NewMar PT-24-20W User manual

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
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

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
www.newmarpower.com
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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

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
www.newmarpower.com
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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

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
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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.

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
www.newmarpower.com
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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