NewMar Centurion II User manual

Powering the Network
www.newmartelecom.com • 800-854-3906Newport Beach, CA USA
Centurion II Power System
M-C2RS
As of 101315
DC Power System
Installation / Operation Manual
Model:
C2RS (-48 VDC and +24 VDC)

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Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [e-mail]
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TABLE OF CONTENTS
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Section Description Page
1 Receiving Instructions ............................................................................................................. 2
2 Scope.......................................................................................................................................2
3 System Overview .................................................................................................................... 3
4 Installation................................................................................................................................3
4.1 Unpacking & Installing in Frame ........................................................................................... 3
4.2 AC Cabling.............................................................................................................................. 4
4.2.1 Upstream Over-current Protection............................................................................. 5
4.3 DC Cabling.............................................................................................................................. 6
4.3.1 Terminal Block Labeling……………… .....................................................................6
4.3.2 Terminal Block Max Wire Size/Recommended Torque……………………………..6
4.4 Alarm/Ancillary Cabling.......................................................................................................... 8
5 LVD Operation ......................................................................................................................10
6 Commissioning ......................................................................................................................11
7 Appendix 1 – Newmar Essential System Set – Up Parameters ....................................... 18
8 Appendix 2 – Maintenance .................................................................................................. 20
9 Appendix 3 – AC Input Transient Protection ...................................................................... 21
10 Appendix 4 – Rectifier Input Fuse Curves .......................................................................... 23
11 Appendix 5 – Installation of AC JunctionBox.......................................................................24
12 Appendix 6 – Troubleshooting .............................................................................................. 25
13 Appendix 7 – Field Replacement of Load Circuit Breakers.................................................26
14 Appendix 8 – System Wiring Diagrams............................................................................... 27
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InstallationCD
You may have received a CD with your Centurion II Power System. This contains the user manuals relevant to the
System you have purchased, plus the SM3x Configuration Software. This software enables direct communication
from your computer to the SM3x via the USB port.
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Note: You will require Administrator rights on your computer to install this software.
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If this is the first time you have used the SM3x Configuration Software, then the installation process will guide you
through the installation of:
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 the USB drivers,
 the Microsoft .Net Framework
 the SM3x Configuration Software itself
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Upon inserting the CD, open the file directory. In the root directory there is a file called Setup_sm3xconf_4.2.exe.
Double click on this and you will be guided through the installation process. Normally, you should only be required to
click “next” on all prompts.
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The number “...4.2” denotes the release issue of the Configuration Software (the file you receive may be 4.3, 4.4 or
greater). If you have an earlier version installed than the number denoted there, then you can automatically update
your existing software by double-clicking on this .exe file (it will not re-install your USB drivers or the .Net
Framework).
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The first time you connect your computer to a SM3x via the USB, Windows will “find new hardware”. Proceed to
install the drivers “automatically”. If, during this process, you get a message from Windows stating that the driver is
unsigned, it is not a problem. You must continue with the driver installation.

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Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [e-mail]
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1 RECEIVING INSTRUCTIONS
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CAUTION: For your protection, the following information and the product manual should
be read and thoroughly understood before unpacking, installing and using the
equipment.
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We present all equipment to the delivering carrier securely packed and in perfect condition.
Upon acceptance of the package from us, the delivering carrier assumes responsibility for its
safe arrival to you. Once you receive the equipment, it is your responsibility to document any
damage the carrier may have inflicted, and to file your claim promptly and accurately.
Package Inspection
 Examine the shipping crate or carton for any visible damage: punctures, dents and any
other signs of possible internal damage.
 Describe any damage or shortage on the receiving documents and have the carrier sign
their full name.
Equipment Inspection
 Within fifteen days, open crate or carton and inspect the contents for damages. While
unpacking, be careful not to discard any equipment, parts or manuals. If any damage is
detected, call the delivering carrier to determine the appropriate action. They may require
an inspection.
Save all the shipping materials for the inspector to see!
 After the inspection has been made and you have found damage, call us. We will determine
if the equipment should be returned to our plant for repair or if some other method would be
more expeditious. If it is determined that the equipment should be returned to us, ask the
delivering carrier to send the packages back at the delivering carrier’s expense.
 If repair is necessary, we will invoice you for the repair so that you may submit the bill to the
delivering carrier with your claim forms.
 It is your responsibility to file a claim with the delivering carrier. Failure to properly file a
claim for shipping damages may void warranty service for any physical damages later
reported for repair.
Handling
Handle the equipment with care. Do not drop or lean on front panel or connectors. Keep away
from moisture.
Identification Labels
Model numbers are clearly marked on all equipment. Please refer to these numbers in all
correspondence with Newmar.3
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2 S COPE
This manual covers essential information for the installation and commissioning of the
Centurion II DC Power System
System set-up for the rectifiers, alarms etc., are provided in separate manuals for the SM36 (C2C-
36) supervisory module and rectifiers.
All installation and maintenance must be carried out by suitably qualified personnel.
Note: The Centurion II System is available with Positive Earth (-48Vdc, -60Vdc) or Negative
Earth (+24Vdc). The installation manual covers both Positive and Negative Earth
systems. The standard system is assumed to be a Positive Earth system. Where
parameters and settings differ between systems, the Negative Earth system parameters
are specified within parenthesis i.e. ().
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3 SYSTEM OVERVIEW

