Phase3 PT 80 User manual

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
www.newmarpower.com
1M-PT-U-LNGFM
As of July 2008
Phase Three
Three Stage Smart Charger
Installation/Operation Manual
Models: PT 80, PT24-45U, PT-24-95U
Section Topic
Page
QUICK REFERENCE DRAWING 2
I) GENERAL INFORMATION 3
II) IMPORTANT SAFETY INFORMATION 3
III) INSTALLATION 4
A) Materials Provided 4
B) Location. 4
C) Mounting 4
D) D.C. Output Wiring 5
E) Multiple Unit Parallel Wiring 6
F) A.C. Input Wiring 6
IV) OPERATION 8
A) Three Stage Charge Regimen 8
B) Time-Out Circuit 8
C) Gel-Cell/Lead-Acid Selector Switch 9
D) Remote Monitor Panel Option 9
E) Temperature Compensation Option 9
F) Equalize Timer Option 10
G) Cooling Fan 11
H) Power On Indicator 11
I) Output Ammeter 11
V) APPLICATION NOTES 11
A) Start-Up 11
B) Constant Versus Occasional Use 11
C) Proper Load Sizing 11
D) Operation with Engine 11
E) Operation as a D.C. Power Supply
or Radar Rectifier 11
VI) SPECIFICATIONS 12
VII) TROUBLESHOOTING 12
VIII) BATTERY CARE TIPS 13
IX) REFERENCE APPENDIX 14
X) PT 80/PT-24-45U UNIT DIMENSION DRAWING 15
XI) PT-24-95U UNIT DIMENSION DRAWING 16

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
www.newmarpower.com
2
Quick Reference Drawing

























Note: PT 80/PT-24-45U
illustrated in drawing.

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
www.newmarpower.com
3
I) GENERAL INFORMATION
Your Phase Three Series Battery Charger represents a new phase
in charger design and performance, employing “smart” switching
circuitry which puts batteries through the optimum three-step
charge process, adapts for gel-cell or lead-acid batteries, features
precise voltage compensation for varying battery temperature, is
rated for continuous duty and is housed in a rugged stainless steel
and aluminum case.
Following is a brief listing of some of the more important features/
options of your Phase Three Charger. Each is fully detailed later in
this manual:
• Three step “smart” charging: bulk, absorption, float
• Gel cell/lead-acid switch selects optimum charge/float voltages
based on battery type
• Multiple output banks charge independently based on demand
• “Universal” input of 90-264V A.C., 50-60 Hz input with no setting
of selector switch required—can be used anywhere in the world
• Current limiting prevents damage from overload
• Cooling fan allows continuous operation at full-rated output
• High charge voltage time-out circuit prevents overcharge
during continuous high amperage demand
• Optional temperature compensation sensor (model TCS-12/24)
fine tunes output voltage based on battery temperature
• Optional remote panel (model RP) allows remote monitoring of
charger phase status and manual re-initialization of three stage
charge cycle.
• Optional equalization circuit connection.
• Use as a power supply without in-line battery; allows continued
use of D.C . powered electronics (when A.C. is available) in the
event that batteries must be taken off-line or removed.
• Built to last – rugged stainless steel and aluminum powder
coated case with marinized internal circuitry; drip sheild
provided.
• Carries CE mark
In addition, your Phase Three Charger carries a full two year
warranty against defects in materials or workmanship from the
date of purchase. Careful attention to these instructions should help
you to enjoy years of trouble-free service.
Product Registration
NEWMAR warrants that your charger be free from defects in
material and workmanship for two years from date of purchase. If
you wish to register your product with us and provide comments
or questions, please log onto www.newmarpower.com/product_
registration.html or for immediate response to your questions or
comments, please call tech service at !-800-241-3897 or E-mail:
[email protected].
II) IMPORTANT SAFETY
INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS — This manual contains important
safety and operating instructions for the Phase Three Battery
Charger.
