NewMar NAV-PAC Owner's manual

THEORYOF NAV-PAC OPERATION
NOISE FILTER / VOLTAGE TRANSIENT PROTECTOR WITH BATTERY
BACK-UP
The NAV-PAC is wired in series with the DC power to sensitive electronics and:
(1) Filters out noise interference on incoming power lines.
(2) Clamps voltage spikes and transients to a safe level.
(3) Provides battery back-up power during voltage drops due to starter motors
and momentary losses of power.
P.O. Box 1306• Newport Beach,CA 92663
Shipping: 2911 W. Garry Ave. • Santa Ana, CA 92704
Phone: [phone]
Fax: [phone]
e-mail: [email protected]
INSTALLATION AND OPERATION MANUAL
SPECIFICATIONS
INPUT: 12 VDC, Nominal Charging:13.8-14.4 VDC,
To Prevent Discharge:13.4 -14.4 VDC, Maximum: 15.5 VDC
OUTPUT: Filtered, Voltage Spike Protected With Back-Up Battery 20 amps Max.
BACK-UP POWER: 12.0 VDC Nominal
5.0 AH Capacity
7 amps for Fifteen (15) Minutes
10 amps for Eight (8) Minutes
15 amps for Two (2) Minutes
0-50 C 20 amps for One (1) Minute
BATTERY: Sealed Rechargeable 5.0 AH, 5-7 Years Typical Life - Replaceable
FILTERING: Audio Through 200 MHz
VOLTAGE SPIKE PROTECTION:
Transient Energy Capability; 100 Joules, 4,000 amps Max
OPERATING TEMPERATURE: 0-50 C
SIZE-WEIGHT HW D
5.25" 6.2" 7.4" 5.2 lbs.
13.3 (cm) 15.7 (cm) 18.8 (cm) 2.4 kg
-8-
M-NAVPAC-G
AS OF November 2009
www.newmarpower.com
°

TABLE OF CONTENTS
FEATURES .................................................................................... 2
GENERAL INFORMATION ........................................................... 3
Voltage Spike Protection
RF Noise Filtering
Back-Up Power
Warning of Imminent Loss of Power
Timed Disconnect Circuit
Low Battery Disconnect Circuit
MATERIALS PROVIDED .............................................................. 4
INSTALLATION ............................................................................. 4
Main Unit
Remote Panel
OPERATION .................................................................................. 5
BATTERY CHARGING/REPLACEMENT .................................. 6
TEST/TROUBLESHOOTING ....................................................... 7
THEORY OF OPERATION........................................................... 8
SPECIFICATIONS .......................................................................... 8
FEATURES
•Back-Up Battery maintains DC output voltage during dips and black-outs —
prevents memory loss and system crashing in GPS, MDTs, and other critical
electronics.
•Multi-Stage Filter eliminates electronic noise and interferences, providing
pure power navigation electronics require.
•Power Status Panel alerts operator to possible loss of power.
•Overvoltage transient protection prevents damage to sensitive circuitry due
to voltage line spikes.
•Low voltage and timed disconnect circuits protect internal battery against
shortened life or damage due to excessive discharge.
•Maintenance-free solid state circuitry assures years of dependable service.
•Conformal coated printed circuit board resists corrosion.
•Rugged, rust and corrosion-proof vinyl laminated aluminum case provides
protection for components.
•All components selected for dependable performance in the most hostile
environments.
•Each unit thoroughly tested and inspected before shipment.
•Two year limited warranty.
GENERAL INFORMATION
The NAV-PAC protects electronics from voltage spikes, power surges, momentary
power losses, abrupt voltage changes and noise interference on incoming DC power
to MDTs, GPS, CHART PLOTTERS and other Onbaord Electronics prone to
memory loss or “crashes”.
NAV-PAC is a solid state device which provides “pure” power to navigation
electronics by performing several essential functions.
1) Voltage Spike Protection: Engine cranking, pump and motor operation send
voltage “spikes” through a boat’s electrical system that often “bulldoze” their
way through the electronic circuitry. NAV-PAC eliminates this ruinous condi-
tion.
2) R.F. Noise Filtering: The NEWMAR NAV-PAC contains a four-element low-
pass LC filter which provides very high radio frequency attenuation in both
positive and negative power leads to the receiver preventing noise from
adversely affecting signal reception and related operation.
