NewMar PFM-500 User manual

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Power Function Manager
MODEL: PFM-500
INSTALLATION / OPERATION MANUAL
SECTION TOPIC PAGE
I) OVERVIEW............................................................................. 3
II) INSTALLATION...................................................................... 3
A) Materials Provided............................................... 3
B) PFM Mounting...................................................... 3
C) Bus Bar Mounting................................................. 3
D) Input Voltage Selection (Universal) and Wiring.. 3
1) Simplified Wiring Option
DC Quick Connect Wiring Kit
2) Standard Wiring
E) Output Wiring........................................................ 5
1) Unswitched Output
2) Switched Output
F) Battery Wiring........................................................ 6
G) Status and Alarm Contact Wiring........................ 7
H) Chassis Grounding................................................ 8
I) Circuit Breakers...................................................... 8
1) Breaker Installation
2) Breaker Functions
III) FRONT PANEL INDICATORS, DISPLAY AND SETTINGS........ 10
A) Setttings................................................................ 10
1) Meter Power Source Selector Switch
2) LVD Switch
B) INDICATORS..........................................................11
1) Alarm LVD
C) LCD DISPLAY.........................................................11
1) Screen Selection Flow Chart
2) Programming Sequence
D) LVD Operation and Programming...................... 13
1) Manual/Auto Selecor Switch
2) LVD Adjustment
3) LVD Alarms
4) LVD Voltage Sequencing Example
IV) TROUBLESHOOTING..............................................................14
V) SPECIFICATIONS...................................................................16
VI) BREAKER SPECIFICATIONS/ORDERING GUIDE....................16
M-PFM500
As of 112818

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QUICK REFERENCE CONTENTS
Each of the main front or rear panel accessible features of the PFM-500 is illustrated below, along with the page number
where information on that particular feature is located.
Chassis Ground:
Page 8
Return/Ground:
Page 5
Status Contacts:
Page 7
Hot Switched Outputs:
Page 6
Status Contacts:
Page 7
Hot Power Module
Input: Page 7
Hot Unswitched
Output: Page 6
Chassis GND
Switched Outputs
12345
TO REDUCE THE RISK
OF ELECTRIC SHOCK,
DISCONNECT POWER
BEFORE OPENING COVER
OUTPUT INPUT (POWER MODULE)
HOT BATTERY
POSITIVE, NEGATIVE, OR FLOATING GROUND
STATUS CONTACTS
RETURN/
GND
INPUT
1
INPUT
2
INPUT
3
LVD
SUMMARY
ALARM
OUTPUT
INPUT
4
INPUT
5
INPUT
6
NC NO C
•
••
CONTACTS
SHOWN IN
FAILED
POSITION
1 2 3 1 2 3 1 2 3 1 2 3
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
PRE
LVD
WARNING!
Hot Battery Input/Output:
Page 5
LCD DISPLAY:
Page 11
Menu Knob:
Page 10
TEMPERATURE
SENSOR: Page 4
LVD Selector:
Page 10
Circuit Breaker Installation
Ports: Page 8
NEWPORT BEACH, CA USA
www.newmarpower.com
E-MAIL: [email protected]
TEL: [phone]
FAX: [phone]
POWER FUNCTION MANAGER
Model: PFM-500
INPUT:
+12, +24, -48 VDC
500 AMPS MAX
MENU
ALARM
LOW VOLTAGE
BATTERY
DISCONNECT
AUTO
METER
POWER
SOURCE
MANUAL
CONNECT
MANUAL
DISCONNECT
BATTERY
RECTIFIER
FIGURE 2: PFM REAR PANEL
POWER SOURCE SELECTOR:
Page 10
ALARM LED:
Page 12
FIGURE 1: PFM FRONT PANEL
Summary Alarm
Contacts: Page 7
Pre-LVD Activation
Alarm: Page 11