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Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [e-mail]
The Centurion II DC Power System has a maximum power output of 6.0kW (+24V rated to
3.0kW @ 24V, 3.3kW @ 27V), producing a maximum current output of 125A/-48V (125A/
+27V).
The system is intended to be a complete power system in a box, so no connections need to be
made internally. All the AC, DC (Load and Battery) connections are made at the rear of the unit.
Alarm connections are accessible from the front by pulling the Supervisory Module forward.
The system is designed to be extremely simple to install and set up.
The following is a summary of the system:
- Overall size is 483mm wide (19” standard mounting) x 88.9mm (3.5”) high (2U) x 350mm
(13.78”) deep
- Up to 3x 37 amp (-48V or +24V) C2R-2000 or C2RX-2048 rectifiers 41.7A max (may be packaged
separately) or 3 x 18 amp (-48V) C2R-1000 rectifiers
- SM36 supervisory module (fully integrated in the system)
- Battery Low Voltage Disconnect fitted as standard (125A rating).
- 2x 100A Battery Circuit Breaker.
- 8x 10A, 4x 20A, 4x 30A default Load Circuit Breakers, these maybe specified as different values
(from 2A to 30A) at time of order.
- System weight is approximately 8.4kg (18.5 lbs.) without rectifiers, and 13.2kg (29 lbs.) with
three rectifiers fitted.
- Three sets of single phase input terminals: A-L1, B-L1, C-L1 & A-L2, B-L2, C-L2 plus Earth
are provided to allow several input wiring options: See drawing #M-C2ACOPT located in
manual bag for more information on AC wiring options . Note: Two 3 position terminal
block links/jumpers areprovided (in manual bag) for single high current AC source
wiring.
Note: This system is supplied with the AC and DC earths connected unless chassis DC
isolation is specified when ordering. The standard -48 VDC system output has the DC
Common inthe positive side of the circuit (+ve earth system). On +24 VDC systems,
the DC Common has thenegative side of the circuit (-ve earth system) connected to
system chassis/earth. The earth link can be removed from the system to isolate
earths. Please see section 4.2 'AC Cabling'.
4 I NSTALLATION
4.1 Unpacking & Installing in Frame
Upon unpacking, check that the unit is not damaged, and that you have the required number of
rectifiers.
The unit flush mounts into a standard 19” mounting frame. The mounting screws should be
#12-24; however #10-32 may be used with washers. Be sure to mount the unit in the 19” frame
squarely if #10-32 screws are used.
Please note the complete system weight is 13.2kg. (29 lbs.). Ensure the 19” mounting rails are
able to withstand mounting of the system.
A 5/32" (4mm) wide slotted screwdriver has been provided to allaow ease of accessing some of
the smaller recessed DIN style terinal block screws.