3) Back-Up Power: A special long-life, completely sealed “Dry Battery” pack is
built-in the NAV-PAC which acts a power reservoir and is charged from the
shipboard 12 Volt power. In the event of a drop in DC voltage due to engine
cranking or total power interruption, the battery will maintain power to navigation
equipment for a short period of time. This is essential for preventing memory and
data loss.
4) Warning of Imminent Loss of Power: A remote panel is supplied with the
NAV-PAC and its function is very important; it warns of loss of input power and
indicates output is available to your navigation equipment. A flashing “Out put OK”
indicator light warns the operator that the NAV-PAC has lost DC input and that the
navigation equipment is being powered by the NAV-PAC’s internal battery only.
This allows the user time to restore DC input to the NAV-PAC and navigation
equipment or to turn off the navigation equipment before the input voltage
drops, causing memory loss.
5) Timed Disconnect Circuit: This circuit prevents damage to the internal battery
from extreme discharge by disconnecting the NAV-PAC battery approximately
15 minutes after abrupt drop or complete loss of DC input.
6) Low Battery Disconnect Circuit: This circuit prevents damage to the internal
battery from extreme discharge by disconnecting the battery whenever battery
voltage reaches 10.2 VDC.
2 3

MATERIALS PROVIDED
Your NAV-PAC comes with the following materials:
(3) # 8 ring lugs for 22-16 gauge wire
(4) # 8 ring lugs for 12-10 gauge wire
(3) butt connectors
(1) Installation/Operation Manual
Check to see that these have been included with the packaging. For any missing
items, please contact the factory.
INSTALLATION
1)After you have determined the best location in the system, locate a flat
surface close to the power line that feeds the GPS, SAT-NAV or plotter. For
best results the NAV-PAC unit should be within 24" of the critical electronics.
The case need not be grounded, so it is acceptable to mount the unit on wood
or metal. Securely mount the NAV-PAC.
Turn off power to the wires that will be cut or worked on by disconnecting the
battery or shutting off the appropriate circuit. Identify the positive and
negative lead in the power line and cut at an appropriate location. Use the
lugs supplied to hook up the NAV-PAC to your system.
2) Using the table below, select the proper wire size for your installation:
AMPS * CABLE LENGTH (feet)
10' 15' 20'
0 - 10 AMPS 14 AWG 12 AWG 12 AWG
10 - 20 AMPS 10 AWG 10 AWG 10 AWG
*Current draw of NAV equipment being powered.
Replace terminal block cover to prevent accidental shorting of the terminals.
Imporant Installation Note: If there is to be a continuous load on the Nav-Pac
output during normal operation, the DC input must be a minimum of 13.4 VDC to
prevent discharge of the internal battery.
3) Remote Panel: Mount in a conspicuous location where the loss of power
indication will be noticed. The NAV-PAC will function normally without the
remote panel or with the remote panel switch off. Connect the wiring as
follows: (see diagram)
OPERATION
When the remote status panel is properly hooked up and DC power is being
applied to the NAV-PAC, both the “INPUT OK” and “OUTPUT OK” LED’s will
steadily illuminate. This indicates that pure DC power is available at the output
terminals and that the internal 5.0 amp-hour battery is being kept charged. (The
LED lights draw only about .01 amp each.)
In the event of a loss of DC input to the NAV-PAC, the “INPUT OK” LED will be
extinguished and the “OUTPUT OK” LED will begin to flash. This indicates that the
navigation equipment is being powered by the NAV-PAC’s internal battery only.
It will also indicate that the timed battery disconnect circuit has been initiated. After
approximately 15 minutes the NAV-PAC’s internal battery will automatically
disconnect from the NAV-PAC’s output. This is to protect the battery discharge if
TYPICAL INSTALLATION DIAGRAM
NOTE: Remove both fuses before wiring the NAV-PAC. Reinstall fuses only after
carefully checking installation and wiring.
45

number starting "0435" was manufactured the 35th week of 2004, Be sure to
mark the date of replacement on this sticker for future reference.
Caution: Take care to ensure that you do not short the battery terminals during
installation. The resulting high current can melt wires and cause other damage to
the unit.
1. Turn off power to the input wiring and disconnect all input and output
connections to the NAV-PAC. Remove the unit from the mounting surface.
