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RoHS
Copyright © NewMar 2021 All rights reserved.
Manual Version 1.1
Release Date: 30 JUL 2022
Disclaimer: NewMar reserves the right to make changes to the information within this document without notice
NewMar Power System Manual
Model: COMMANDER II AND COMMANDER II+
Commander II Series
The Powerful Difference
Manual
POWERING THE NETWORK
www.poweringthenetwork.com | 800.854.3906
Costa Mesa, CA
M-CMDRII 063022
M-CMDRII 063022
Page 1 of 43
Version 1.0
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Table of Contents
Related Manuals for NewMar Commander II Series
Summary of Contents for NewMar Commander II Series
- Page 1 RoHS Copyright © NewMar 2021 All rights reserved. Manual Version 1.1 Release Date: 30 JUL 2022 Disclaimer: NewMar reserves the right to make changes to the information within this document without notice M-CMDRII 063022 NewMar Power System Manual M-CMDRII 063022...
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Page 2: Table Of Contents
Circuit Breaker Fail Monitoring LVD Operation Maintenance System EM4x Controller Rectifiers and Converters Batteries Ventilation Maintenance Troubleshooting and Servicing 10.1 Servicing Essential System Setup Parameters NewMar Power System Manual M-CMDRII 063022 Page 2 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0... - Page 3 Figure 10: Cable Management Figure 11: Securing the Top Cover Figure 12: Battery Connections Figure 13: Controller Layout Figure 14: RM3048HE Front Panel NewMar Power System Manual M-CMDRII 063022 Page 3 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0...
- Page 4 Figure 20: Rectifier Input Fuse Tripping Curves List of Tables Table 1: Commander II & II+ dimensions and weights Table 2: IO Board 1 Relay Alarm Assignments NewMar Power System Manual M-CMDRII 063022 Page 4 of 43 Model: COMMANDER II AND COMMANDER II+...
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Page 5: Admonishments
A grounding strap should be worn. The equipment is intended only for use in a restricted access area. The equipment is not suitable for use in locations where children are likely to be present. NewMar Power System Manual M-CMDRII 063022 Page 5 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0... -
Page 6: Receiving Instructions
: Save all the shipping materials for the inspector to see. After the inspection has been made, if damage has been found, contact NewMar. We will determine if the equipment should be returned to our plant for repair or if some other method would be more expeditious. If it is determined that the equipment should be returned to us, ask the delivering carrier to send the packages back at the delivering carrier’s expense. -
Page 7: Power System
The base unit is supplied with the following standard options: AC Input: Single Phase, 240VAC input • DC Output: Nominal voltage: 48V DC (contact NewMar for other voltage options) • EM4x energy manager system controller (fully integrated in the system) •... -
Page 8: Additional Features
22.7kg Weight with max. 38.3kg 46.7kg rectifiers Energy Manager 5.2.1 EM4x-01 Interface Touchscreen Status LEDs Micro-USB Figure 2: EM4x-01 Front Panel Interface NewMar Power System Manual M-CMDRII 063022 Page 8 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0... -
Page 9: Alarms And Status Indicators
5.2.4 EM4x Features The EM4x microcontroller-based DC system energy manager provides the control and monitoring functions for all NewMar Energy’s power systems. With an appropriate communications connection third party lithium battery can also be managed. The EM4x monitors all power system conditions including DC voltage, rectifier current, battery current, battery temperature, distribution failure and battery pack status. -
Page 10: Rectifier Modules
The RM3048HE is a telecommunications grade rectifier with the following features: High efficiency • Hot pluggable • Forced air cooled • Thermally protected • NewMar Power System Manual M-CMDRII 063022 Page 10 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0... -
Page 11: Installation
All upstream AC, Load and Battery breakers must be switched OFF prior to installation. The system must be completely de-powered. All circuit breakers in a NewMar power system must be in their OFF position prior to installation. WARNING Use extreme care when fitting batteries & their connections. Remove all conductive materials from yourself such as watches, jewelry and rings prior to commencing the installation. -
Page 12: Unpacking
Terminate the cables to the input circuit breakers and the terminal blocks for Earth and phase to phase (or L1 Figure 5 Top Cover to L2) (see AC wiring options for Commander II series). : the AC terminals accept up to 1/0 AWG/55mm cables. -
Page 13: Figure 8 Connecting The Load
Battery breaker terminals are sized to accept cables up to 1/0 AWG/55mm : make sure all incoming cables have adequate strain relief. Figure 9 Connecting the battery NewMar Power System Manual M-CMDRII 063022 Page 13 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0... -
Page 14: Figure 10 Cable Management
: The inputs are normally activated by connecting system positive (usually system common) to the input. : Route and secure Alarm Extension Loom away from AC and DC cables : For full EM4x functionality and operation information, refer to the EM4x Manual. NewMar Power System Manual M-CMDRII 063022 Page 14 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0... - Page 15 STEP 10: Secure the Drip Cover Secure the drip cover to the top of the unit with the thumbscrews Figure 11 Securing the drip cover NewMar Power System Manual M-CMDRII 063022 Page 15 of 43 Model: COMMANDER II AND COMMANDER II+...