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I) OVERVIEW
The Power Function Manager (model PFM-500) converts multiple DC power sources (or NEWMAR Power Modules) into a
fully integrated and multi-functional power system. The unit provides control, monitoring, paralleling and protection of
12V, 24V or 48V DC, positive, negative or floating ground power sources.
A heavy duty (500 amp) parallel bus bar, digital metering, individual power source and total system status lights, five
load distribution breaker capacity, low voltage battery disconnect and summary alarm contacts are all combined into the
compact, rackmount housing of the PFM, which serves as a master DC power management and distribution center.
The PFM may be used for integration, control, monitoring and protection of numerous different types of power sources,
such as AC-DC rectifiers, regulated power supplies or DC-DC converters. In addition, any rack power product, including
distribution panels, can be connected to the PFM's alarm system, provided they employ form C or Normally Open (NO)
alarm contacts. For simplicity of explanation in this manual, reference is made to the NEWMAR Power Module as the
power source(s).
Note: Installation of Oring diodes is required for paralleling of DC power sources. Oring diode output is standard on NEWMAR PM
Series Power Modules.
II) INSTALLATION
A) Materials Provided
Prior to installation, please check to see that each of the following items have been included with the PFM. Check both the
information packet and the cardboard insert which is labeled "ACCESSORIES INSIDE". For any missing items please contact
the factory or warehouse.
B) PFM Mounting
The PFM is designed for mounting in a 19" or 23" relay rack and occupies two rack-units (2RU; 3.5"). A 19" set of mounting
ears and six 6-32 x 3/8" pan head phillips screws for attaching the ears to the PFM chassis are provided. Optional 23" rack
mounting ears are available - please contact Newmar for P/N: 699-3918-0, qty 2. Attachment holes in the chassis are
provided to allow either flush or 6" off-set or center mounting - rear support is required if choosing flush mounting.
C) Bus Bar Mounting
The PFM is shipped with a rackmount ground bus bar assembly kit (BBA-800). The bus bar is typically mounted on the rear
of the rack and is designed for installation on 19" or 23" racks using the provided mounting brackets and isolated stand-
offs. Refer to the instruction sheet provided with the BBA for complete mounting instructions and specifications.
BBA and PFM Rack Location Note: When wiring multiple power sources for parallel n+1 redundant wiring, equal length
positive and negative conductors are required for optimum load current sharing. Mounting the BBA at the opposite end
of the rack as the PFM (i.e., BBA at top-of-rack; PFM at bottom, or vice versa) will help facilitate equal length conductor
wiring.
D) Input Voltage Selection (Universal) and Wiring
The PFM has a universal input so no input selection switch is required. It will operate on 12, 24, or 48V DC with positive or
negative ground.
1) Simplified Wiring Option: DC Quick Connect Wiring Kit
A DC wiring harness quick connect kit is available from NEWMAR which simplifies parallel wiring installation of
multiple Power Modules with the Power Function Manager, and also facilitates “hot change-out” of modules for repair or
replacement. Note: This option is available only for systems which incorporate 1,000 watt models of the NEWMAR PM Series Power
Modules.
The kit consists of a power wiring harness with wires which are pre-cut to proper length and properly terminated with ring
lugs. The harness is neatly tie-wrapped into proper position for a simple and professional installation.
(2) ea. Mounting Ears for 19" rack mounting
(6) ea. 6-32 X 3/8" Phillips Screws (for mounting ear)
(1) ea. Circuit Breaker Finger Guard Cover
(2) ea. 6-32 x 1-3/8" Phillips Screw (Finger Guard Cover)
(2) ea. #6 23MM Spacer (Finger Guard Cover)
(1) set Circuit Breaker Identification Labels
(1) ea. Status Contact Wiring Harness with
3 position connectors
(3) ea. 3 Position Terminal Block Connector for Summary,
Pre-LVD and LVD Alarm Contacts
(6) ea. 1/4"-20 x 1" Hex Head Screws S.S. (Input/Output
Busbar Wiring)
(11) ea. 1/4"-20 Hex Nut S.S. (Input/Output Busbar Wiring)
(11) ea. Flat Washers S.S. (Input/Output Busbar Wiring)
(11) ea. 1/4" Split Lock Washers S.S. (Input/Output Busbar
Wiring)
(5) ea. 1/4"-20 x 3/4" Hex Head Screws S.S. (Hot
Switch Outputs)
(1) ea. BBA-800 Bus Bar Assembly Kit (see BBA instructions
for parts diagram)
(1) ea. Installation/Operation Manual