2. Before using this battery charger, read all instructions and
cautionary markings on (1) the battery charger (2) the battery, and
(3) any product powered by the battery.
3. CAUTION — To reduce the risk of injury, charge only 6 cell
(PT 80) or 12 cell (PT-24-45U & PT-24-95U) lead-acid rechargeable
batteries (flooded, AGM, gel or sealed). Other types of batteries
may burst, causing personal injury and damage.
4. Do not expose charger to rain or spray.
5. Use of an attachment not recommended or sold by NEWMAR
may result in a risk of fire, electric shock or injury to persons.
6. To reduce the risk of damage to the electric plug and cord (if
plugged into an A.C. outlet), pull by plug rather than cord when
disconnecting the charger.
7. Make sure the cord is located so that it will not be stepped on,
tripped over, or otherwise subjected to damage or stress.
8. An extension cord should not be used. Use of an improper cord
could result in a risk of fire and electric shock.
9. Do not operate the charger with a damaged cord or plug;
replace them immediately.
10. Do not operate the charger if it has received a sharp blow,
been dropped, or otherwise damaged; take it to a qualified
serviceman.
11. Do not disassemble the charger; take it to a qualified
serviceman when service or repair is necessary. Incorrect
reassembly may result in a risk of electric shock and fire.
12. To reduce the risk of electric shock, disconnect the charger from
A.C. source before attempting any maintenance or cleaning.
WARNING—RISK OF EXPLOSIVE GASES
1. WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS
DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING
NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF
UTMOST IMPORTANCE THAT BEFORE INSTALLING AND USING
YOUR CHARGER, YOU READ THIS MANUAL AND FOLLOW THE
INSTRUCTIONS EXACTLY.
2. To reduce the risk of battery explosion, follow these instructions
and those published by the battery manufacturer and by the
manufacturer of any equipment you intend to use in the vicinity of
the battery. Review all cautionary markings on these products.

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
www.newmarpower.com
4
PERSONAL PRECAUTIONS
1. Someone should be within range of your voice or close enough
to come to your aid when you work near a lead-acid battery.
2. Have plenty of fresh water and soap nearby in case battery
acid contacts skin, clothing or eyes.
3. Wear complete eye protection and clothing protection. Avoid
touching your eyes while working near a battery.
4. If battery acid contacts skin or clothing, wash immediately with
soap and water. If battery acid enters the eye, immediately flood
the eye with running cold water for at least 10 minutes and get
medical attention immediately.
5. NEVER smoke or allow a spark or flame in the vicinity of the
battery or engine.
6. Be extra cautious to reduce the risk of dropping a metal tool
onto the battery. It might spark or short-circuit the battery or other
electrical part and cause an explosion.
7. Remove personal metal items such as rings, bracelets, necklaces
and watches when working with a lead-acid battery. A lead-acid
battery can produce a short-circuit current high enough to weld a
ring or the like to metal, causing a severe burn.
8. Use the battery charger for charging gel-cell, AGM or flooded
lead-acid batteries only. It is not intended to supply power to a low
voltage electrical system other than in a starter-motor application.
Do not use the charger for charging dry-cell batteries that are
commonly used with home appliances. These batteries may burst
and cause injury to persons and damage to property.
9. NEVER charge a frozen battery.
PREPARING TO CHARGE
1. Be sure the area around the battery is well ventilated.
2. Clean battery terminals. Be careful to keep corrosion from
coming in contact with eyes.
3. Add distilled water in each cell until battery acid reaches level
specified by battery manufacturer. This helps purge excessive gas
from cells. Do not overfill. For a battery without cell caps, carefully
follow manufacturer’s recharging instructions.
4. Study all battery manufacturers’ specific precautions such
as removing or not removing cell caps while charging and
recommended rates of charge.
GROUNDING AND A.C. POWER CORD CONNECTION
1. The charger should be grounded to reduce the risk of electric
shock.
