NewMar Centurion III C3RS-48-124 User manual

1
Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626
Phone: [phone] • E-mail: [e-mail]
854-3906
M-C3RS Rev B as of 082123
Centurion III Power System
POWERING THE NETWORK
www.poweringthenetwork.com | 800.854.3906
Costa Mesa, CA
DC Power System
Installation / Operation Manual
Model:
C3RS-48-124 (-48VDC, +24VDC, & +12VDC)
RoHS
Copyright © NewMar 2021 All rights reserved.
Manual Version 1.0
Release Date: 24 May 2022
Disclaimer: NewMar reserves the right to make changes to the information within this document without notice
Product Compliance

2
Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626
Phone: [phone] • E-mail: [e-mail]
TABLE OF CONTENTS
1. ADMONISHMENTS 2
2. SAFETY 2
3. RECEIVING INSTRUCTIONS 3
3.1. Package Inspection 3
3.2. Equipment Inspection 3
3.3. Handling 3
3.4. Identification Labels 3
4. SCOPE 3
5. SYSTEM OVERVIEW 4
5.1. Power System 4
5.2. Physical Dimensions and Weights 4
5.3. Alarms and Status Indicators 5
5.4. EM4x Features 5
5.5. Rectifier Modules 6
6. INSTALLATIONS 7
6.1. Unpacking & Installing in Frame 8
6.2. AC Cabling 8
6.3. Upstream Over-current Protection 8
6.4. Discrimination 8
6.5. DC Cabling 8
6.5.1. Terminal Block Labeling 8
6.5.2. Terminal Block Max Wire Size/Recommended Torque Specification 9
6.6. Alarm/Ancillary Cabling 11
6.7. Temperature Sensors 11
7. ENERGY MANAGER CONNECTIVITY AND THE WEB UI 11
7.1. Access Levels 11
7.2. Ethernet Port Connection 12
7.3. USB Connection 12
7.4. Energy manager & IO PCB Alarm Output Configuration 13
7.5. EM4x LED Alarm Mappings 13
7.6. EM4x Main PCB Alarm Mappings 14
7.7. EM4x Main PCB Digital Input Alarm Mappings 15
7.8. Circuit Breaker Fail Monitoring 15
8. LVD OPERATION 15
9. MAINTENANCE 16
9.1. System 16
9.2. EM4x Controller 16
9.3. Rectifiers and Converters 17
9.4. Batteries 17
9.5. Ventilation Maintenance 17
10. TROUBLE-SHOOTING AND SERVICING 17
10.1. Servicing 17
11. ESSENTIAL SYSTEM SET-UP PARAMETERS 18
11.1. Systems with Lead Acid Batteries 18
11.2. DC System Lead Acid Battery Commissioning Checklist 21
11.3. Systems with Lithium Batteries 23
Appendix 1 AC INPUT TRANSIENT PROTECTION 24
Appendix 2 RECTIFIER INPUT FUSE CURVES 27
Appendix 3 INSTALLATION OF AC Junction Box 28
Appendix 4 TROUBLESHOOTING 29
Appendix 5 Field Replacement of Load Circuit Breakers 30
Appendix 6 System Wiring Diagrams 31

3
Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626
Phone: [phone] • E-mail: [e-mail]
ADMONISHMENTS
The admonishments are the symbols and wording used in this manual to alert readers to specific
dangers and instructions. The meanings of the various admonishments are explained as follows:
Warning = risk to life or personal injury and equipment
damage
Caution = risk of equipment damage.
= risk of electrical shock potentially causing death
or injury.
= alert of risk potentially causing death or injury.
= risk of burn injury from hot surfaces
= an alert that must be understood and
undertaken.
= instruction of mandatory reading of product
manual.
= risk of electrostatic
damage to components.
Proper precautions must be
taken.
= access for children prohibited.
= restricted access area.
= tip over hazard.
1. SAFETY
All installation and maintenance must be carried out by suitably qualified personnel.
For your protection, the product manual should be read and thoroughly understood
before unpacking, installing, and using the equipment.