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Two kits are available: QCK-3 for wiring up to three 24 or 48 volt Power Modules, and QCK-6 for wiring four to six 24 or 48
volt modules. For more information or to order the quick connect kit, please contact the factory. For 12 volt model PM-12-
80, use model QCK-3A for up to three PM-12-80s and model QCK-6A for wiring four to six
PM-12-80s .
Note: If using the QCK for Power Module/PFM wiring all Power Modules must be stacked in the rack, one atop another, above the
PFM. (See FIGURES 3, 4 or 5)
2) Standard Wiring Instructions
Up to six power modules with the same voltage output may be wired to the PFM input, with the total load current not to
exceed 500 amps.
Refer to FIGURE 3 for the PFM input wiring instructions which follow.
FIGURE 3: Typical PFM DC Input Wiring
* Negative Ground Systems: Connect Ground Wire to (-) NEGATIVE OUTPUT Terminal and Hot Wire to (+) POSITIVE OUTPUT Terminal
* Positive Ground Systems: Connect Ground Wire to (+) POSITIVE OUTPUT Terminal and Hot Wire to (-) NEGATIVE OUTPUT Terminal
** Power Plugs shown present only if using NEWMAR QCK DC Quick Connect Kit, specify model QCK-3 (3 inputs) or
QCK-6 (six inputs)
Figure 3 illustrates a typical input wiring configuration with three power modules and one PFM (either positive or negative
ground system).
1) “Hot” input wires are attached to the heavy duty bus bar labeled “INPUT (POWER MODULE)” on the rear of the PFM.
Use the provided 1/4" hex head screws-washer-net sets. These may be replaced with 5/16" hardware if required for the
installation.
Wiring should be terminated with ring lugs to ensure a safe installation. The ring lugs must make direct contact with the
bus bar. If more than four units are wired to the PFM, lugs may be doubled up on the posts by removing the post first, then
reassembling the connection so that one lug seats against the bottom of the bus bar and the other against the top. Use an
FIGURE 3: Typical PFM DC Input Wiring
* Negative Ground Systems: Connect Ground Wire to (-) NEGATIVE OUTPUT Terminal and Hot Wire to (+) POSITIVE OUTPUT Terminal
14 or 12 AWG
Return/Ground

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additional stainless steel flat washer and lock washer set for proper installation of the second lug.
An elongated hole is provided directly behind the round hole to accommodate a second post for double hole wire lugs.
This hole will accept either 1/4" or 5/16" hardware also and the rear post at each position is adjustable for center-to-center
hole spacing between 3/4" and 1".
2) System or load ground wires are typically attached to the provided BBA bus bar, which has an assortment of hole sizes
to suit most terminal requirements.
Refer to the output wiring recommendations of the instruction manual which accompanies the power modules for proper
PFM input wire gauges.
3) A return/ground wire must also be run from the BBA bus bar (or other grounding point) to the terminal on the PFM
labeled “RETURN/GND”. This is not a system ground; rather, it is a reference ground for the PFM’s volt/amp meter and low
voltage battery disconnect. Note: Do not confuse this post with the chassis grounding point on the left rear of the PFM. Wiring
for the return/ground wire should be 12 or 14 AWG.
Note: When paralleling multiple early model NEWMAR Power Modules (PM-12-70, PM-24-35, or PM-48-18), use (+) Positive and (-)
Negative V OUT terminals only. Do not use V2 terminal.
E) Output Wiring
Output may be taken from a single unswitched output terminal or via up to five switched outputs. Installation of an
optional circuit breaker (available from NEWMAR) is required for each switched output. (See section E Circuit Breaker
Installation.) Refer to FIGURE 4 for the Output and Battery Wiring sections which follow.
FIGURE 4: Typical PFM DC Output and Battery Wiring