(For marine applications only) EXTERNAL CONNECTIONS TO THE
CHARGER SHALL COMPLY WITH UL RECOMMENDATIONS AND/
OR UNITED STATES COAST GUARD ELECTRICAL REGULATIONS
(33CFR183, SUB-PART I)
(For marine applications only) THE INSTALLATION AND
PROTECTION OF VESSEL WIRING ASSOCIATED WITH BATTERY
CHARGERS SHALL COMPLY WITH ABYC STANDARDS; E-11) AC
& DC ELECTRICAL SYSTEMS ON BOATS, AND A-31) BATTERY
CHARGERS & INVERTERS.
III) INSTALLATION
A) Materials Provided
1) Installation/Operation manual
1) Clear plastic output terminal cover
The Phase Three charger is provided completely assembled and
ready for installation. The installer must provide four suitable 1/4”
mounting screws/washers, as well as D.C. output wiring and
connectors. Proper sizes and gauges for the wire and connectors
are noted in section III-D following.
B) Location
The charger should be mounted on a wall, bulkhead or other
suitable mounting surface as close to the batteries to be charged
as possible. Do not mount the charger directly over the batteries
as battery fumes may cause excessive corrosion. WARNING:
The charger is not ignition protected so it must not be located
in an area where ignition protected equipment is required. The
area should be well ventilated and free from excessive moisture,
exhaust manifolds and battery fumes.
Vertical mounting is preferred. However, horizontal mounting is
acceptable where absolutely necessary. Do not mount the charger
where water, spray or condensation can occur, as this will shorten
charger life. It should not be located where there is a possibility
of dust or debris being drawn into the unit through the fan. A
minimum of 2” clearance around the charger is recommended for
proper cooling.
If the charger is located in an extreme heat area, such as an
unventilated engine room, and maximum operating temperature
is exceeded, an automatic thermal shutdown protection circuit
will turn the charger completely off. Thermal cycling will shorten
the life of the charger, so if this condition occurs repeatedly, the
charger should be relocated. For optimum performance and
longer life the charger should not be located in an area of extreme
high temperature.
C) Mounting
Important Pre-Installation Note: The wiring access port for A.C.
input is located on the bottom of the charger. If the factory-installed
A.C. cord must be changed for any reason, this should be done
before mounting, as access will be difficult afterwards. Also, the
drip shield will need to be removed prior to setting the gel/lead
acid selector or installing the optional temperature compensation
probe. The drip shield is removable with the charger mounted,
but if there is limited overhead clearance, the installer may wish
to accomplish these tasks also, prior to mounting the charger. For
information on these installation procedures, refer to sections III-F
and IV-E.
The charger may be mounted on either a metal or non-metal
surface*. You will require four screws (wood or machine screws,
depending on mounting surface) with washers, sized for 1/4”
holes, to mount the charger, plus two temporary holding screws.
Note that, in addition to the four permanent mounting holes in the
flanges, there is a hole in each mounting flange which is “keyhole”
shaped. This is provided to ease vertical installation.

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
www.newmarpower.com
5
*Per ABYC A-31: A D.C. chassis grounding conductor shall be
connected from the case of the battery charger to the engine
negative terminal or its bus, and must not be more than one size
under that required for the D.C. current-carrying conductors, and
not less than 16 AWG.
Make a mark on the wall or bulkhead where each of the
keyhole slots will be located. Then drive a screw about halfway
in at each of these marks. Hang the charger onto the bulkhead
using the keyhole slots. Doing this will save you from having to
support the charger’s weight while you are driving in the four
permanent mounting screws. Note: The keyhole slots may be
used for additional support screws but they are not to be used as
permanent mounting points by themselves.
IMPORTANT: Although the charger is constructed of materials
and in a manner which makes it highly resistive to the corrosive
effects of moisture in the environment, the charger is not water-
resistant. Do not mount the charger where there is a possibility of
water entering the unit. Evidence of water entry into the charger
will void the warranty.