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Page 16: Rectifier Module Insertion And Removal
Check that any blank rectifier slots have the rectifier blank panel Press the locking button inserted to prevent air back-flow. Figure 15: Removing a Rectifier NewMar Power System Manual M-CMDRII 063022 Page 16 of 43 Model: COMMANDER II AND COMMANDER II+... -
Page 17: Ventilation
The energy manager contains static sensitive components that require careful handling and proper precautions to be taken – an electrostatic discharge protection device must be worn. Figure 16: Energy Manager Ethernet Port NewMar Power System Manual M-CMDRII 063022 Page 17 of 43 Model: COMMANDER II AND COMMANDER II+... -
Page 18: Usb Connection
Note: USB connection to the energy manager is possible without AC, battery or other external power supply. The EM4x operates drawing power through the USB port. However, USB supply does not power the IO Board. NewMar Power System Manual M-CMDRII 063022... -
Page 19: Em4X Alarm Mappings
EM4x Red LED Urgent Alarm Mapping ( For reference only. Actual system alarm mapping may vary) 7.4.1.2 EM4x Yellow LED non-Urgent Alarm Mapping NewMar Power System Manual M-CMDRII 063022 Page 19 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0... -
Page 20: Em4X Main Pcb Alarm Mappings
Alarms Mapped to Relay/Output Relay (In NewMar Config.) (All multiple states “OR-ed”) Output Relay 1 CPU Fail Relay 2 Non-Critical Alarms Orange LED NewMar Power System Manual M-CMDRII 063022 Page 20 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0... -
Page 21: Em4X Main Pcb Digital Input Alarm Mappings
(i.e., until the DC bus voltage is re- established). LVD adjustments/settings are all made in the supervisory module. AINTENANCE As NewMar power systems are state of the art electronic systems, little routine maintenance is required. NewMar Power System Manual M-CMDRII 063022... -
Page 22: System
• If symptoms persist, contact a service agent. • If the yellow LED is alight: Check the monitor Non-Urgent Alarm list. • NewMar Power System Manual M-CMDRII 063022 Page 22 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0... -
Page 23: Essential System Setup Parameters
EM4x Web UI page Battery>Battery Settings Done 11.1.2 Check/Set Float Voltage Consult battery manufacturer’s data for proper setting. The Float voltage is for 25°C reference temperature in NewMar systems. EM4x Web UI page: Control Example: Site Setting: NewMar Power System Manual... -
Page 24: Set Battery Temperature Compensation
The Battery Discharge Threshold is a buffer to prevent false triggering of discharge notification and is usually related to the size of the battery shunt. A larger shunt requires a larger discharge threshold. NewMar Power System Manual M-CMDRII 063022 Page 24 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0... -
Page 25: Set Batter Current Limit
EM4x Web UI page: Battery>Battery Settings Enable Battery Current Limit by clicking on the tick icon beside the field. Example: Site Settings: Done NewMar Power System Manual M-CMDRII 063022 Page 25 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0... -
Page 26: Low Voltage Disconnect Settings
Tests Without Batteries Connected Value Results Check Float Voltage Meter:______ __________ V / Check Load Current Meter:______ __________ A / Alarms NewMar Power System Manual M-CMDRII 063022 Page 26 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0... - Page 27 AC Fail (urgent) Urgent / Rectifier Fail (non-urgent) Non-urgent / Urgent Rectifier Fail (urgent) No. Modules:____ / NewMar Power System Manual M-CMDRII 063022 Page 27 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0...
- Page 28 Note: as the BCL is based on fine voltage control of the system bus, the BCL make take one or two BCL functions / minutes to “settle”, i.e., you _______% NewMar Power System Manual M-CMDRII 063022 Page 28 of 43 Model: COMMANDER II AND COMMANDER II+ Version 1.0...