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1) Unswitched Output
Use of the PFM unswitched output may be required under certain circumstances; for instance:
* PFM output is routed through an external DC distribution panel
* The load is in excess of 100 amps (maximum load through any switched output is 100 amps)
1) The hot load wire is attached to a 1/4" bolt-washer-nut set provided on the heavy duty bus bar labeled “UNSWITCHED
OUTPUT” on the rear of the PFM.
The post hardware and bus bar hole configurations are identical to those on the “INPUT (POWER MODULE)” bus bar as
described previously.
2) Use the chart below to determine minimum gauge for the output wire depending on the maximum load current and the length
of the run from the PFM to the load or distribution bus (or refer to N.E.C. or local codes for any questions regarding proper DC wire
gauges):
Note: Use this chart also to determine proper wire gauge for switched loads in the section following.
DC Wire Size Table:
Output Current Amps Minimum Wire Size per N.E.C. AWG (mm)
up to 10 #16 (2mm)
11-20 #14 (2.5mm)
21-30 #12 (4 mm)
31-35 #10 (6 mm)
36-50 #8 (10 mm)
51-70 #6 (16 mm)
71-90 #4 (25 mm)
91-125 #2 (35 mm)
126-150 #1 (50 mm)
151-200 #0 (70mm)
To minimize line loss at lengths greater than 5 feet, it is recommended to increase wire size one gauge for each additional
5 feet of cable run.
2) Switched Outputs
Five switched output bus bars are provided for systems with multiple loads or where over-current protection/on-off
switching at the PFM is required. Use of any of the switched outputs requires installation of a model 'PBA' plug-in breaker
(available from NEWMAR) at that position. (See section II-I Fig. 7 for installation details and breaker functions. See section
VII for available amperages and ordering guide.)
Wires are attached to the numbered output bus bars labeled “SWITCHED OUTPUTS”. Terminate wires with 1/4" ring
terminals to fit the attached posts.
Before wiring loads to the switched outputs make note of the following: The conductor for each breaker position runs straight
through to the rear of the PFM so that the breaker in Position 1 (as you face the front) is on the far left, and the Position 1
output terminal (as you face the rear) is on the far right, and so on with each breaker/output terminal position reversed
from front to back.
Refer to the DC Wire Size Table above to determine proper output wire gauges.
Note: 100 and 75 amp may not be installed side by side. There must be an open breaker position or a breaker rated at 50
amps or less between them.
F) Battery Wiring
The “HOT” (+) Postive or (-) Negative battery wire is attached to the heavy duty terminal labeled “BATTERY” on the rear of
the PFM.
The terminal sizes and adjustability are identical to those of the “INPUT (POWER MODULE)” bus bar as described previously.
Prior to attaching battery wires ensure that the Low Voltage Battery Disconnect (LVBD) switch located on front panels is in
the “MANUAL DISCONNECT” position. If it is not, use a ball point pen or similar object to move the recessed switch into this
position. When in the disconnect position the LVBD contactor is forced open and the batteries are disconnected from the
system, to ensure safe wiring. It is recommended that this switch be placed in the disconnect position whenever servicing
Note: For applications in which a
single wire will be required to carry
more than 200 amps, refer N.E.C

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or making or breaking any connections to the batteries.
For safety, a fuse should be installed on the hot input/output battery wire, as close to the battery as possible.
Refer to the DC Wire Size Table to determine proper battery wire gauges.
G) Status and Summary & Pre-LVD Activation Alarm Contact Wiring
A color-coded status wiring harness for up to six sets of contacts has been provided with the PFM for ease of installation
and to ensure proper connections. This harness is designed for installations which employ NEWMAR Power Modules,
though it may be modified for use with other types of equipment, as well, provided they are equipped with Form C or
Normally Open (N.O.) failure contacts.
All status contact connectors are for alarm inputs only and each is labeled INPUT. Two 3 position terminal block
connectors are provided for the summary alarm output and the Pre-LVD alarm. The output of the PFM summary alarm
and Pre-LVD alarms is Form C.
Refer to FIGURE 5 below for the wiring instructions which follow.
FIGURE 5: Typical Status Contact and Summary Alarm Wiring
Note: This diagram depicts a system employing NEWMAR 2nd generation Power Modules, however, any equipment
which utilizes Form C or Normally Open (N.O.) alarm contacts may be wired to the PFM's six Status Contact input
connectors.

