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NewMar Power System Manual  

M-CMDRII 063022

Page 1 of 43 

Model: COMMANDER II AND COMMANDER II+ 

Version 1.0 

Product Compliance 

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

 

Commander II Series 

Manual

 

POWERING THE NETWORK

 

www.poweringthenetwork.com | 800.854.3906

Costa Mesa, CA

The Powerful Difference

 

M-CMDRII 063022

Summary of Contents for Commander II

Page 1: ...yright 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 Commander II Series Manual POWERING THE NETWORK www poweringthenetwork com 800 854 3906 Costa Mesa CA The Powerful Difference M CMDRII 063022 ...

Page 2: ... Suitable Racks 12 6 3 Unpacking 13 6 4 Installing the Commander II and II System 13 6 5 Rectifier Module Insertion and Removal 16 6 6 Ventilation 17 7 Energy Manager Connectivity and the Web UI 17 7 1 Access Levels 17 7 2 Ethernet Port Connection 17 7 3 USB Connection 18 7 4 Energy manager and IO PCB Alarm Configuration 19 7 4 1 EM4x Alarm Mappings 19 7 4 1 1 EM4x Red LED Urgent Alarm Mapping 20 ...

Page 3: ...Appendix II AC Input Transient Protection 33 II A Upstream Over Current Protection 34 II B Cable Rating 34 II C Discrimination 34 II D Surge Suppression Device Protection 34 II E AC cable installation and surge protection 34 Appendix III Warranty Exclusions and Restrictions 36 III A Battery Warranty 38 III B Initiating a Warranty Claim 37 III C Disclaimer 37 III D Remark 37 Appendix IV System Sche...

Page 4: ...a Rectifier 18 Figure 16 Removing a Rectifier 19 Figure 17 Energy Manager Ethernet Port 20 Figure 18 EMX4x 01 Front Panel micro USB 20 Figure 19 EM4x Relay Outputs 23 Figure 20 Rectifier Input Fuse Tripping Curves 33 List of Tables Table 1 Commander II II dimensions and weights 9 Table 2 IO Board 1 Relay Alarm Assignments 23 ...

Page 5: ...ust be understood and undertaken instruction of mandatory reading of product manual risk of electrostatic damage to components Proper precautions must be taken access for children prohibited restricted access area tip over hazard 2 SAFETY All installation and maintenance must be carried out by suitably qualified personnel For your protection the product manual should be read and thoroughly underst...

Page 6: ... delivering carrier s expense If repair is necessary we will invoice you for the repair so that you may submit the bill to the delivering carrier with your claim forms It is your responsibility to file a claim with the delivering carrier Failure to properly file a claim for shipping damages may void warranty service for any physical damages later reported for repair 3 3 Handling Handle the equipme...

Page 7: ...DC contact NewMar for other voltage options EM4x energy manager system controller fully integrated in the system Commander II Commander II EM4x Controller Hinged Front Panel DC Distribution 4x 125A Battery MCBs standard 18 x 48V Load MCBs standard Load Battery Common Terminals 500A 50mV Battery Shunt 500A LVD AC Input Terminals at rear Up to 12 x 3kW Rectifiers 36kW 720A max 4 x 125A Battery Break...

Page 8: ...p to 480A with a maximum of 8x RM3048HE and a maximum of 8 DC DC converters with 12V or 24V output at 40A and 43A respectively 5 1 3 Additional Features AC input MCB with surge protection device type 2 I O board AC monitoring including voltage frequency and current Fan control Battery control monitoring Battery fuse fail Site monitoring 5 1 4 Physical Dimensions and Weights Table 1 Commander II II...

Page 9: ...itoring 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 It has an in built web based configurator allowing setup of system parameters monito...

Page 10: ...or cards Temperature compensation of float voltage when fitted with optional temperature sensors Manual equalize charging to prolong the life of the batteries Periodic equalize charging to prolong the life of the batteries Fast charging after battery discharge Battery capacity remaining indication Battery testing facility Battery current limit Six user defined General Purpose Inputs GPIPs which ca...