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Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [e-mail]
4.2 AC Cabling
The AC terminals are clearly marked at the rear of the system as shown in Fig 1.0 & 1.1. The
terminals can accept up to 8AWG/10mm2 cables.
Once cables are connected, ensure cable clamps are secured. Refer to appendix 5 for AC
junction box cover removal (page 24)
The ACearth terminal earths the System chassis. The AC earth is also internally bonded to
the System chassis by earth stud as shown in Fig 1.1. The AC earth terminal can accept
several small cables or up to a single 2 AWG cable.
DC Common (+ve) is connected to the AC earth as shown in Fig 1.1, but can be removed if
output is required to be isolated.
Note: Refer Appendix 3 for AC Input Transient Protection
Fig.1.0 AC Input Terminals
CAUTION: For 3 phase operation remove the Single Phase link fitted between the
phases.
AC Input Terminals
AC Junction Box AC Junction Box
w/CoverRemoved
Note:SeeAppendix5forinformationregardingthe AC junction box.
Shown with 3
position jumper
installed
Shown with 3
position jumper
installed
AC Input Terminal

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Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [e-mail]
Earth
Stud
AC-DC Earth Link
(Remove link for
Isolated DC Output)
Fig.1.1 AC – DC Earth Link
4.2.1 UpstreamOver-currentProtection
There are two considerations to take into account when selecting an appropriate fuse/circuit
breaker.
- The upstream protection should protect the downstream cable from overload situations.
- Discrimination should be maintained with the downstream device fuses.
(i) Cable Rating
The maximum current drawn by the DC power system is 12.5A per 2kW rectifier (6.2A for 24V
system and 48 VDC/1 kW rectifier modules), or 37.3A (18.7A for 24V system and 48 VDC/1 kW
rectifier modules) per fully populated rectifier shelf at a minimum input voltage of 175V AC and
full output power. The upstream protection device must be able to supply this load under all
conditions without tripping. Therefore, typically at least 20% headroom is allowed for the
protection device, making its minimum rating 15A/per 2kW rectifier (7.5A) or 44.8A (22.5A) for
fully populated rectifier shelf.
Note: The current carrying capacity of cables is dependent on the type of cable used. Please
check with your local supplier and local regulations for appropriate sizing.
(ii) Discrimination
Discrimination ensures that the upstream circuit breaker or fuse does not blow if a rectifier input
fails (short circuit). Therefore it is important to ensure the upstream protection discriminates
with the internal fuse of the rectifier. The fuse used in the RM2048/24, C2R-2000, and C2RX-
2048 rectifiers is a slow-blow 15A fuse. The tripping curve for this is shown in Appendix 4 at the
rear of this manual.
A minimum circuit breaker to use for this system is a 20A, D-curve (note, a 20A C-curve breaker
will not discriminate with the rectifier fuse). Therefore, when used with the 2.5mm2 cable
supplied, a 20A, D-curve breaker should be used.

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Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [e-mail]
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Alternatively, a 32A C-curve breaker, or greater, can be used. However, AC cable provided
may have to be replaced for a larger cable1.
If a fuse is used upstream, then any BS88 or NH g style fuse, of 20A or greater rating will
discriminate.
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4.3 DC Cabling
CAUTION: Use extreme care when fitting batteries & their connections. Remove all jewelry
and rings from oneself prior to commencing the installation. Always use insulated
tools when fitting batteries and take extreme care not to short terminals when
working on them.
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4.3.1 Terminal Block Labeling
Note: Your Centurion II Load & Battery Terminal Blocks maybe labeled differently than shown in
photos on the following page. Some Centurion II shelves’ terminal blocks are identified by
Numbers which are the Live or Hot terminals and the words Batt. Common or Load Common
which are the Return or Ground terminals – see polarity table below.
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System Voltage “Numbered’ (AKA: Live or Hot) ‘Common’ (AKA: Return or Ground)
-48 VDC - +
+24 VDC + -
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4.3.2TerminalBlockMaxWireSize/RecommendedTorqueSpecification
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Connection Max AWG Recommended Torque
AC Input 8 10.5 in/Lbs.
AC Earth 2 22 in/Lbs.
Loads 1 –8 8 10.5 in/Lbs.
Loads 9 - 16 10 10.5 in/Lbs.
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1
NOTE: Alargerbreakermaybeusedeventhoughintheoryitmayappearthatthe2.5mm
2
wireisnotfullyprotected.Infact 
itisprotectedontwoaccounts.Firstlyitisprotectedbytherectifierinputfuse(whichisonlyashortdistanceaway).Secondly, 
therectifiersarepower‐limitedontheirinput.Therefore,theycanneverbeoverloaded.Asaresult,thewirecanneverbe 
over‐loadedbytherectifier–itcanonlyseefaultcurrent.Asaresult,dependingonlocalauthorities,onlyfaultcurrent 
protectionmaybecateredforbytheupstreamprotectivedevice. 