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Status Contact Harness Connection
A typical system with three NEWMAR Power Modules is illustrated on the previous page. The provided status contact
harness may also be used with non-NEWMAR equipment, however, it is likely that each connector on the harness
which would normally plug into the power module will require removal and replacement with another suitable for that
particular piece of equipment.
Careful attention to correct wire connections will be required when installing an alternate connector due to the uniform
color of each wire group. Wiring from the alternate equipment contacts to the PFM contacts must be identical: (fail-to-fail,
OK-to-OK) and Common-to-Common. “FAIL” and “OK” contact positions are illustrated on the rear of the unit beneath the
Hot Output terminal. (Or see FIGURE 6, following.)
Alarm Wiring with NEWMAR DST-20A Distribution Panel
NEWMAR's DST-20A is provided with its own four-wire harness for alarm wiring. Plug one end of the harness into the keyed
connector on the rear of the DST which is labeled BREAKER STATUS. Note: The harness is reversible, therefore it does not
matter which end is plugged in. For PFM-500 use, cut off one Molex connector from the
DST-20A harness and parallel the brown and blue wires. Parallel the orange and yellow wires. Select an un-used STATUS
CONTACT Input and connect the parallel brown/blue wires to terminal #1 and the paralleled
orange/yellow wires to terminal #3.
If all STATUS CONTACT positions are occupied (i.e., five or six Power Modules are in the system), and a summary alarm
from the DST is required, this may be accomplished through parallel wiring of the status wires. Please contact the factory
for information on how to perform this modification.
When wired to the PFM in this fashion any tripped breaker within the DST will result in illumination of the ALARM light on
the front of PFM, as well as activation of the PFM summary alarm contacts.
Summary Alarm Wiring
The summary alarm contacts will be in the “FAIL” position under the identical conditions in which the “CHECK SYSTEM”
indicator on the front panel is illuminated. (See Section III - B: Meter & Indicator for a complete description of failure
conditions.)
This alarm may be wired with the relay “normally open” or “normally closed”, as required for the installation. The position
of the contacts during DC output failure and normal operating condition is illustrated below:
FIGURE 6: DC “FAIL” and DC “OK” Summary Alarm Contact Positions (as viewed from rear of chassis)
Note: The three right-hand connector positions are unused in this installation
Relay contact rating for status and summary alarms is 5a @ 30V DC
H) Chassis Grounding
If grounding of the PFM chassis is required for the installation, use the provided 1/4" grounding stud on the rear panel
identified as “CHASSIS GND” for this purpose. Note: Do not confuse the chassis ground with the smaller return ground labeled
“RETURN/GND”, also on the rear panel of the PFM.
I) Circuit Breakers
1) Circuit Breaker Installation
Circuit breakers must be installed to use any of the switched outputs. The PFM accepts only specially designed plug-in
“mid-trip” circuit breakers with auxiliary contacts, which are available from NEWMAR. (The mid-trip function is explained
later). Refer to the Specifications section for available breaker values and ordering info.
Refer to Figure 7, on the next page and install the plug-in circuit breakers as follows:

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FIGURE 7: Circuit Breaker Installation
1) Shut off all power to the PFM and slide the LVBD switch on the front panel into the “MANUAL DISCONNECT” position
before proceeding. Remove the two flat head screws on either side of the breaker retaining plate and pull firmly
outward to remove it. Note: The protective circuit breaker clear plastic toggle handle cover is not shown in the above diagram.
Installation is optional. If it has already been installed, it is not necessary to remove the cover in order to remove the
retaining plate.
2) Remove the plastic breaker hole plugs as necessary.
3) Prior to installing circuit breakers, make note of the following: The conductor for each breaker position runs straight through
to the rear of the PFM so that the breaker in Position 1 (as you face the front) is on the far left, and the Position 1 output
terminal (as you face the rear) is on the far right, and so on with each breaker/output terminal position reversed from front
to back.
4) Install each circuit breaker into the PFM with “OFF” facing upward (toggle down) by lining up the push-in studs of the
breakers with the internal mating holes inside the breaker receptacle and pushing firmly into place. The two top auxiliary
contact terminals in the middle of the breaker should press against the mating clips. The bottom auxiliary contact is
unused in this installation.
5) Ease the breaker retaining plate back into position over the breakers and onto the PFM. The holes in the retaining plate
are beveled to help adjust the breakers into position, but it may be necessary to retract the plate and nudge breakers
individually to achieve the necessary alignment.
6) Replace the retaining plate mounting screws.
7) Restore power to the PFM (if all other aspects of installation have been completed) and return the LVBD switch to the
“AUTO” position.
Circuit Breaker Finger Guard Cover, Labeling
Installation of the circuit breaker toggle handle finger guard cover is optional. Use the provided 6/32-1/4" screws and
spacer for mounting the cover onto the retaining plate. Blank labels are provided with the packaging to be placed on the
clear Finger Guard cover over each position for identifying each circuit function.
Note: 100 and 75 amp breakers may not be
installed side by side. There must be an open
space or a breaker rated at 50 amps or less
between them.
Breaker Retaining Plate
Retaining Plate Mounting Screw
(one on each side)
Breaker Hole Plugs
Finger Guard Cover
Breaker Push-In Studs
Plug-In Circuit Breaker
Auxiliary Contacts
(COM and N.O. used)
Breaker Mating Holes
Aux. Contact Mating Clips
Finger Guard Mounting Screw and Spacer
(one on each side)

