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NewMar 12-1800IC Installation & Operation Manual Download Page 1

Phone: 714-751-0488

Fax: 714-957-1621

E-Mail: [email protected]

www.newmarpower.com

P.O. Box 1306
Newport Beach,
California 92663

1

P

ERFECT

 W

AVE

I

NVERTER

/C

HARGER

Inverter/Chargers

Perfect Wave Series

Models:

12-1800IC
12-1801 ICF
24-2200IC
24-2201 ICF
32-2400IC

Guided Wave Series

Model:

12-2500IC

INSTALLATION/OPERATION MANUAL

CONTENTS

Section

Topic

Page

I)

OVERVIEW................................................................................. 2

II)

IMPORTANT SAFETY CAUTIONS AND WARNINGS....................... 3

III)

INSTALLATION............................................................................ 3

A) Materials Provided........................................................ 4
B) Location....................................................................... 4
C) Mounting..................................................................... 4
D) Case Grounding........................................................... 5
E) Battery Selection and Sizing......................................... 5
F) Battery (DC) Wiring.......................................................6
G) Charging Multiple Battery Banks.................................. 8
H) Temperature Compensation Sensor.............................. 9
I) AC Input Wiring.............................................................9
J) AC Output Options....................................................... 10
K) Remote Panel (optional)................................................ 11

IV)

BATTERY CHARGER OPERATION................................................ 12

A) Battery Capacity Selector.............................................. 12
B) Charger Output Selector............................................... 13
C) Battery Charging Cycle Explained................................. 14

V)

INVERTER OPERATION............................................................... 17

A) Start-Up/Operation...................................................... 17
B) Inverter ON/OFF Switch Functions...............................18
C) Inverter Auto-Shut-down Indicators/Causes................. 18

VI)

SPECIFICATIONS........................................................................ 19

VII)

BATTERY CARE TIPS...................................................................21

VIII)

REFERENCE APPENDIX.............................................................. 23

M-IC2
OCT 2004

Summary of Contents for 12-1800IC

Page 1: ...ATION 3 A Materials Provided 4 B Location 4 C Mounting 4 D Case Grounding 5 E Battery Selection and Sizing 5 F Battery DC Wiring 6 G Charging Multiple Battery Banks 8 H Temperature Compensation Sensor 9 I AC Input Wiring 9 J AC Output Options 10 K Remote Panel optional 11 IV BATTERY CHARGER OPERATION 12 A Battery Capacity Selector 12 B Charger Output Selector 13 C Battery Charging Cycle Explained ...

Page 2: ...batteries whenever shore or generator AC power is available All models feature numerous circuit and safety protections such as thermally controlled cooling fans and ground fault protected duplex outlets utilize automatic AC transfer relays and are housed in rugged rust resistant powder coated aluminum cases suitable for perma nent bulkhead or horizontal mounting An optional remote indicator and co...

Page 3: ...asses during operation There is a risk of acid exposure There is also a risk of high current discharge from shorting the battery that can cause fire and explosion CAUTION UL and ABYC specify that the DC input shall be fused no further than 18 from the battery This is the responsibility of the installer CAUTION Be sure both the inverter and if used the external AC input circuit breaker or fuse are ...

Page 4: ...fe 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 unit is recommended for proper cooling If the inverter charger is located in an extreme heat area such as an unventilated engine room and maximum operating temperature is exceeded an automatic thermal protection circuit will shut the unit complete...

Page 5: ...tion F is 1 AWG then the minimum size of the grounding cable is 2 AWG Use stranded copper wire for case grounding A screw compression lug located on the right hand side of the unit is provided for attaching the ground wire to the case The lug accommodates wires up to 1 0 AWG A flat blade screwdriver is required to tighten the lug E Battery Selection and Sizing The inverter charger should only be w...

Page 6: ...etermine total DC battery amp hours consumed 12 Volt Inverters Divide Watt Hours by 10 24 Volt Inverters Divide Watt Hours by 20 32 Volt Inverters Divide Watt Hours by 27 Note These divisors allow for standard inefficiency during voltage conversion 4 Finally since it is generally recommended that batteries never be discharged below 50 the result must be multiplied by 2 to obtain the proper total b...

Page 7: ...ire from Charger to Batteries in feet 10 15 20 Over 20 Minimum Wire Gauge AWG 12 1800IC 1 0 2 0 Not Recommended 12 1801 ICF 1 0 2 0 Not Recommended 12 2500IC 2 0 2 0 2 0 Not Recommended 24 2200IC 4 4 4 Not Recommended 24 2201 ICF 4 4 4 Not Recommended 32 2400IC 4 4 4 Not Recommended Meets minimum requirements of ABYC 10 voltage drop table for inverter maximum input current 3 voltage drop table for...

Page 8: ...recommendations cited above in the positive leg of the battery wiring then attach the wires to the battery carefully observing correct polarity Note It is normal to encounter a spark when connecting the final battery wiring due to the initial charging of an internal input capacitor Note The temperature compensation sensor will also be attached to the negative terminal of the battery so complete th...

