NewMar POWER-PAC User manual

VI) SPECIFICATIONS
8 1
Input: 115/230 VAC + 10%, 50-60 Hz.
Output:
13.8 VDC
20 Amps Surge (10% duty cycle, 10 minutes max.)
5 Amps continuous (100% duty cycle)
Regulation:
1% Line and Load
Ripple:
4 mV RMS (@5 amp continuous duty rating)
Current Limit: Power supply current limit set @ 110% of continuous
duty rating.
Low Voltage Alarm:
Engages @ 10.6 - 10.9 VDC Output
Terminal Voltage
Low Voltage Disconnect:
10.3 VDC Output Terminal Voltage
Internal Battery(s):
Sealed, Lead-Acid, Rechargeable, Deep-Cycle
12 Volt, 7 Amp-Hour
Back-Up Battery Float Voltage:
13.8 VDC
Dimensions (H x W x D): 5.25" x 9" x 10.5"
Weight: 16 Ibs. (with one battery)
22 Ibs. (with two batteries)
POWER-PAC
INSTALLATION / OPERATION
MANUAL
R

TABLE OF CONTENTS
I) General Description ............................................................................. 2
II) Features ............................................................................................... 2
III) Features Illustration ........................................................................... 3
IV) Operation ............................................................................................ 4
V) Theory of Operation ........................................................................... 7
VI) Specifications .................................................................................... 8
I) GENERAL DESCRIPTION
II) FEATURES
The is a regulated linear power supply which produces a 13.8
VDC output from either a 115 or 230 VAC input. It incorporates a built-in
battery which will continue to supply the 12 volt load with DC power in the
event of a temporary loss of AC input to the supply. Provision is made for
increasing the amount of time available for operating on emergency back-
Power-Pac
up with the addition of another internal or external battery.
Regulated Noise-free Output The Power-Pac features a highly regulated,
low ripple output (see specifications) to power radios and other sensitive
communications equipment without causing RF or audio interference.
Battery Back-up A 7 amp-hour battery is built into the unit to provide up to
20 amps of emergency transmit power. It is charged automatically by the output
of the Power-Pac during normal operation. In addition, mounting space and
battery terminals are provided within the unit for an optional second 7 amp-hour
battery (available from NEWMAR), thus allowing the operator to double the
amount of time that the radio can operate on emergency power. If more back-
up power is desired, terminals are provided for the addition of an external battery.
Battery and Input/Output Status Indicators The operator is kept informed
of all important functions such as AC input, DC output and battery status with
front-panel indicator lights and a warning buzzer.
Automatic Low Battery Disconnect The battery is protected against
damage from extreme discharge by a circuit which will automatically disconnect
the load when output voltage reaches 10.3 VDC.
Over-Voltage Protection The radio being powered is protected against
damage from any condition which might cause excessive output voltage by an
over-voltage protection (OVP) circuit.
2
7
Should emergency communication be necessary after this automatic shut-down,
the Power-Pac provides a Shut-down Override Button. This button, when
pressed, reconnects the battery to the radio or other communication load. This
reconnect circuit works only when the Override Button is being pressed.
Disconnect occurs when it is released. Batteries may be permanently
damaged by being re-engaged with the Override Button.
Note:
If the Power-Pac is already connected to the radio when AC power fails,
engagement of the battery back-up is automatic. However, there may be
occasion to install the Power-Pac when there is no AC power available initially.
In this case, it will be necessary to position the On/Off switch to “On” and then
press the Override Button once to engage the battery back-up.
V) THEORY OF OPERATION
AC
Input
5 Amp Power Supply
S1
AC “ON”
Indicator
Crowbar
SCR
Battery
Status and
Low Voltage
Disconnect Solid State
Relay
S2
Battery Status
LED
“NORMAL” LED Buzzer and
Silence Switch
Out, 13.8 VDC
External Battery
Out
5. Buzzer When battery output voltage reaches the point where the Battery
Status light begins to flash, at the same time an audible Buzzer will begin to
sound. If desired, this automatic Buzzer may be disabled by positioning the
Buzzer Switch to “Off”.