D) D.C. Output Wiring
Note: Only qualified service personnel should access the output
terminals of the charger.
Whether working with existing battery charger output wires or
installing new ones, make sure the battery(s) is disconnected
from these wires before connecting them to the charger’s output
terminals.
For secure installation D.C. output wires must be attached with ¼”
crimp ring lug terminals sized appropriately to fit wire gauges as
listed below.
The D.C. wire size table below may be used to determine the
correct gauge wire based on the model you have and the length
of wire run from the charger to the batteries. Once the output
wiring has been attached to the chargers output posts, install the
clear plastic terminal cover provided with the charger
Model Length of Wire from Charger to Batteries (in feet)
10’ 15’ 20’
Minimum Wire Gauge AWG (mm)
PT 80 #2 (35mm) #1 (50mm) #1/0 (70mm)
PT-24-45U #6 (16mm) #6 (16mm) #4 (25mm)
PT-24-95U #2 (35 mm) #2 (35 mm) #2 (35 mm)
*Based on N.E.C. Minimum Wire Size Chart and ABYC 3% Voltage
Drop Chart
ENSURE THAT LEADS ARE PROPERLY FUSED AT THE BATTERY.
(REFER TO ABYC RECOMMENDATIONS.)
A note about the internal D.C. fuse: The internal wiring of the
Phase Three charger is protected against dangerous overheating
in the event of an internal short, or reverse polarity hook-up, by an
internal d.c. fuse. The fuse is not user replaceable. If this fuse blows
the unit must be returned to NEWMAR or a qualified electronic
technician for repair.
Typical D.C. wiring configurations are illustrated in FIGURES
1 and 2.
FIGURE 1: Simple D.C. Wiring (Preferred Method)
Phase
Three
Battery
Charter
T
C
S
AC Input
House
Bank 1
House
Bank 2
Gen
Bank
B
A
T
T
1
B
A
T
T
2
B
A
T
T
3
C
O
M
M
O
N
*
* Per ABYC A-31: A D.C. chassis grounding
conductor shall be connected from the case
of the battery charger to the engine negative
terminal or its bus, and must not be more
than one size under that required for the D.C.
current carrying conductor and not less than
16 AWG
Note: This diagram does not illustrate a
complete system. Refer to ABYC standards
E-11 AC & DC electrical system on boats
Important: Install fuses at batteries per ABYC
recommendations.
Optional Temperature
Compensation Sensor See page
9 for installation information. Use
provided cable clamps to secure
probe cable
Note: PT 80/PT-24-45U
illustrated, same configuration
applies to PT-24-95U.

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
www.newmarpower.com
6
E) Multiple Unit Parallel Wiring
If increased power or system redundancy is required, a second
charger may be wired in parallel. The unit is diode protected so
it will not be damaged by feedback from the second unit and
current limiting will prevent overloading in the case of a failure of
one of the units.
Observe the following guidelines when wiring a parallel unit.
1) Use only another identical charger model PT 80, PT-24-45U,
or PT-24-95U).. Do not use a different charger model, either
from NEWMAR or from another manufacturer.
2) Output wire length and gauge must be identical for each
charger to ensure proper load sharing.
3) Wire gauge for each charger must be the same used as if a
single charger were wired into the system by itself. Wire each
battery charger directly to the battery (Figure 1) or battery
switch (Figure 2) DO NOT daisy chain charger outputs.
F) A.C. Input Wiring
A.C. input is “universal” and operates in a range of 90-264 VAC,
47-63 Hz. No switch setting is required for either 115V A.C. or 230V
A.C. applications. Caution (230V applications only): If A.C. input is
derived from a source consisting of two HOT leads (phase-to-phase
230V A.C. input voltage) an external fuse or circuit breaker must
be used to protect the unfused (formerly NEUTRAL, now HOT) lead.
A.C. input for the charger must be routed through fuse or circuit
breaker on an A.C. distribution panel with proper safety/earth
chassis ground in accordance with all applicable local codes and
ordinances.