Page 9: ... may result in overcharging or undercharging of the batteries Extreme overcharge may cause severe damage or exploding batteries and fire I AC Input Wiring The inverter charger is designed for hardwire AC input only The AC input serves two func tions 1 It provides power for the internal battery charger whenever external AC is available 2 It allows routing of an external AC source through the invert...

Page 10: ...rcuit Interrupter which automatically disconnects the outlets when any significant amount of AC is detected on the ground circuit which could present a shock hazard Note The AC hard wire output is not GFCI protected 2 AC Output Hard Wiring CAUTION Integrating the inverter output with existing AC branch circuits must only be at tempted by a qualified marine electrician Options may include isolating...

Page 11: ...t it may still be operating due to the automatic functioning of the inverter A set of AC distribution panel warning labels has been provided in the installation kit Choose the preferred black or white background label and affix it in a clearly visible location at the panel CAUTION The AC outlets and AC hard wire outputs on the inverter remain live when derived from an external source even when the...

Page 12: ...r to secure the connection Upon inserting the plug tighten the collar until a click is felt indi cating it has locked together properly Note In order for the remote on off switch to operate the on off switch on the inverter front must be in the ON position IV BATTERY CHARGER OPERATION Battery capacity and battery type selections must be set prior to applying AC to the charger A Battery Capacity Se...

Page 13: ...l equalization output which is dis cussed shortly Verify the type of batteries being used then use a small flat tip screwdriver to place the selector into the correct position according to the following chart this information is also duplicated on the unit beside the selector port Note Mixing of battery types such as gel cell and flooded on the output of the charger is not recommended even if outp...

Page 14: ...ch it will revert to the float mode discussed later If longer equal ization time is desired turn the charger off for about five seconds then turn it back on to start another four hour cycle As long as the switch is left in either of the equalization settings A or B it will return to that high output voltage as part of the charge cycle every time the charger is turned off and back on Be sure to ret...

Page 15: ...begin to output the float voltage specified in the charts on page 13 while delivering enough amperage to supply the DC loads At the same time the Float Mode L E D will illuminate Note While in the Float stage the charger is still able to deliver its full rated current output as load demands At the same time a four hour cycle is initiated If at the end of four hours the batteries remain higher than...

Page 16: ...VDC 24 VOLT MODEL 33 3 VDC 32 VOLT MODEL START FLOAT MODE 13 2 VDC 12 VOLT MODELS 26 4 VDC 24 VOLT MODEL 35 2 VDC 32 VOLT MODEL START 4 HOUR TIMER SATISFACTORY GAS POINT DETECTION TESTS BATTERY ACCEPTS MORE THAN 20 AMPS APPROX NO NO FIGURE 5 Charger Operation and L E D Indication Flow Chart NO YES Note Three stage charge cycle resumes goes to top of chart each time external AC is removed then reap...

Page 17: ...There is a high wattage draw on the inverter output which reduces power available to the charger condition described in previous section 2 The actual battery amp hour capacity is higher than was designated using the Battery Capacity Selector switch 3 A DC load greater than 20 amps is drawn from the batteries during the initial 12 hour cycle 4 The charger is unable to detect the 80 charge level due...

Page 18: ...lied within the unit at the duplex outlets or the AC hard wire output 1 The ON OFF switch either on the front or remote panel controls only whether the internal DC AC inverter is operating Whenever external AC is applied the internal battery charger is operational and AC is being applied to both the duplex outlets and the AC hard wire output Only shutting off the external AC at its source will pre...

Page 19: ... a small enclosure which restricts air flow or due to a blockage of the air intake of the cooling fan Ensure free flow of air around and into the unit Relocate it if necessary Note The thermal switch is self resetting so the inverter charger will automatically return to service when it cools to a safe operating temperature Nevertheless thermal cycling of this sort will shorten the life of the unit...

Page 20: ...ging 37 9 35 2 D Gel Cell Charging 36 8 35 2 Operating Temperature all models 22 C to 40 C 0 F to 104 F Mechanical Features all models Thermally controlled cooling fan GFCI protected duplex outlets Powder coated aluminum case with integral mounting flanges Conformal coated printed circuit boards Protection Features all models Automatic low battery shutdown Output circuit breakers Auto high tempera...

Page 21: ... the battery and can cause the battery to discharge by itself Therefore at least twice a year it is a good idea to disconnect the battery cables and scrub the battery with a baking soda solution Rinse with fresh water and dry with a clean cloth You may wish to purchase a set of terminal post corrosion prevention rings These are alkali saturated felt rings that slip over the battery post to reduce ...

Page 22: ...t or hold a charge one of the following conditions may exist 1 A BAD BATTERY You may have a battery with an open or shorted cell a battery without any life left Check by charging the battery until all cells have a specific gravity of 1 225 or greater at 80 F If you are unable to obtain 1 225 in each cell replace the battery 2 A BAD BATTERY CHARGER If the battery open circuit voltage is low and or ...

Page 23: ...ments Government Printing Office Washington DC 20402 Request 33 CFR 183 Subpart I For information about American Boat and Yacht Council recommendations for boat wiring write to American Boat and Yacht Council 3069 Soloman s Island Road Edgewater MD 21037 Request Standards and Recommended Practices for Small Craft AC systems Section E8 DC systems Section E9 A 20 Battery Charging Devices A 25 Invert...

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