value is
specified on the lower left hand of the corner of the charger panel.
B) Constant Versus Occasional Use
In general, it is recommended that the charger be left connected
continuously to the AC distribution system so that it will be in
operation whenever AC is available. This will maintain batteries at
peak voltage and will automatically compensate for the natural
self-discharge of the battery system. When a load is applied to the
battery system, the charger’s output will automatically increase to
supply the current which would otherwise draw battery voltage
down. Repeatedly allowing batteries to become completely
discharged before recharging will greatly shorten their life.
Leaving the charger on continuously will prevent this.
While the output regulation of the charger will minimize battery
gassing and water loss, monthly checks of the electrolyte level
(for wet lead acid batteries) are still strongly recommended. Some
water loss is an inevitable aspect of the charging process, and
maintaining the correct electrolyte level in your batteries is the
most important you can do to assure their maximum performance
and long life.
C) Proper Load Sizing
The Phase Three Charger is rated for continuous duty (e.g., the
PT-40W can deliver up to 40 amps continuously, 24 hours a day,
seven days a week). While the charger cannot be damaged
by overloads that exceed this continuous rating, excessive load
demands may draw battery voltage down faster than the charger
can resupply it. If the battery voltage continues to drop and the
output current is at maximum while the charger is in service,
check to see that your average DC loads are not exceeding the
charger’s rated output. If they are, you may wish to consider
adding another charger in parallel to provide sufficient power
for your requirements. (See section III-E, Multiple Unit in Parallel
Wiring.)
D) Operation with Engine
It is perfectly acceptable to allow the charger to remain on
when the engine is started and while it is running. The current
limit feature of the Phase Three Charger will protect against any
damage due to the high current demands of the engine cranking.
Output diodes will prevent any back-feed of current into the
charger from the alternator while the engine runs.
As the alternator starts to charger the battery, the charger output
will decrease. When the battery voltage exceeds the rated output
voltage of the charger, it will shut off and stay off as long as the
batteries are in this high state of charge. If the battery voltage
should drop below the charger’s rated output voltage, it will
automatically return to service.
E) Operation as a DC Power Supply (stand alone DC Power Source)
Most battery chargers are not suitable for powering electronic
devices directly, without a battery attached to the output, as the
high ripple and pulsing DC output (i.e., rectified AC output) can
interfere with the operation of the device. The Phase Three charger
is different. It employs a circuit that produces an extremely
well-filtered DC output. Therefore the charger is able to power
virtually any DC powered device (within the unit’s rating) without
the battery attached in-line (if, for instance, the battery must be
removed for any purpose and AC is still available). All but the
most sensitive DC powered electronic devices will function as
normally as if powered by a battery. In addition, the current
limiting circuitry enables the charger to handle the high start-up
surges associated with inductive loads, such as DC motors in radar
sets.
VI) TROUBLESHOOTING

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Routine Checks and Maintenance
Batteries should periodically be “exercised” (slowly discharged and
Condition Possible Cause Solution
A) Batteries are not coming up
to full charge
1) Extremely discharged batteries requiring
long recharge time.
2) Charger limiting its output due to overload
or over temperature conditions.
3) Fan not operating properly causing
charger to protect against over-heating by
reducing power.
1) Turn off all D.C. loads and allow charger 24-48
hours to recharge batteries. See section
IV-B for explanation of time-out circuit.
2) Reduce D.C. load and/or determine cause of over
temperature state (See section III-B, “Location”).
3) Replace fans if necessary.
B) Charger continues to charge
at 3 amps or more – does not
taper back into charge
1) D.C. load drawing current from batteries
(not a problem condition).
2) Bad cell in one of the batteries to which
charger is connected.
1) Turn off main battery switch to DC electrical panel
or turn off all DC loads if you wish to confirm charger
will output minimal amperage to fully charge
batteries.
2) Check for shorted cell in all wet lead-acid batteries
using a hydrometer. Replace battery if cell is shorted.
Refer to manufacturer for testing maintenance-free
batteries.
C) Charger does not charge. 1) Blown input fuse.
2) Charger is not receiving AC input voltage
or is not receiving correct AC input voltage.
3) Charger output is not properly connected
to batteries.
4) Blown output fuse.
5) Defective charger.