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2) Circuit Breaker Function/Mid-Trip Feature
The plug-in circuit breaker functions as an on/off switch and provides over-current protection as rated. However, the
special mid-trip feature allows the operator to distinguish between a condition where the breaker has been tripped by
over-current and where it has been intentionally shut off.
When the circuit breaker is manually shut off, the summary alarm contacts within the PFM will remain in the “OK”
position, to avoid setting off alarms unnecessarily when disconnect is intentional. When the breaker is tripped by over-
current into the mid-trip position, the toggle handle will rest midway between the on and off positions, the PFM “ALARM”
light will illuminate and the Form C summary alarm contacts will be in the “FAIL” position. (See Status Indicators section
following.)
III) FRONT PANEL INDICATORS, DISPLAY AND SETTINGS
A) Settings
1) Meter Power Source Selector: The LCD meter can be powered from the rectifier side or the battery side by using the
selector switch on front panel. Powering the meter from the rectifier side (default) causes the PFM-500 to completely
shutdown during a Low Battery Voltage Disconnect thus reducing battery drain. Powering from the battery side will allow
the LCD meter to continue operating even with a LVD disconnect event.
CAUTION: Moving the Meter Power Source Selector may momentarily remove power from meter causing a momentarily
glitch in the meter display.
B) Indicators
1) Alarm LED on Front Panel: This red LED will illuminate when any of the following conditions occur:
• LVD Pre-disconnect threshold crossed (see Section III-A3 for more info)
• LVD activation- manually or automatically
2) Manual/Auto Selector Switch: The LVD selector switch, located on front panel, sets the way the LVD circuit functions.
• Manual connect - Battery always online
• Automatic - LVD function enabled (factory default)
• Manual disconnect - Battery always offline
LCD DISPLAY Menu Knob
LVD Selector
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POWER FUNCTION MANAGER
Model: PFM-500
INPUT:
+12, +24, -48 VDC
500 AMPS MAX
MENU
ALARM
LOW VOLTAGE
BATTERY
DISCONNECT
AUTO
METER
POWER
SOURCE
MANUAL
CONNECT
MANUAL
DISCONNECT
BATTERY
RECTIFIER
POWER SOURCE SELECTOR
ALARM LED

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C) LCD Display
1) Digital Meter Programming Sequence Flow Chart
Figure 8: Digital Meter Programming Sequence Flow Chart - see page 12 for screen reference number detail
4A
4B
4C
4D
4E
4F
1
2
3
4
5
1B
5B

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2) Digital Meter Programming Sequence:
Screen diagram reference number, corresponds to flow chart on page 11.
1) Home screen: displays DC voltage & total amperage consumed by system (loads and battery charge current), and
temperature in degrees Celsius. When in programming mode the screen will revert to home after 30 second of
inactivity. Note, it is normal the ammeter may toggle between 0 and 1 amp with no load or battery connected.
1B) If system battery is disconnected, screen will automatically display “Batt Offline” until battery is reconnected.
Rotating the knob will select other screens, or pushing the menu button will take you directly to the alarm screen.
2) LVD settings Screen: Displays the disconnect and reconnect voltages
Rotate knob to:
3) Ambient Temperature Screen: Displays temperature in degrees C and F.
Rotate knob to:
4) Programming Portal Screen: Displays when in 'ready to program' mode; push of menu button to move to
programming screens, or rotating knob displays alarm screen (#5)
4A->LVD voltage disconnect Screen, press programming button to enter set mode, rotate knob to change, push to
confirm setting. See page 13 for detailed directions.
4B->LVD voltage connect Screen, press programming button to enter set mode, rotate knob to change, push to
confirm setting. See page 13 for detailed directions.
4C->LVC pre disconnect voltage screen, press programming button to enter voltage at which pre trip alarm should
activate, push to confirm setting. See page 13 for detailed directions.
Rotate knob to:
4D Display brightness setting , press programming button to enter adjustment mode, rotate knob to change, push
button to confirm
Rotate knob to:
4E) Restore factory setting screen, press programming button to access authorization screen, rotate knob to yes if
you wish to apply factory global factory default settings, press programing button to confirm.
Rotate knob to:
4F) Exit screen, press programming button to return to Programming portal screen (ref #4)
5) Alarm system status screen: displays ’system ok’ if no alarms have been tripped.
5B) If alarm conditions are present, screen will automatically display what alarm condition has occurred”
• BRK OFF= Breaker off
• LVDdiscon= Low voltage disconnect activated
• Prelvd= voltage approaching disconnect point, disconnect eminent.
• CHK PM= Summary alarm received from rectifier
Rotate knob to return to Home screen.