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Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [e-mail]
Battery 
Live
Battery
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Common
CableTieSlots
LoadLive 
(‐48V)
Load
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Common
LoadLive
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(‐48V)
Load
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Common
Fig. 2 Battery & DC Output Terminals (+ve Earth System, -48V or -60V)
Battery
Live
Battery
Common
CableTieSlots
LoadLive 
(+24V)
Load 
Common
LoadLive 
(+24V)
Load 
Common
Fig 2.1 Battery & DC Output Terminals (-ve Earth System, +24V)

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Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [e-mail]
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All live DC and Common connections are made to the connectors at the rear of the unit as
shown in Fig 2 and Fig 2.1.
For 1-8 load breakers 8Awg/10mm2 terminals are used whereas for 9-16 load breakers,
10 Awg/6mm2 terminals as shown in Fig 2 and Fig 2.1.
The battery terminals shown can accept cables up to 2 Awg/35mm2.
The internal battery cabling goes directly to the circuit breaker, then via a Low Voltage
Disconnect relay and current shunt to the internal live bus. This can be seen on the wiring
diagram at the rear of this manual & in Fig 5.
Ensure cables are strain relieved by utilizing the cable tie slots provided as shown in Fig 2.
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4.4 Alarm/Ancillary Cabling
Alarm and communication cables terminate directly into the terminals of the Supervisory
Module. These terminals are accessible by pulling the monitor forward to expose connections
as shown in Fig 3, Fig 3.1, Fig 3.2 & Fig 3.2a.
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Fig. 3 (left): For removal, unlock SM31/32 by lifting green locking tab.
Fig. 3.1 (right): For SM35/36 removal, pull monitor forward to release the ball catch
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When routing the cables, ensure they are kept away from the AC and DC power cables when
possible.
For SM31/32 relay states labelled Normally Open or Normally Closed are for their de-energized
state.
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Volts – Free
Relays
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SM31/32
Supervisory
Monitor
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Fig. 3.2 SM31/32 Monitor Cabling

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Newmar • PO Box 1306, Newport Beach, CA 92663
• Phone: [phone] • E-mail: [e-mail]
Volts–FreeRelay
Battery Temperature CompensationSensor
Fig.3.2a SM35/36 Monitor Cabling
For SM35/36Relays1‐ 6canbeusedfornormallyopenornormallyclosedstatesbyjumper
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selection.TherelaystateslabelledNOorNCisfortheirde‐energizedstate.
If an alarm is programmed for the relay to be normally energized (as may be required in the
case of a low voltage alarm where loss of power will put the alarm into its active state), then be
sure to connect the remote wiring appropriately.
For full monitor functionality and operation information, refer to the appropriate monitor manual.
Temperature Sensors
Uncoil the battery temperature sensor tie wrapped to rear of shelf and place in the middle of the
middle battery string. If the lead is not long enough, ordinary 2-core copper (approx. 18
AWG/0.75mm2) wire can be used as an extension. The purpose of the battery temperature
sensor is to monitor the ambient temperature of the batteries over long periods of time and
adjust the rectifier output (float) voltage accordingly. As a result, it is not necessary to have the
temperature sensor touching the batteries. If the Battery Temperature Sensor is removed a
“battery temp fault” alarm is generated.
The “Ambient” temperature sensor (optional) can be used to monitor the temperature in another
location if required.
Connecting via Computer
For remote communications and direct computer connection to the Compact System, refer to
the SM36 Manual. These connections can be made via the mini-USB port on the front panel of
the monitor (computer connection to the SM36, USB cable included) and the Ethernet port
(SM36 web-based communications only). The Ethernet port has been extended to the rears of
the shelf via a patch cord and RJ45 coupler for installer convenience.
When a laptop/pc isconnected for the first time to the SM36, the USB drivers will have to be
installed on the connected computer. See the SM36 manual for details.
Help files can be accessed for a field by left clicking inside the field and pressing the F1
key on the keyboard. Example shown in Fig. 4