1) Replace fuse with another of correct value. Check
to see if AC input select switch is in proper position.
Check to see if input fuse value is correct for
input AC voltage.
2) Using a voltmeter, confirm, AC input voltage,
check input connections. Confirm AC input
select switch is in correct position or correct AC
connector/adapter is installed.
3) Refer to DC wiring installation diagram for proper
connections to batteries.
4) Replace with another of correct value (see section
III-D, “DC Output Wiring”).
5) Return for analysis/repair by servicing dealer
where charger was purchased or contact
NEWMAR for a Return Materials Authorization
number.
D) Charger repeatedly blows
input fuse with no batteries
connected.
Internal Short. Same as above.
E) Reverse polarity connection
to charger has caused charger
to stop charging.
DC Output fuse and possibly
other components blown.
Replace output fuse with another of correct value.
If fuse again blows, return to servicing dealer or
contact NEWMAR for Return Materials Authorization.
F) High output voltage
measured across charger
output terminals.
1) Batteries not connected to charger. It is
normal to read volt higher across any output
bank when no batteries are connected.
2) Equalize time function activated.
1) Check for tight connection of charging leads from
charger to batteries.
2) Check to verify proper installation and operation of
equalize timer.

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VII) Specifications
INPUT RANGE (ALL MODELS): 85-135/170-270V AC (via selector
switch); 47-63 HZ (automatic) Derate Models, PT-24-20W and PT-
40W from 560 watts @ 95V AC to 500 watts @ 85V AC
OUTPUT BANKS (ALL MODELS): 3
Model
Input
Amps
115/230V
Output Weight
Volts Amps
(Cont.) Lbs. Kgs.
PT-40W 8.5/4.3 12 40 12 12
PT-24-
20W 8.5/4.3 24 20 5.5 5.5
OUTPUT VOLTAGES WITHOUT TEMPERATURE COMPENSATION
OPTION
24 VOLT MODEL 32 VOLT MODEL
Charge Float Charge Float
Setting @ 50%
load
@ .1 amp
load
@ 50%
load
@ .1 amp
load
Gel-Cell 28.0 V D.C. 27.2 V D.C. 37.3 V D.C. 36.2V D.C.
Lead Acid 28.4 V D.C. 26.8 V D.C. 37.8V D.C. 35.7V D.C.
Temperature Compensation: -5mV per cell per _ C
Temperature Ratings: -40°C to + 60°C; Derate linearly from 100% @
50°C to 75% @ 60°C
INPUT/OUTPUT FUSE VALUES:
CASE SIZE
Inches Centimeters
H x W x D H x W x D
13.8 x 9.8 x 5.0 35.0 x 24.9 x 12.7
Add 1.27” (3.2 cm) to height and 1.1” (2.8 cm) to depth with drip
shield installed.
OUTPUT VOLTAGES
(without Temperature Compensation option installed):
TEMPERATURE COMPENSATION: - 5 mV per cell per ° C
PROTECTION FEATURES
Input Fuse; Output fuse for reverse polarity protection; Current
limiting; Automatic high temperature power reduction; Time and
load controlled high rate charge circuit; Ignition protected; IP 21
COMPLIANCES
Safety: EN60335-1
EMC: IEC 1000-4-2, -4
EN55014
Carries the CE Mark
VIII) BATTERY CARE TIPS
Regular maintenance and proper care will assure you reliable
service from the most depended upon and sometimes most
neglected items, your batteries and battery charger. NEWMAR
battery chargers are designed to keep your batteries fully charged
but your batteries also need proper regular maintenance to
provide a maximum life of service.
ALWAYS READ AND FOLLOW THE BATTERY MANUFACTURER’S
INSTRUCTIONS
Battery Installation
Batteries must be securely mounted to prevent them from falling
over when the vehicle or boat is in motion. A loose battery can
do serious damage. Batteries should be mounted in a battery
box to contain any acid spill. Batteries give off a certain amount
of hydrogen gas when they are charging. When concentrated,
this gas is highly explosive. Therefore make sure they are in an
accessible place with adequate ventilation for any hydrogen gas
discharge.
Cleaning Batteries
Dirt and electrolyte salts can build up on the top of your batteries.