4
Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626
Phone: [phone] • E-mail: [e-mail]
The energy manager contains static sensitive components that require careful handling
and proper precautions to be taken. A grounding strap should be worn.
The equipment is intended only for use in a restricted access area. The equipment is not
suitable for use in locations where children are likely to be present.
2. RECEIVING INSTRUCTIONS
Newmar provides all equipment to the delivering carrier securely packed and in
perfect condition. Upon acceptance of the package from Newmar, the delivering
carrier assumes responsibility for its safe arrival. Once the equipment is received,
it is the recipient’s responsibility to document any damage the carrier may have
inflicted, and to file the claim promptly and accurately.
NOTE: the period to make a claim against damage by a transport carrier can be short,
a matter of days, and varies by transport method, the transport contract, and local
laws.
2.1. 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.
2.2. Equipment Inspection
Open the 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.
NOTE: Save all the shipping materials for the inspector to see.
After the inspection has been made, if damage has been found, contact Newmar.
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.
2.3. Handling
Handle the equipment with care. Do not drop or lean on front panel or connector.
Keep away from moisture.

5
Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626
Phone: [phone] • E-mail: [e-mail]
2.4. Identification Labels
Model number and serial number are clearly marked on all equipment. Please refer
to these numbers in all correspondence with Newmar. Ideally provide a photograph
of the product label for reference.
3. SCOPE
This manual covers essential information for the installation and commissioning of
the Newmar Power System Centurion III.
Note: System set-up for the controller, power modules and other ancillary devices are
provided in separate manuals. Where appropriate these are supplied with the system.
4. SYSTEM OVERVIEW
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 Energy Manager
forward.
The system is designed to be extremely simple to install and set up.
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 in the positive side of the circuit (+ve earth system). The earth link can be removed
from the system to isolate earths.
4.1. Power System
Standard Features
The base unit is supplied with the following standard options:
 AC Input: single-phase input terminals: Line, Neutral and Earth.
 DC Output: maximum power output of 4.0kW producing a maximum current output of
83.4A/-48V.
 Two power bays will accept -48V to 12V or -48V to 24V DC-DC Converters.
 EM4x energy manager system controller (fully integrated in the system)
 Battery Low Voltage Disconnect 125A rating
 2x 100A Battery Circuit Breaker.

6
Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626
Phone: [phone] • E-mail: [e-mail]
 10x DC Load Circuit Breakers, these may be specified as different values (from 2A to 30A)
at time of order.
 2x DC-DC Converter Output Breakers with tripped breaker alarm
4.2. Physical Dimensions and Weights
Model
Centurion III
Depth (Total) 350mm
Width (Total) 483mm (19” mount)
Height 88.9mm (2U)
Weight without
rectifiers/converters
8.4kg
Weight with max.
rectifiers/converters
13.2kg
Table 1
Energy Manager
4.3. Alarms and Status Indicators
• Status LEDs:
◦ Red LED Urgent alarm state.
◦ Orange LED Non-Urgent alarm
◦ Green LED DC power is connected to the unit; Energy Manager is functioning
NOTE: The LED mapping can be user modified.