Page 11: ... 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 DO NOT short terminals when working on them WARNING Use extreme care when fitting solar panel connections D...

Page 12: ...e STEP 2 Connect the AC supply Terminate the cables to the input circuit breakers and the terminal blocks for Earth and phase to phase or L1 to L2 see AC wiring options for Commander II series NOTE the AC terminals accept up to 1 0 AWG 55mm2 cables NOTE the AC earth terminal is connected directly to the system chassis NOTE AC and DC EARTHING This system has a built in AC to DC earth connection No ...

Page 13: ...d from circuit prior to the primary battery LVD operation to extend the time of operation of the priority loads Load distributions in systems without the secondary LLVD are all removed from circuit together at the battery LVD disconnect point Please refer to the specification of the system to determine which breakers are priority and non priority loads if optioned NOTE make sure all incoming cable...

Page 14: ...rectifier output float voltage accordingly NOTE Refer to the specifications supplied by the battery vendor for battery operational temperature requirements STEP 8 Affix the Ambient Temperature Sensor Uncoil and affix the ambient temperature sensor in a position that will give an indication of average cabinet room temperature NOTE refer to the EM4x energy manager RM3048HE Rectifier STEP 9 Terminate...

Page 15: ...tem Manual M CMDRII 063022 Page 15 of 43 Model COMMANDER II AND COMMANDER II Version 1 0 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 ...

Page 16: ...ectifier addressing IMPORTANT if a rectifier is removed from the system and then plugged into another rectifier slot you must wait for the red LED to extinguish this clears the address setting in the EPROM When inserting the module ensure that it is pressed hard into the system The locking button should click See Figure 14 To remove the module press the locking button while pulling on the handle t...

Page 17: ...air does not re circulate to the front of the rack as this will be drawn into the rectifiers again in effect raising the apparent ambient temperature Check the operating environment is low dust and fiber Pay particular attention to the quality of rectifier air intake Insects sand and other extraneous matter ingress seriously impacts the performance of the rectifiers 7 ENERGY MANAGER CONNECTIVITY A...

Page 18: ...gure 17 3U EM4x 01 Front Panel micro USB 1 Connect the communicating device to the micro USB port on the front of the energy manager See Figure 17 A driver installation prompt appears 2 Double click the appropriate USB driver 32bit or 64 bit 3 Follow the installation wizard instructions to install the driver 4 Open an internet browser such as Edge Chrome Firefox or similar 5 Enter the USB default ...

Page 19: ...nergy manager IO PCB Alarm Output Configuration For full EM4x functionality and operation information refer to the EM4x Installation and Operation Manual 7 4 1 EM4x LED Alarm Mappings Refer to the Alarm Configuration Alarm Configuration page of the Web UI to see the priority setting of each alarm Refer to the Relay Output page Configure Relay section of the Web UI to understand the how the Alarm C...

Page 20: ...uration for installation requirements If an alarm is programmed for the relay to be normally energized such as a low voltage alarm where loss of power will put the alarm into its active state then be sure to connect the remote wiring appropriately Table 2 lists alarm assignment for the EM4x controller as matches the relay outputs shown in Figure 18 Figure 18 EM4x Relay Outputs Table 2 IO Board 1 R...

Page 21: ...alarm The battery circuit breakers however use voltage sense to detect tripping or whether they are turned off This is because when a battery breaker is tripped there may be very little voltage difference across the breaker making electronic fail detection problematic Hence if no battery is connected the breaker must be ON to clear the Battery Breaker Fail alarm 8 LVD OPERATION The primary Low Vol...

Page 22: ...s The positioning of the system and surroundings will determine the regularity of this requirement In extremely dusty positions it is recommended that the units are removed and cleaned with compressed air to prevent airflow blockages Check the air flow front and back to the rectifiers is unimpeded by cables or otherwise Check nothing has entered the rectifiers such as insects or geckos 9 4 Batteri...

