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E) AC Input Wiring
An IEC certified 3 foot AC cord is provided that plugs into
the charger and a proper outlet. If the plug is not suited to
the available outlet, 1) obtain an IEC cord with appropriate
plug or 2) obtain the correct plug for the outlet and install
it on the provided IEC cord. When installing the plug, pay
careful attention to the pin wiring as follows:
Black.....................................................AC Hot (fused)
white.........................................................AC Neutral
Green ........................................AC Ground (safety/earth)
The charger will operate on 90-264 VAC input-No selectors
with setting required
A power cord cable clamp has been provided to prevent
accidental disconnect of the AC cord. After the plug has
been inserted into the charger, snap the pre-formed clamp
around the AC input cable as close to the insertion point
as practicable and use a screw to fasten the clamp tightly
to the surface on which the charger is mounted..
Hard-wiring AC Input
If desired, the AC input to your charger may be hard-wired
directly to the AC distribution panel or junction box. Install
the charger end of the provided input cord as described
above, then cut off the plug and splice onto three conductor
marine-grade cable with crimp butt connectors, observing
color codes and fuse/circuit breaker ratings as above. Use
minimum 16 AWG cable.
AC input for the charger must be plugged into an
appropriate, over-current protected three prong outlet
OR routed through a separate dedicated fuse or circuit
breaker on an AC distribution panel with proper safety/
earth chassis ground in accordance with all local codes
and ordinances.
CAUTION (230 VAC applications only): If AC input is
derived from a source consisting of two HOT leads
(phase-to-phase 230 VAC input voltage), an external fuse
or circuit breaker must be used to protect the unfused
(formerly NEUTRAL, now HOT) lead.
Input Fuse Replacement - The AC input of your charger
is protected by an internal input fuse. This indicates the
charger has an internal short, return the charger for service.
IV) OPERATION
A) Three Stage Charge Regimen
The Battery Charger features the three stage charge
regimen which is widely recommended by battery
manufacturers for allowing the fastest possible recharge
P.O. Box 1306
Newport Beach
California 92663
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 AC is first
applied, when drained batteries are most likely to be
encountered.
1) Bulk Charge – When batteries are significantly discharged
the charger responds initially by delivering a high amount
of DC 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 reached 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
2) Absorption Charge – 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 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 B following for a complete
explanation of the purpose and functioning of the time-
out circuit.
3) Float Charge – 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 months without attention (though periodic checks
of electrolyte level in flooded batteries is recommended.)
FIGURE 3: Typical Charger Output Graph (into battery
without load)
* Approximately 10 hours maximum
www.newmarEVpower.com
*
Phone: 714-751-0488
Fax: 714-957-1621
E-Mail: techservice@newmarpower.com
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