Recommended A.C. Input Wire Size:
115 VAC Input = 14 AWG minimum
230 VAC Input = 16 AWG minimum
Recommended Input Circuit Breaker:
115 VAC Input = 15 Amp
230 VAC Input = 10 Amp
FIGURE 2: Wiring With Battery Switch
AC Input
*
Phase Three
Battery
Charger
Home
Bank 1
Master
Battery
Switch
+ Bus
– Bus
Home
Bank 2
Gen Bank
B
A
T
T
1
B
A
T
T
2
B
A
T
T
3
C
O
M
M
O
N
T
C
S
* Per ABYC A-31: A D.C. chassis
grounding conductor shall be
connected from the case of the
battery charger to the engine
negative terminal or its bus, and must
not be more than one size under that
required for the D.C. current carrying
conductor and not less than 16 AWG
Note: This diagram does not illustrate a complete system. Refer to ABYC standards E-11 AC
& DC electrical system on boats
Important: Install fuses at batteries per ABYC recommendations.
Optional
Temperature
Compensation
Sensor See
page 9 for
installation
information.
Use provided
cable clamps
to secure
probe cable
Note: PT 80/PT-24-
45U illustrated, same
configuration applies to
PT-24-95U.

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
www.newmarpower.com
7
(In marine applications) All charger wiring should be installed in
accordance with UL, U.S. Coast Guard and/or A.B.Y.C. regulations
and recommendations, as well as all relevant local codes. See
REFERENCE APPENDIX at the end of this manual for sources.
A note about the A.C. input fuse: The A.C. input of your charger
is protected by an input fuse which is located inside the unit.
Due to the current limiting characteristic of the charger, it is
highly unlikely that this fuse will blow unless there is some other
malfunction within the charger. This fuse is not user-replaceable.
Replacement of the input fuse must be performed by a qualified
service person.
FIGURE 3: AC Input Wiring
Input Wiring
Acess Plate
Hot (All Systems) ‘L1’
Neutral (Euro 230V)or
Hot(USA 230V) “L2/N”
Earth Ground Safety
AC Input Cable Strain
Relief Clamping Range: .2” - .47”
Note: PT 80/PT-24-45U illustrated,
same wiring configuration
applies to PT-24-95U, but access
plate is on left side.
Note: access plate on left
side on PT-24-95U.

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
www.newmarpower.com
8
IV) OPERATION
A) Three Stage Charge Regimen
The Phase Three Battery Charger utilizes the three stage charge
regimen which is widely recommended by battery manufacturers
for allowing the fastest possible recharge time without loss of
batteries’ electrolyte (gel or liquid) which may be caused by
sustained charging at higher voltages.
This three stage regimen is initiated each time A.C. is first applied,
when drained batteries are most likely to be encountered, and
proceeds slowly or quickly through each stage depending on
the battery’s relative state of charge. (This also occurs when the
reinitialize button on the optional remote panel is activated; see
Remote Panel Option section for more information). Note: An
audible “clicking” noise from an internal relay may be heard when
the charger switches from one phase to another. This is normal
operation. The charge regimen proceeds as follows:
1) Bulk Phase: When batteries are significantly discharged the
charger responds initially by delivering a high amount of D.C.
current, at or near the charger’s maximum rated output, in order
to rapidly replenish them. It is during this stage that charging
current is maintained at a high level as battery voltage increases.
Bulk charging continues until battery voltage reaches the “charge”
voltage level (where batteries are at about 75-80% of capacity).
A current limit circuit prevents charger overload during this
maximum output stage.
Note: During this bulk phase the charger is in a “constant current”
mode; therefore, output current will stay constant while output
voltage decreases. Full output voltage is achieved and maintained
only when the charger switches to the absorption stage.
2) Absorption Phase: During this second stage of the charge cycle,
battery voltage is maintained at the “charge” voltage level. Output
current begins to taper off as the battery plates become saturated.
