Phase3 PT 80 Bedienungsanleitung

P.O. Box 1306, Newport Beach, California 92663 • Phone: 714-751-0488 • Fax: 714-957-1621 • E-Mail: techservice@newmarpower.com

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: 714-751-0488 • Fax: 714-957-1621 • E-Mail: techservice@newmarpower.com

www.newmarpower.com

Quick Reference Drawing

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Note: PT 80/PT-24-45U

illustrated in drawing.

P.O. Box 1306, Newport Beach, California 92663 • Phone: 714-751-0488 • Fax: 714-957-1621 • E-Mail: techservice@newmarpower.com

www.newmarpower.com

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: 714-751-0488 • Fax: 714-957-1621 • E-Mail: techservice@newmarpower.com

www.newmarpower.com

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: 714-751-0488 • Fax: 714-957-1621 • E-Mail: techservice@newmarpower.com

www.newmarpower.com

*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

AC Input

House

Bank 1

House

Bank 2

Gen

Bank

* 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: 714-751-0488 • Fax: 714-957-1621 • E-Mail: techservice@newmarpower.com

www.newmarpower.com

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

* 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: 714-751-0488 • Fax: 714-957-1621 • E-Mail: techservice@newmarpower.com

www.newmarpower.com

(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: 714-751-0488 • Fax: 714-957-1621 • E-Mail: techservice@newmarpower.com

www.newmarpower.com

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

VOLTS

TIME

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(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: 714-751-0488 • Fax: 714-957-1621 • E-Mail: techservice@newmarpower.com

www.newmarpower.com

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

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











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

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