Page 23: ...S The following steps are system settings that must be checked at the time of commissioning for each system installed You can print this section and fill it out for each site commissioned NOTE these steps are battery chemistry dependent Follow the appropriate section 11 1 Systems with Lead Acid Batteries Failure to correctly follow the items below may cause incorrect system functionality and in so...

Page 24: ...ications the 10 hour rate is usually the name plate rating of the battery However once again check the battery manufacturer s data sheets as some manufacturers state the 20 hour rate which is usually a little more optimistic The second rate is required specifically for the time remaining algorithm A 4 hour rate is usually a good one to use This information is available from the battery manufacture...

Page 25: ...urrent Limit Consult battery manufacturer s data for maximum battery recharge current settings The Battery Current Limit is set as a percentage of the 10 hour rate entered above It is recommended this value is set at the highest rate allowable to ensure the battery is recharged as fast as possible In some systems especially larger systems this may require limiting further because of the number of ...

Page 26: ...scharge of 1hr this may be as low as 1 75Vpc 42 0V for a 48V battery or for an 8 hour discharge it may be 1 85Vpc 44 4V for a 48V battery Note that if only one LVD is fitted LVD2 and LVD3 thresholds are set outside of possible tripping voltages This avoids any confusion over which LVD signal is being used by the EM4x energy manager EM4x Web UI page IO Configuration IO Boards Toggle LVD latching On...

Page 27: ...est is complete be sure to rest the Load Current High Setpoint to its previous value or check with the customer for the correct value they require Load Current High Setpoint __________ A Temperature alarm tests are performed by heating up using a heat gun or other source and cooling down using an aerosol can of freeze or a tub of ice the temperature sensors Battery Temperature High urgent ________...

Page 28: ...Check Vf is set to 54 0V Web UI Control Float Voltage Turn on Battery Breaker s Check Battery current is positive if charging For systems fitted with Battery Monitoring BCM cards Go to EM4x Web UI Battery Battery Status Check cell voltages are approximately the same at about 2 25V or 13 5V for 12V monoblocs If any are out by a large amount then check the BCM sense wiring is correct Set load to req...

Page 29: ..._____ V OK Check Alarm Relay Contacts To generate these alarms refer to the procedures described earlier in the Commissioning Checklist Spare relays will not be able to be tested unless an alarm is mapped to them As these are tested in the factory it is not essential to test them at time of commissioning On main EM4x PCB Relay 1 Monitor Fail pull out the RJ45 lead connecting the monitor to the sys...

Page 30: ...s connected via Modbus RTU to a battery BMS check the correct specific battery is selected from the Product drop down list and mapped to the correct address EM4x Web UI page IO Configuration Modbus Master Device Map Done 11 3 3 Check Set Float Voltage Consult the battery manufacturer s data for the proper setting Note that the float voltage directly impacts the state of health of batteries after m...

Page 31: ...d that the primary stages of the rectifier are operating This yellow LED indicates a non urgent alarm notification state within the rectifier This could be caused by the following rectifier in output power current limit rectifier over temperature fan failed rectifier soft starting This red LED indicates an urgent alarm state within the rectifier This could be caused by the following rectifier fail...

Page 32: ...e or over temperature Appendix II AC INPUT TRANSIENT PROTECTION Information to assist the installer for AC input protection is detailed in this section Illustration A Surge Protection Installation Illustration A shows the surge protection installation principles utilizing the 3 stage protection zone concept The Type 1 SPD1 surge arrester fitted in the installation s main incoming electrical switch...

Page 33: ... There are three considerations to take into account when selecting an appropriate fuse circuit breaker Firstly the upstream protection should protect the downstream cable from overload situations Secondly discrimination should be maintained with the downstream device fuses and Thirdly protection of the surge suppression devices should be taken into account II B Cable Rating The maximum current dr...