Charge voltage is maintained until the current sensing circuit
detects that output current has tapered to about 5-15 % of charger
rating*. At this point the batteries are at about 95 % of full charge
and the Phase Three charger switches to the third and final stage of
the charge cycle.
* Note: The absorption phase may also be ended by the time-out
circuit. See section IV-B, for a complete explanation of the purpose
and functioning of the time-out circuit.
3) Float Phase: For extended battery life the Phase Three then
automatically switches to a lower float voltage level. This float
charge keeps batteries at peak condition without overcharging.
The charger may be left in this stage for lengthy periods of time
without attention (though periodic checks of electrolyte level
in flooded batteries is recommended). It is not necessary or
recommended to shut the charger off when this stage is reached.
A typical three stage charging cycle is illustrated in FIGURE 4.
* Approximately 10 hours maximum at factory setting.
Note: If a load is applied during the absorption phase, the charger
may revert to the bulk phase depending on the total current draw.
When the charger times-out into the float phase, it will remain in
that phase regardless of current draw. The charger is still able to
deliver full output current when in the float phase. To re-initialize
the three stage process shut the charger off momentarily, then
back on again (or press the reinitialize button on the optional
remote panel)
B) Time-Out Circuit
Batteries have a tendency to lose their electrolyte and may be
damaged if they are maintained for long periods of time in the
elevated voltage of the absorption phase. Therefore, the Phase
Three Charger employs a special time-out circuit. This circuit is
initialized each time A.C. is first applied to the charger (or when the
reinitialize button on the optional remote panel is activated) and
runs for a pre-set interval before forcing the charger to go into the
float (lower voltage) mode. The functioning of the charger during
this interval is as follows:
If the current demand of the batteries/load falls below 5-15 % of
the charger’s output capacity prior to the circuit timing-out, the
charger will automatically switch to the float mode. If demand
rises to about 10-20 % of charger output capacity, it will return to
the elevated output voltage of the absorption phase. This switching
back and forth between modes may occur until the circuit times-
out (8-10 hours after A.C. is first applied), after which the charger
will remain at float voltage, until the circuit is re-initialized, either
by turning the charger off and then on again or by pressing the
re-initialize button on the optional remote panel.
Installation Note: The time-out circuit of the PT charger has
been set at about 8-10 hours, which is appropriate for battery
systems within the capacity range specified on the front panel of
the charger. If the charger is used with a battery system with a
capacity near (or outside) the upper or lower ranges of the specified
range of the charger, adjustment of the internally located time-out
circuit adjustment pot may be recommended. The procedure is as
follows:
FIGURE 4: Typical Charger Output Graph
(into battery without load)
BULK PHASE
ABSORPTION PHASE
FLOAT PHASE
AMPS
AMPS
VOLTS
VOLTS
TIME

P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
www.newmarpower.com
9
(Caution: Ensure A.C. input has been disconnected before
proceeding)
1) Remove the three screws on the front panel and seven screws
on the sides of the unit.
2) Remove the main cover from the charger base, taking care
not to bend the two jacks on the right side of the charger out
of position. Locate the potentiometer labeled “TIMER ADJ” on
the small charger function circuit board on the right side of the
charger.
3) Using a small flat tip screwdriver, turn the potentiometer
clockwise to increase the amount of time the charger remains
in the absorption mode before timing out, or counterclockwise
to decrease the amount of time. The approximate ranges are
illustrated below.
Note: Once the time-out circuit has put the charger into float
mode, the charger will remain in this mode. Since the Phase
Three Charger is well regulated, it is able to deliver its full rated
output current in this mode and battery discharge will not occur
(provided load current does not exceed charger rating and output
wiring is properly sized).
4) Reinstall the charger cover
C) Gel-Cell — Flooded/AGM Switch
According to most battery manufacturers, the ideal charge
regimen for gel-cell and flooded (wet) lead-acid or AGM (Absorbed
Glass Mat) batteries differs somewhat.