6. Shut-down Override Button Because batteries may be permanently
damaged by being completely discharged, particularly if they are left discharged
for a long period of time, the Power-Pac employs an automatic low-voltage
disconnect circuit. If the back-up battery is drained to the point where only 10.3
VDC is sensed at the output terminals, the Power-Pac will automatically
disconnect the load from the battery back-up.

The internal battery is a sealed rechargeable type and will normally last 5-7
years.
In addition to providing back-up power in the event of an AC power failure, the
battery will supplement the output of the Power-Pac to provide for loads up to 20
amps. At loads of 5 amps or less the Power-Pac both supplies the load and
charges the battery to a finishing voltage of 13.8 VDC. Installing additional
back-up batteries does not increase the maximum amperage output of the
Power-Pac, as the unit is current-limited at 20 amps. Additional batteries will only
allow radio operation to continue for a longer period on back-up power.
Note:
If you wish to increase the back-up capacity beyond 14 amp-hours, a set of
terminals are provided for you to add an additional battery bank. These terminals
are located on the rear of the unit and are labeled “EXTERNAL BATT” The
external battery will also be charged by the Power-Pac during normal operation.
Refer to the wire size notes in Section B to determine the correct gauge for wires
to the battery.
Note: Because all back-up batteries are in parallel it is important that they be of
the same type and approximate age. Also, it is not recommended to increase
total battery back-up capacity to more than 28 amp-hours, as the Power-
Pac may not be able to recharge a larger bank if it should become deeply
discharged during an extended AC power outage.
The fuseholder for the internal battery is located beneath the output “RADIO”
terminals. The fuseholder for the external battery is directly beneath the
“EXTERNAL BATT” terminals. To gain access to either fuse, depress the
fuseholder cap slightly and turn ccunterclockwise. Should either fuse ever need
replacing, be sure to use a standard 20 amp AGC fuse. As always, slo-blo fuses
should be not used.
5
amp-hour ratings in the matrix on the bottom of the unit.
Battery Back-up The Power-Pac comes equipped with either (1) or (2) 7 amp-
hour batteries installed. To find out whether your Power-Pac has 7 or 14 amp-
hours of back-up, check the “BATTERY BACK-UP RATING” matrix on the
bottom of the unit. The appropriate designation will be marked. If you have the
7 amp-hour model and wish to double the back-up capacity, an additional battery
may be obtained from the factory. (Specify part number 360-2015-0.) Your
Power-Pac already has an internal mounting space and bracket for the second
battery, and is pre-wired with color coded leads that simply snap onto the battery
terminals. If you install a second battery, be sure to mark the box next to the 14
C)
IV) OPERATION
If you require the Power-Pac to operate at 230 VAC input, take the following steps
before you apply AC power:
AC Input The Power-Pac comes from the factory wired for 115 VAC input.
It is equipped with a UL-approved power cord with three-pin plug. the input
fuseholder is on the rear of the unit to the left of the power cord.
been installed, Should this fuse ever need replacing, be sure to do so with a
A 4 amp fuse has
standard AGC fuse. Do not replace with a slo-blo fuse.
A)
1) Remove the 4 amp input fuse and replace it with a 2 amp fuse. (A 2 amp fuse
is provided.)
2) Using a ball-point pen or similar tool, slide the input selector switch from the
115 to the 230 VAC position. This switch is located directly above the input
fuseholder.
3) Cut off the three-pin plug from the power cord and replace with the appropri-
ate type to match the available 230 VAC outlet. The black wire is hot (fused),
white wire is neutral and green is earth/safety ground.
No adjustment is necessary to accommodate 50 or 60 Hz input.
Wire gauge
WIRE LENGTH (IN FEET)
5'
#14
10'
#12
15'
#10
20'
#10
NOTE: If external battery back-up is used, the wire length is the total combined
length of the wire from the battery bank to the Power-Pac and the Power-Pac to
the radio.
4
DC Output The DC output terminals are located on the rear of the unit and are
labeled “RADIO”. These terminals will accommodate standard banana plugs,
spade lugs sized to fit a #10 stud, or stripped stranded wire leads.