2. Remove the fuse from the fuseholder labeled “BATTERY” on the front panel.
3. Remove the four screws on the top of the unit and the four screws on either
side of the unit.
4. Remove the cover.
5. Disconnect the battery terminals.
6. Remove the four screw / washer sets that are securing the battery hold-down
bracket.
7. Slide the battery and bracket out from under the PCB.
8. Slide the new battery and bracket into the NAV-PAC and reverse all above
procedures.
Dispose of the old battery properly and according to local codes. Although the
battery is sealed, it is a lead-acid type and there may be restrictions on its disposal.
TEST / TROUBLESHOOTING
To test the battery operation, disconnect the input power at the source or remove
the input fuse, and, using a voltmeter, note that DC output power is still present
on the output terminals. Note that after approximately 12-15 minutes the output
will disconnect automatically to protect the internal battery. You should then
measure no voltage on the output terminals. To reset this timed circuit, reconnect
the NAV-PAC input to the ship’s battery.
The noise filtering and spike protection circuitry won’t require testing unless the
NAV-PAC blows fuses repeatedly, or has had a nearby lightning strike, or other
very high energy transient.
If the NAV-PAC blow fuses repeatedly (replace with 20 Amp Fast Acting Fuse:
ABC-20 or AGC-20), this usually indicates a shorted component. Have a qualified
technician perform the repairs or return the unit to NEWMAR for factory inspection.
Always verify that the replaced fuses are of the correct rating. Use standard AGC
or fast-blow fuses. Do not use slow-blow fuses.
BATTERY REPLACEMENT PROCEEDS AS FOLLOWS:
the input is switched off. To reset this circuit input to the NAV-PAC must be
restored.
Bear in mind that the NAV-PAC has another disconnect circuit which may cause
it to shut down sooner. The battery is also protected by a low-voltage disconnect
circuit. Should the current draw of the device being powered cause the battery
voltage to drop to 10.2 VDC before 15 minutes have passed, then this circuit will
disconnect the battery from the output. The amount of time the equipment will
continue to function normally before the NAV-PAC will shut down will depend, in
this case, upon the current draw of the device being powered. (See BACK-UP
POWER in the SPECIFICATIONS section on page 8.) To reset this circuit, the
internal battery must be recharged. Reduce or shut off the electronic load, and
insure that an adequate charge voltage is restored to the input. (See BATTERY
CHARGING/REPLACEMENT.)
If you are unable to restore DC power immediately it is probably a good idea to turn
off the equipment being powered by the NAV-PAC. Most communication or
navigation equipment with built -in memory has a “keep alive” or “soft” shutdown
that is activated by the on/off switch. But if the input voltage is slowly reduced, as
will occur when the NAV-PAC battery discharges, this “keep alive” feature may not
activate, resulting in loss of memory, waypoints, etc.
REMEMBER: When you wish to shut off your com/nav equipment, you must shut
it off with the power switch to the equipment itself. Do not shut off the input to the
NAV-PAC. The NAV-PAC will simply treat this the same as an emergency loss
of DC input, and will continue to supply the comm/nav equipment with DC power
from its internal battery until auto-shutdown occurs.
If you are not powering equipment with the NAV-PAC and it is not being supplied
with DC input, it is recommended that you turn off the remote panel. Though the
current draw from the LED’s is slight, it will unnecessarily drain the battery over
time if they are left on.
BATTERYCHARGING/REPLACEMENT:
CAUTION: DO NOT LEAVE THE BATTERY DISCHARGED FOR EXTENDED
PERIODS OF TIME. IT MAY BE PERMANENTLY DAMAGED AND MAY NOT
TAKE A RECHARGE.
The battery requires no maintenance and is completely sealed. Battery life is up
to five years. To charge the battery requires an input voltage of 13.8 to 14.8 VDC
for 3-4 hours or more per month. To prevent discharging requires a nominal input
of 13.4 - 14.4 VDC. These voltages are normally produced by an engine alternator
or good quality battery charger.
The battery storage time @ 23°C is 400 days. The battery should be replaced no
less frequently than every five (5) years to guarantee proper operation of the NAV-
PAC. (Request part #425-1204-0 )
To determine the age of the battery in your NAV-PAC, check the quality control
sticker on the end of the unit. The first four digits of the serial number (designated
"S/N") refer to the year and month of manufacture. For instance, a unit with a serial
67