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The DC wire size table below may be used to determine
the correct gauge wire, based the length of the wire run
from the charger to the batteries.
DC Wire Size Table
Distance from Batteries, Feet
Model
10
EV-40
#8 (10mm)
*Based on 10% voltage drop table and NEC minimum
wire size charge
Note: If batteries are closer to charger than battery switch,
wire directly to battery posts.
It is recommended that DC wiring from the charger to the
batteries be as direct as possible. Line voltage loss and
electronic noise interference of sensitive electronics are
possible if the charging leads are routed through a central
electrical distribution panel.
ENSURE THAT LEADS ARE PROPERLY FUSED AT THE
BATTERY.
Ensure that your connections are tight and that correct
polarity is carefully observed at all times. The battery posts
should be free of any rust or corrosion
IMPORTANT NOTE: EVEN MOMENTARY REVERSE
POLARITY CONNECTION MAY SEVERLY DAMAGE YOUR
CHARGER. THE POSITIVE (+) TERMINAL MUST BE WIRED TO
THE POSITIVE POST OF THE BATTERY AND THE NEGATIVE
OR COMMON (-) TEMINAL TO THE NEGATIVE POST OF
THE BATTERY OR COMMON BUS.
CAUTION: Do not attempt to increase battery bank
capacity by splitting the output of one of the banks with
a diode-type battery isolator. Undercharging may occur
on the output bank, as a result. If you wish to add another
isolated battery bank, use of NEWMAR's Battery Integrator
is recommended. Contact the factory for details.
An important Note about the DC Output Fuse(s): internal
DC wiring is protected by the internal DC output fuse(s). The
current limiting circuit of the charger should prevent these
fuses from blowing under normal operating conditions. If
the DC fuse(s) blow, this may indicate a reverse polarity
hook-up or an internal short.
Always disconnect AC to the charger before checking
fuses. To check or replace the DC fuse, the cover must be
removed. To do this requires removal of two screws from the
front of the unit and five screws on each side. The DC fuse
is mounted on the main circuit board. Be sure to replace
with the same type and value as indicated on the fuse.
P.O. Box 1306
Newport Beach
California 92663
15
20
Wire Gauge AWG (mm)
#8 (10mm)
#6 (16mm)
.
www.newmarEVpower.com
If the battery was connected to the charger backwards, the
fuse should blow to protect DC wiring, however; damage
to internal components may also have occurred. If the
replacement fuse blows, return the charger to an electronics
service professional or to the factory for a thorough
inspection. Note: The internal fuses do not provide protection
if there is a short in the wiring between the charger and the
battery. The battery is itself a power source and charging
leads should be fused at the battery.
Auxiliary Output
As shown in Figure 4, there are two terminals on the output
connection block labeled auxiliary +/-. This output is
intended for auxiliary loads such as air pumps, electronics,
and hand lights, and is rated at 15 amps. Installer has the
option, via a front panel selector switch, of powering the
auxiliary output only when the AC is applied to the charger
(switch position A), thus never discharging the battery
directly, or alternatively, allowing the auxiliary circuit to be
powered all the time from the vehicle battery, regardless
of whether the charger is operating or not (switch position
B). Note that in position "B", if the charger is not operating
for an extended period of time or the engine alternator
not running, the auxiliary loads will eventually drain the
vehicle battery.
The auxiliary output circuit is protected by an auto-resetting
circuit breaker, so if the auxiliary loads exceeds 15 amps,
the breaker will cycle on and off. A front panel LED is
wired to this breaker and will extinguish when power is
not available at the aux circuit terminals.
Figure 4: DC Output Wiring
BATT AUX
+
-
+
-
12 Volt
Battery
Note: Output Fuse Size Recommended
125-150% of Cable Ampacity.
E-Mail: techservice@newmarpower.com
-
+
A - B
+
-
Auxiliary Loads:
15 Amps Max
• Air Pump
• Hand Lights
• Electronics
Phone: 714-751-0488
Fax: 714-957-1621
6
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