The gelled electrolyte in a sealed battery may be lost or damaged
by high voltage and, once lost, cannot be replaced as it can
with a wet lead acid battery. Manufacturers of gel-cells usually
recommend an ideal charge voltage which is slightly lower
for a gel-cell than a lead-acid battery. (The charge regimen
recommended for AGM batteries is typically similar to that of
flooded lead-acid batteries.)
However, when the charger is in the float voltage mode over
lengthier periods of time, gelled electrolyte in a sealed battery
is not susceptible to evaporation, as is the non-immobilized
electrolyte of a wet lead acid battery. This evaporation can be
accelerated by the applied voltage. Consequently, the ideal float
voltage is slightly higher for a gel-cell than a lead-acid or AGM
battery.
The ideal charge/float regimen has been programmed into the
Phase Three Charger for either sealed gel-cell or flooded lead-acid/
AGM batteries. Simply make the proper selection for your battery
type via the slide switch on the right side of the charger. The switch
positions are indicated on the Charger’s left side panel (see Figure
6) l. Use a ball point pen or similar object to slide it into the correct
position.
Note: A wide variety of batteries are now available which do not
conform to conventional descriptions as “gel-cell” or “lead-acid”.
You are advised to consult the manufacturer of your particular
battery as to proper charging regimen, and use the battery
type selection switch setting which most closely conforms to the
recommended voltages.
See the SPECIFICATIONS section for the actual preset charge and
float voltages for the PT-80 and PT 80, PT-24-45U, and PT-24-95U.
D) Remote Monitor Panel Option
A Remote Monitor Panel is available from NEWMAR (model RP)
which will enable you to monitor the charger’s status at-a-glance
from a remote location. Red and green L.E.D.’s indicate whether
the charger is in the bulk, absorption or float phase of the charge
cycle. In addition, the panel features a re-initialize button, which,
when pressed, will cause the charger to restart the three phase
cycle. This resets the time-out circuit (see section B, above) Time-
out Circuit, above). Note: The charger may not stay in the bulk or
absorption mode after pressing the re-initialize button. If batteries
are at or near full charge, the charger will quickly revert to the
float mode.
The panel comes pre-wired with 30’ of cable and 4 mounting
screws. Simply install the panel at the desired location and insert
the plug on the end of the cable into the remote panel jack which
is located on the right side of the charger. (See Figure 10.) The
remote panel jack is identified on the front panel.
Note: Inadvertently putting the remote panel plug into the temp
compensation jack (or vice versa) will not harm the charger. If the
panel does not appear to function correctly, check to see that it is
plugged into the correct jack.
If additional cable length is required, additional cable is commonly
available from most electronics supply retailers such as Radio
Shack/Tandy. Request a 6 conductor modular-to-modular line cord
(part number 279-422, 25 feet long) and 6 pin modular in-line non-
reversing coupler (279-423).
E) Temperature Compensation Option
Because low battery temperature increases resistance to charging
and high battery temperature reduces impedance, requiring
a lower charge voltage, the ideal charging voltage will vary
depending on the temperature of the battery’s environment when
it is being charged.
If a charger has a fixed output voltage which is ideal at, say 72° F,
that same output may cause a battery charged in a consistently
high temperature environment to be overcharged, resulting
in excessive loss of electrolyte. Conversely, if the batteries are
in a consistently cool environment, they may be chronically
undercharged, resulting in sulfation of the battery plates. Either of
these two conditions will shorten battery life.
FIGURE 5: Adjusting the Time-out Circuit
 


P.O. Box 1306, Newport Beach, California 92663 • Phone: [phone] • Fax: [phone] • E-Mail: [e-mail]
www.newmarpower.com
10
Therefore, the Phase Three charger is designed to utilize an
optional remote sensor (available from NEWMAR; model TCS-
12/24) which provides automatic temperature compensation. The
remote sensor will signal the charger to fine tune its output voltage
so that it is properly matched to the temperature of the battery/
battery environment. The adjustment rate is approximately -5 mV
per cell per °C. (Note: The temperature compensation option is
strongly recommended for sealed, valve-regulated, AGM or gel-
cell batteries.)