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D) LVD Operation and Programming
Low Voltage Disconnect: The PFM-500 incorporates a 500 amp LVD circuit which automatically removes the battery
when battery voltage drops to a pre-set DISCONNECT threshold (or when manually activated- see section 5.11) and
automatically re-connects the battery when battery voltage rises above the selected CONNECT threshold (see Specification
8.0 for default LVD thresholds and adjustment ranges)
1) Manual/Auto Selector Switch: The LVD selector switch, located on front panel, sets the way the LVD circuit functions.
• Manual connect - Battery always online
• Automatic - LVD function enabled (factory default)
• Manual disconnect - Battery always offline
2) LVD Adjustment: The PFM-500 offers easy adjustment of both dis-connect and re-connect LVD settings without the need
for an external, adjustable power supply. These thresholds can be selected on the front panel meter from the SETTINGS
page (see Flow Chart on page 10) using the menu knob, the default factory setting for the particular item is also displayed.
A press on the menu knob will save the settings and is retained even after powering down the unit. LVD threshold
adjustment can be made while the system is operating.
3) LVD Alarms: Pre-disconnect & disconnect - Two external alarms can be triggered by the PFM-500: the Pre-disconnect
(‘PRELVD’) and the LVD dis-connect (‘LVDDISCON’). The LVD Pre-disconnect alarm is a warning to an impending battery
disconnect. It is triggered by an adjustable voltage thresholds set above the LVD dis-connect threshold and below the
re-connect threshold. The LVD dis-connect alarm is automatically set using the LVD dis-connect threshold (see 5.12). Both
alarms will trigger the LED Alarm light.
4) LVD Voltage Sequencing Example - 12 VDC shown
12.5v NORMAL SYSTEM VOLTAGE
12.3v LVD RE-CONNECT (ADJUSTABLE)
11.6v PRE-DISCONNECT WARNING ALARM (ADJUSTABLE)
11.0v LVD DIS-CONNECT (ADJUSTABLE)
a) Normal Voltage: Typical system voltage with rectifiers supplying load(s), batteries not deeply discharged.
b) LVD Re-Connect: Level at which the battery will be re-connected after a dis-connect event when system voltage is
restored.
c) Pre-LVD Alarm: Level at which the pre-LVD alarm contact triggers as an early warning for impending low battery
disconnect. (See Specification Section 8.0 for factory default.)
d) Battery Dis-Connect: Minimum allowable battery voltage level has been reached and will disconnect battery to
prevent damage. Will also trigger LVD alarm. (See Specification Section VI: Specifications for factory default.)

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PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
A. “ALARM” L.E.D. illuminated 1. See Section II - G: Status and Alarm
Contact Wiring for proper status
contact wiring.
2. One or more Power Modules not
outputting current.
2. Verify Power Module is wired
correctly. See Power Module
Installation/ Operation manual to
verify proper operation.
3. LVD in disconnect position. 3a. Verify LVD switch is in the “AUTO”
position.
3b. Check to see if battery voltage is
below the LVD disconnect threshold.
If so, remove load and recharge
battery.
3c. Check to see if LVD disconnect
voltage is set too high. See Section
III-D for LVD adjustment procedure.
4. PFM load circuit breaker tripped.
(Breaker is in mid-trip position.
Note: Breaker will not activate
the “ALARM” L.E.D. if manually
switched into the off position.)
4. Identify cause of over-current
condition and reset breaker.
B. LVD contactor rapidly cycles between
open and closed
LVD out of adjustment. See section III-D for LVD adjustment
procedure.
1. Status contacts for one or more
power modules or other monitored
equipment mis-wired.
IV) TROUBLESHOOTING
C. LVD disconnects battery from load
too soon-batteries not low.
1. Disconnect threshold set too high.
2. Large voltage drop between (+) or
(-) battery terminal and BATTERY HOT
input post.
3. Sudden voltage drop due to heavy
intermittent load.
1. See section III-D for LVD
adjustment procedure.
2. Shorten wire length and/or
increase wire size. Check for loose
connections.
3. Increase battery capacity or test
and replace batteries if necessary.