7
Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626
Phone: [phone] • E-mail: [e-mail]
• The energy manager is fitted with an audible buzzer which can be configured to alert to any
alarm depending on the alarm mapping.
NOTE: To disable the buzzer when active, tap any button.
• Micro-USB Connector: can independently power the EM4x and provides access to the Web
UI
Note: when there are multiple alarms raised the Active Alarm display cycles through the
list. The complete list can be viewed by tapping Alarms.
• Tap the buttons to navigate through the menus.
Note: the EM4x-01 has the option to PIN lock function change through the front screen
interface. See the EM4x manual for details.
4.4. EM4x Features
The EM4x microcontroller-based DC system energy manager provides the control and
monitoring functions for all Newmar Energy’s power systems. With an appropriate
communications connection third party lithium battery can also be managed.
The EM4x monitors all power system conditions including DC voltage, rectifier current,
battery current, battery temperature, distribution failure and battery pack status. It has an in-
built web-based configurator allowing setup of system parameters, monitoring, updating and
download of logs using a web browser as well as a front panel interface through which key
parameters are also configurable. Visual notification of alarm conditions is given by LEDs and
a display mounted on the front of the EM4x, with remote notification being enabled by relay
contacts, RS232 or TCP/IP (using SNMP).
The EM4x utilizes a USB communications port which allows for local monitoring of system
operations as well as pre-commission and power down configuration of the Web UI.
The EM4x also incorporates the following features:
• Support for third-party external batteries, both lead-acid and lithium based
• Support for AC-DC rectifiers (48V Outputs)
• Support for DC-DC converters (12V & 24V)
• Network connectivity (web access)
• System voltage metering for primary system DC supply. (e.g., 48V primary DC output)
• Load, battery and rectifier current metering and alarms
• Active rectifier current share
• Automatic system voltage control
• Effectively unlimited alarm thresholds as standard, for use with multiple DC outputs
• Advanced monitoring, display and logging of battery packs, and system performance data
• Advanced hybrid site control and monitoring with patented anti-stall feature for
generators.
• Phase balance controls for multi-phase and single-phase AC input management
• Sophisticated programmable logic control
• For lead-acid external batteries -
◦ Battery and room temperature metering and alarms (when fitted with optional
temperature sensors)
◦ Temperature compensation of float voltage (when fitted with optional temperature
sensors)
◦ Manual equalize charging to prolong the life of the batteries
◦ Periodic equalize charging to prolong the life of the batteries
◦ Fast charging after battery discharge
◦ Battery capacity remaining indication
◦ Battery testing facility
◦ Battery current limit
• Six user defined General Purpose Inputs (“GPIPs”) which can be software configured as
either digital or analogue inputs* (up to 10 may be made available under special
circumstances)
• Six relay outputs*

8
Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626
Phone: [phone] • E-mail: [e-mail]
4.5. Rectifier Modules
The RM2048HE is a telecommunications grade rectifier with the following features:
• High efficiency
• Hot pluggable
• Forced air cooled
• Thermally protected
• Power factor corrected
• Wide input AC voltage
• Constant power output limit
• Input/Output voltage and current protected
• Active load sharing
• Serial alarm and control interface
• Microprocessor controlled
There are 3 LED indicators on the front panel which indicate the operational state of the
rectifier:
Red
LED
Urgent alarm state.
Yellow
LED
Non-Urgent alarm.
Green
LED
DC power is connected to the unit.
This LED flashes during power save mode.
5. INSTALLATIONS
WARNING - All upstream AC, Load and Battery breakers must be switched OFF
prior to installation.
The system must be completely de-powered.
All circuit breakers in a Newmar power system must be in their OFF position prior to
installation.
WARNING - Use extreme care when fitting batteries & their connections. Remove all
conductive materials from yourself such as watches, jewelry, and rings prior
to
RM3048HE
3.0 kW 48V DC
Status LEDs
Fan Cooled
Unlock Button
R M
2
048HE
2
.0kW 48V DC
Figure 4: RM2048HE Rectifier

9
Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626
Phone: [phone] • E-mail: [e-mail]
commencing the installation. DO NOT short terminals when working on them.
CAUTION - Avoid resting cables on sharp edges (cold-creep)
The energy manager contains static sensitive components that require
careful handling and proper precautions to be taken. A grounding strap
should be worn.
5.1. 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 can withstand mounting of the system.
A 5/32" (4mm) wide slotted screwdriver has been provided to allow ease of
accessing some of the smaller recessed DIN style terminal block screws.
Note: Do not fit rectifier modules until the Centurion III DC power system has been installed
into the rack.
5.2. 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 8 AWG/10mm2 cables.
Once cables are connected, ensure cable clamps are secured. Refer to appendix 5
for AC junction box cover removal (page 24)
The AC earth 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
Figure 2 AC-DC Connection
Earth Stud
P
N
L
Figure 1 Terminal Block

10
Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626
Phone: [phone] • E-mail: [e-mail]
5.3. Upstream Over-current Protection
There are two considerations to consider 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.
Cable Rating
The maximum current drawn by the DC power system is 24A from a single-
phase supply (12A per rectifier 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 in the protection device, making its minimum rating
28.8A/ph for single phase input.
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.
5.4. 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 RM2048HE 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 32A, D-curve (note, a 32A 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.
Alternatively, a 40A 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.
5.5. 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.
2x +12V/-12V or
1x +12/-12V & 1x +24V/-24V or
2x +24V/-24V
Battery Connections