This accumulation conducts electricity stored in the battery and
can cause the battery to discharge by itself. Therefore, at least
twice a year, it is a good idea to disconnect the battery cables
and scrub the battery with a baking soda solution. Rinse with fresh
water and dry with a clean cloth.
You may wish to purchase a set of terminal post corrosion
prevention rings. These are alkali-saturated felt rings that slip over
the battery post to reduce corrosion. Do not apply grease to any
part of the battery terminals, but you may use an occasional light
spray of silicone lubricant.
Condition Possible Cause Solution
G) Charger will not stay in bulk/
absorption mode when
re-initialize button on Remote
Panel is pressed.
Batteries at or nearing full charge (not a
problem condition).
Verify proper operation by pressing re-initialize
button (on optional Remote Panel) and applying a
larger DC load.

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15
then recharged) to keep them in top condition. New batteries may
need to be exercised before they will be capable of their full rating.
If your batteries are not the sealed type, distilled water should be
added to them whenever needed. The electrolyte should cover
the plates by about 1/2”, allowing a small air space at the top. Do
not fill the cells up to the filler cap as this could cause the battery
to sputter out electrolyte when it is being charged. Only distilled
water should be used never plain tap water. Tap water contains
chemicals and elements that can alter the properties of the
electrolyte, including specific gravity. Some chemicals may also
create an insulating coating on the battery plates which will retard
current flow.
The rate that water is lost by the battery is dependent on several
factors; battery condition, ambient temperature, battery use,
charge voltage, etc. It is normal for batteries which are not
maintenance-free to require topping off about once a month.
A battery’s state of charge may be monitored by checking the
specific gravity or by open circuit voltage. You may use the
following table to evaluate the condition of your batteries:
Battery Condition Table
Specific Gravity
Measured by
Hydrometer
Open Circuit Voltage State of
Discharge @
80° F
24 Volt
System
32 Volt
System
1.265 12.6 or more 25.2 or mre Fully Charged
1.225 12.4 24.8 25% Discharged
1.190 12.2 24.4 50% Discharged
1.155 12.0 24.0 75% Discharged
1.120 11.7 or less 23.4 or less 100% Discharged
*Note: Wait at least 5 minutes after charging or discharging before
checking specific gravity or open circuit voltage. The battery’s
voltage needs to stabilize in order to get an accurate reading.
Troubleshooting Your Battery System
If your battery will not accept or hold a charge, one of the
following conditions may exist:
1. A BAD BATTERY. You may have a battery with an open or
shorted cell, a battery without any “life” left. Check by charging
the battery until all cells have a specific gravity of 1.225 or greater
at 80° F. If you are unable to obtain 1.225 in each cell, replace
the battery. For maintenance-free or gel-cell batteries consult the
manufacturer.
2. A BAD BATTERY CHARGER. If the battery open circuit voltage is
low and/or the hydrometer indicates your batteries are low, the
battery charger should be providing current to the batteries. If it
is not, check AC input and check to see that you have charging
voltage on the output with no battery attached. Note: You will not
get an accurate voltage reading on the output of the charger with
no batteries attached. This is checked merely to ensure that you do
not have an open circuit on the output.
The battery charger has a thermal cutout switch to turn the
charger off if it is overheating. If you suspect this is the case, refer
to the information regarding charger location in the Installation
section and cooling fans in the Application Notes section.
3. ELECTRICAL LEAKAGE. You may have a previously unsuspected
source of current drain from the battery. To check for a leakage
of this sort, disconnect the battery ground cable and connect an
ammeter between the negative battery post and ground. If you
have a reading over .1 amp, there is a source of current drain from
the batteries which must be located and removed.
IX) REFERENCE APPENDIX
• For more information about boat wiring to conform to U.S.
Coast Guard regulations, write: Superintendent of Documents
aaaRequest : 33 CFR 183 Subpart I
Government Printing Office Washington, DC 20402
• For information about American Boat and Yacht Council
recommendations for boat wiring, write to:
American Boat and Yacht Council
3069 Soloman’s Island Road
Edgewater, MD 21037
Request: Standards and Recommended Practices for
Small Craft.
AC & DC systems: Section E11
A-20: Battery Charging Devices
• For additional installation instructions, refer to:
ANSI NFPA 302

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16
X) UNIT DIMENSION DRAWING
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