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POSSIBLE CAUSE CORRECTIVE ACTION
PROBLEM
D. LVBD will not connect battery to PFM
although battery is fully charged.
1. LVD out of adjustment. 1. See section III-D for LVD adjustment
procedure.
2. LVD selector is in “MANUAL
DISCONNECT” position.
2. Reposition switch to “AUTO”.
Factory Contact Information
If a problem with the PFM-500 persists after you have applied the above-outlined solutions, or if you have any
questions about the installation and proper operation of the unit, please contact NEWMAR's Technical Services
Manager:
Phone: [phone] — From the hours of 7:00 A.M. to 4:30 P.M. weekdays, P.S.T.
Fax: [phone] — Anytime
E-Mail: [e-mail] — Anytime
We are happy to consult with you to resolve any problems or questions you may have. If, during consultation, it
appears the PFM must be returned to the factory for repair we will issue a Return Materials Authorization at that
time.
E) Meter Display Errors LCD display gets out of sync with the
micro-controller and displays incorrect
information.
Power cycle the LCD. To power cycle
the meter without disconnecting the
load: first ensure
the rectifiers are on, disconnect
battery from PFM, then slide the
meter power to ‘Battery’ then back to
‘Rectifier’. This will briefly disconnect
power to the meter and allow a safe
power cycling and clear the display
error. Reconnect battery to PFM.
F) LVD Stability Issues After Settings
Change
LVD contactor cycles frequently after
making changes to the LVD
default settings
PFM-500 can be restored to factory
settings to aid in troubleshooting (see
section III page 12, item 4-4E and the
Digital Meter Programming Sequence
Fow Chart, page 11 for details).

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V) SPECIFICATIONS
INPUT/OUTPUT: 12, 24 or 48V DC nominal; Positive or Negative Ground
VOLTAGE RANGE: 8 to 65 VDC
GROUNDING: Positive or Negative (Polarity insensitivity)
MAXIMUM TOTAL CURRENT CAPACITY: 500 amps (six power modules maximum)
PROTECTION:
• Up to five branch circuit breakers (optional)
• Low Voltage Disconnect (See LVD Specifications below)
INDICATORS/ALARMS:
• “ALARM” L.E.D. indicator (Red)
• Digital volt/amp meter
• Form C summary alarm contacts; provide for monitoring of up to six inputs from equipment with either
• Form C or Normally Open contacts. Typical indications include Power Module failure, LVBD activation, and
breaker mid-trip condition
• Form C LVD pre-disconnect (see factory default LVD pre-disconnect alarm thresholds below)
TEMPERATURE RATING: 0° C to +60° C
CASE SIZE: H x W x D; 3.5" x 19" or 23" x 20.5"
LVD SPECIFICATIONS:
Factory set actuation voltages:
12 Volt 24 Volt 48 Volt
Disconnect 10.4V DC 21.0V DC 42.0V DC
Connect 12.2V DC 24.5V DC 49.0V DC
FACTORY DEFAULT LVD PRE-DISCONNECT ALARM THRESHHOLD (Adjustable):
System Voltage 12V 24V 48V
LVD Pre-Disconnect 11.2V 22.8V 45.5V
VI) CIRCUIT BREAKER SPECIFICATIONS AND ORDERING GUIDE
Current Ratings: See chart below (breaker value stamped beside toggle)
Voltage Rating: 80 V d.c. max.
Type: Magnetic-Hydraulic Plug-in with Auxiliary Contacts (Normally Open) and Mid-Trip Function UL Listed
Telecom Breaker CSA Certified Carries the CE Mark
To order additional or replacement breakers for the PFM-500 refer to the following NEWMAR model or Carlingswitch part
numbers:
Rating NEWMAR Model
5 amp PBA-5
6 amp PBA-6
10 amp PBA-10
15 amp PBA-15
20 amp PBA-20
25 amp PBA-25
30 amp PBA-30
40 amp PBA-40
50 amp PBA-50
63 amp PBA-63
75 amp PBA-75
100 amp PBA-100
Note: Other circuit breaker values are available on a special order basis. Typical lead time is 10 weeks.