The remote sensor is provided with 30’ of cable. One end of the
cable is plugged into the temperature compensation jack which is
located on the right side of the charger (see FIGURE 6). The location
of temp sensor jack is identified on the front panel.
If additional cable length is required, additional cable is
commonly available from most electronics supply retailers such as
Radio Shack/Tandy. Request a 6 conductor modular-to-
modular line cord (part number 279-422, 25 feet long)
and 6 pin modular in-line non-reversing coupler (279-
423).
The sensor itself should be mounted on the inside of the
battery box, or more ideally, mounted onto one of the
batteries using a clamp or a small amount of silicon-
type adhesive. The sensor has a hole in the center which
will accommodate a # 6 screw. If you have access to
the exterior of a wall of the battery box, you may drill
a hole in the wall of the box and run the screw through
to mount the sensor onto the interior wall. Use caution
when drilling so that you do not accidentally puncture
the case of any battery inside the box.
Important note: When wiring multiple chargers in parallel (see
section III-E) and using the temperature compensation option,
you must use a separate sensor for each charger, and the sensors
must be mounted close together in the same battery box or on the
same battery for proper operation.
Without the temperature sensor installed the output of the charger
will be at the nominal voltages specified in the chart below at 72°
F (22.2° C). The absorption/float output voltage settings at that
temperature are listed in the chart.
To provide some examples which clarify the effect of the
temperature compensation sensor, the chart lists the absorption/
float output voltages of the charger when batteries are at 72° F (or
when the sensor is not installed), and at cold (50° F) or hot (90° F)
battery temperatures with the sensor installed:
Temperature Compensation Chart
* Factory pre-set voltages without temperature compensation
option installed
FIGURE 6: Temperature Compensation Sensor
and Remote Panel Installation







F) Equalize Timer Option
Some manufacturers of flooded lead-acid batteries recommend
a charging process known as equalization for extended battery
life. This process involves occasionally charging a wet lead-acid
battery at a very high voltage for a short period of time in order
to completely de-sulphate each of the battery plates, essentially
equalizing their voltage. The installer of the Phase Three charger
may choose to wire in this option at the time of installation.
Note: The equalization process is not recommended for sealed
valve regulated or gel-cell batteries.
The equalize circuit (connector located inside the PT charger)
should be wired through a manual or electric timer which
provides a closed contact when engaged and an open circuit
when timed out (SPST — Single Pole Single Throw). Do not use a
manually operated switch for activating the equalize circuit. This
is because unless the charger is reverted to a safe float voltage in
a timely manner, the batteries will almost certainly be damaged
or destroyed. The timer should be a 0-12 hour type, capable of
carrying a minimum of 100 mA at 5V D.C.
CAUTION: Do not install the timer in an area requiring ignition
protected equipment unless it has been certified to meet ignition
protection requirements.
The equalization circuit of the Phase Three charger boosts output
voltage to approximately 8 % above float voltage. Refer to the
battery manufacturer’s instructions when deciding the appropriate
time period setting for this voltage to achieve proper equalization,
while ensuring batteries are not damaged by increased battery
temperature. This installation should only be performed by a
qualified technician.
Battery
Temp.
Output V D.C: 12 Volt Models Output V D.C: 24 Volt Models
Charge Float Charge Float
° F ° C Gel-
Cell
Lead
Acid
Gel-
Cell
Lead
Acid
Gel-
Cell
Lead
Acid
Gel-
Cell
Lead-
Acid
50 10 14.4 14.6 14.0 13.8 28.8 29.2 28.0 27.6
72 22.2 14.0* 14.2* 13.6* 13.4* 28.0* 28.4* 27.2* 26.8*
90 32.2 13.7 13.9 13.3 13.1 27.4 27.8 26.6 26.2