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Page 29: Systems With Lithium Batteries
RTU or not. These ‘smart’ batteries are termed modular, where the energy manager is receiving information on alarms and status from the battery internal electronics. Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626 Technical Service: 800-241-3897 • E-mail: techservice@newmarpower.com... -
Page 30: Check The Battery Type
USE AND FRONT PANEL BEHAVIOUR I.A Rectifier Input Fuse Characteristics The NewMar RM3048HE rectifier uses two Conquer UDA-A 025 fuses in its input, one on each phase/line of the AC input. : The curves are for average value, for reference only. - Page 31 • the AC input voltage is outside the operating range. • rectifier shut down due to output over-voltage or over-temperature. • Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626 Technical Service: 800-241-3897 • E-mail: techservice@newmarpower.com...
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Page 32: Appendix Ii Ac Input Transient Protection
The 10/350µs current wave as shown below is the standardized current waveform which passes through equipment when subjected to an overvoltage due to a direct lightning strike. Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626 Technical Service: 800-241-3897 • E-mail: techservice@newmarpower.com... -
Page 33: Ii.a Upstream Over-Current Protection
(such as outdoor enclosures). Note: NewMar Rectifiers are compliant with EN61000-4-5, Level 4 without any external/upstream surge suppression. To maintain a coordinated approach to surge suppression, Type 2 SPD should be installed upstream if not fitted in the system. -
Page 34: Ii.c Discrimination
ARRANTY OLICY NewMar warrants that its products shall be free from defects of material or workmanship under use consistent with correct installation and commission, normal operation, product specifications, NewMar’s written instructions, and regional standards compliance, for a period of one (1) year from the start date. The start date shall be defined as (a) the date the product is Newmar •... -
Page 35: Appendix Iii Warranty Exclusions And Restrictions
NewMar’s factory; or (b) in the case of resale by an authorized NewMar reseller, whichever is the lesser of i) the date on the sales invoice or ii) ninety (90) days after original shipment by NewMar factory. The warranty provides for repairing or replacing, at NewMar’s sole discretion, those products deemed defective by NewMar after inspection of its products returned by the customer to the factory or other NewMar authorized location within the warranty period. -
Page 36: Appendix Iv System Schematic
Appendix IV SYSTEM CHEMATIC Commander II Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626 Technical Service: 800-241-3897 • E-mail: techservice@newmarpower.com... - Page 37 Commander II+ Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626 Technical Service: 800-241-3897 • E-mail: techservice@newmarpower.com...
- Page 38 Upon completion of the programming, the ambient temperature sensor will show a fault. This is normal as the IO board does not receive power when programmed from the USB without power enabled. Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626 Technical Service: 800-241-3897 • E-mail: techservice@newmarpower.com...
- Page 39 Circuit Breaker A-L2 Commander II AC Terminal Commander II PE Terminal Block. 2 AWG Max Wire Size Block. 2 AWG Max Wire Size Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626 Technical Service: 800-241-3897 • E-mail: techservice@newmarpower.com...
- Page 40 Ground C-L1 A-L2 Commander II AC Terminal Commander II PE Terminal Block. 2 AWG Max Wire Size Block. 2 AWG Max Wire Size Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626 Technical Service: 800-241-3897 • E-mail: techservice@newmarpower.com...
- Page 41 L2 TO C-L1 Neutral Ground Commander II AC Terminal Commander II PE Terminal Block. 2 AWG Max Wire Size Block. 2 AWG Max Wire Size Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626 Technical Service: 800-241-3897 • E-mail: techservice@newmarpower.com...
- Page 42 Block. 2 AWG Max Wire Size Option 4: Three 230VAC Feeds (Euro) 60 Amp Block. 2 AWG Max Wire Size Block. 2 AWG Max Wire Size Newmar • 1580 Sunflower Ave, Suite 100, Costa Mesa, CA 92626 Technical Service: 800-241-3897 • E-mail: techservice@newmarpower.com...
- Page 43 AC Input Terminals COMMANDER II SERIES SHELF (FRONT) EACH PAIR OF AC INPUT TERMINALS (L1/L2) FEEDS FOUR RECTIFIER BAYS (COMMANDER II) OR THREE RECTIFIER BAYS (COMMANDER II+). BAYS HIGHLIGHTED IN GREEN ARE ACTIVE. COMMANDER II COMMANDER II+ A-L1/A-L2 Input DC-DC...