B)
The chart below can be used to determine the correct gauge for output wiring,
based on the length of the wire from the Power-Pac to the radio.

3
Current Limit Protection The Power-Pac is protected against damage due
to overloads or shorts on the output by an automatic current limiting circuit.
Fusing AC input and internal and external batteries are fused for additional
protection against high current conditions.
Automatic Thermal Shutdown The Power-Pac is protected against over-
heatinf (when duty ratings are exceeded) by an automatic thermal shutdown
circuit. When a safe operating temperature is restored, the Power-Pac automati-
cally returns to service.
III) FEATURES ILLUSTRATION
For this illustration, refer to section IV) A, B, C:
EXTERNAL
FAILURE
N.C.
C.
N.O.
AC
RADIO
FUSE 20A
115VAC 4A
230VAC 2A
115V
FUSE 20A
WARNING: DISCONNECT POWER BEFORE SERVICING OR
REPLACING THE FUSE. DO NOT OPEN. REFER
SERVICING TO A QUALIFIED TECHNICIAN.
BATT
++
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POWER CORD
For this illustration, refer to the numbered items in section IV)-D:
BUZZER
BATTERY STATUS
NORMAL
SHUT-DOWN OVERRIDE
LIGHT ON: SYSTEM POWERED BY BATTERY ONLY
LIGHT BLINKING & BUZZER: LOW BATTERY VOLTAGE (10.6-10.9V DC)
SHUT DOWN IMMINENT.
SHUT DOWN AT 10.3V DC
INPUT: 115/230 VAC +10%, 50-60 Hz.
-
OUTPUT: 13.8 VDC AT 5 AMPS CONTINUOUS.
20 AMPS INTERMITTENT.
OFF
ON
POWER SYSTEM W/ INTERNAL BATTERY
ON
O
I
OFF
POWER - PAC
TM
5
4
3
6
2
1
6
Front Panel Controls and Indicators
D)
1. On/Off Switch This rocker switch controls both AC power to the Power-
Pac, as well as DC output. When the switch is in the “Off” position there will be
no output from the supply or the back-up batteries to the load. (Exception: the
back-up batteries will be engaged while the Override button is being depressed,
but will disengage when you release it.) If you wish to engage the back-up
batteries, and leave them engaged while there is no AC available to the Power-
Pac, put the switch into the “On” position and press the Override button once. The
batteries will come “on-line” to begin supplying the load with DC voltage and will
stay on-line until AC power is restored or the batteries drain to the prescribed 10.3
VDC disconnect voltage.
3. “Normal” Indicator Light This light will stay illuminated as long as the
Power-Pac is on and the battery charging circuit is functioning normally. It will be
extinguished when AC power to the Power-Pac is lost, the unit is manually shut
off or if the unit has shut down due to thermal overload (see item 4).
It may also illuminate when there is a load surge near 20 amps and the back-up
battery is providing a substantial portion of the current. This is indicated if the
Battery Status Light comes on while the AC Indicator and “Normal” lights remain
on.
If the Power-Pac is operated beyond its temperature rating, the automatic
thermal switch may cause the unit to shut down and the back-up battery to be
engaged. In this case, the Battery Status Light will come on while the “Normal”
light is extinguished and the AC Indicator light remains on. The Power-Pac will
return automatically to normal service when a proper operating temperature is
restored, however, the overload problem should be attended to immediately, as
this thermal cycling will severely shorten the life of the Power-Pac.
If the back-up battery is engaged and continues to supply the load until battery
output voltage drops to 10.9-10.6 VDC, the Battery Status Light will begin to
flash. This is to alert the operator that back-up power is very limited and
corrective steps should be taken immediately in order to maintain system
operation.
4. Battery Status Light This light will illuminate and remain on when AC
power to the Power-Pac is lost and battery back-up is activated. This is indicated
when the light comes on while the AC Indicator and “Normal” lights are
extinguished.
2. AC Indicator Light This light, located directly above the On/Off switch will
illuminate when there is AC available to the Power-Pac and the switch is in the
“On” position. It is unrelated to DC output.
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