Page 34: ...he AC incoming distribution board and the DC Power System is less than 10m then loop the cable until at least 10m of cable is used This ensures correct de coupling of the devices II E AC cable installation and surge protection The following precautions MUST be adhered to when installing AC cabling 1 Avoid running input and output cables from AC Surge Protection Devices together Appendix III NEWMAR...

Page 35: ...mproper installation or maintenance inappropriate on site conditions such as high humidity dust power surges out of range temperatures animal or insect damage water or other liquid damage where serial numbers or identification marks are removed or defaced in any way Force Majeure event has cosmetic shortcomings which do not affect normal operation inappropriate electrical stress for suspected frau...

Page 36: ...Newmar 1580 Sunflower Ave Suite 100 Costa Mesa CA 92626 Technical Service 800 241 3897 E mail techservice newmarpower com Appendix IV SYSTEM SCHEMATIC Commander II ...

Page 37: ...Newmar 1580 Sunflower Ave Suite 100 Costa Mesa CA 92626 Technical Service 800 241 3897 E mail techservice newmarpower com Commander II ...

Page 38: ...rd 1 Temperature 2 Press the Save button to implement changes Navigate to the Alarm Configuration Alarm Configuration General Alarms Expand the General Alarms by selecting the Enable the Ambient Temperature Faulty Ambient Temperature High and Ambient Temperature Low alarms Press the Save button to implement changes This addition can be accomplished with power to the system enabled Exercise extreme...

Page 39: ...mp Two Pole L1 L2 70 Amp Two Pole L3 Neutral Ground Not Used Commander II AC Terminal Block 2 AWG Max Wire Size Commander II PE Terminal Block 2 AWG Max Wire Size L1 L1 L1 L2 L2 L2 L1 TO B L2 L2 TO A L1 L1 TO C L2 L2 TO C L1 L1 L1 L2 L2 PE C 1 A L2 L1 TO A L1 L2 TO C L1 L3 TO B L1 L1 TO C L2 L2 TO B L2 L3 TO A L2 208 VAC 208 VAC 208VAC 208VAC 208VAC 208VAC 208 VAC 208VAC 208VAC Neutral Ground Not ...

Page 40: ...Size Option 3 Three 230VAC Single Split Phase Feeds Option 4 L TO C L1 N TO C L2 L TO B L1 N TO B L2 PE L TO A L1 N TO A L2 Three 230VAC Feeds Euro 70 Amp Circuit Breaker 70 Amp Circuit Breaker 70 Amp Circuit Breaker PE PE PE A L2 C L1 Commander II AC Terminal Block 2 AWG Max Wire Size Commander II PE Terminal Block 2 AWG Max Wire Size Ground N L Ground N L Ground N L ...

Page 41: ... Ground Not Used L1 L2 L3 L1 Verify correct wiring to maintain proper AC phasing L2 L3 Neutral Ground Not Commander II AC Terminal Block 2 AWG Max Wire Size Commander II PE Terminal Block 2 AWG Max Wire Size L1 L1 L1 L2 L2 L2 L1 TO A L1 L2 TO C L1 L1 TO C L2 L2 TO B L2 Neutral Ground Not Used L1 40 Amp Two Pole L2 60 Amp Two Pole L1 L2 60 Amp Two Pole L3 Neutral Ground Not Used Commander II AC Ter...

Page 42: ... Technical Service 800 241 3897 E mail techservice newmarpower com Option 3 Three 230VAC Single Split Phase Feeds Option 4 60 Amp Block 2 AWG Max Wire Size Block 2 AWG Max Wire Size Block 2 AWG Max Wire Size Block 2 AWG Max Wire Size Three 230VAC Feeds Euro ...

Page 43: ...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 B L1 B L2 Input C L1 C L2 Input DC DC CONVERTOR BAYS DC DC CONVERTOR BAYS DC DC CONVERTOR BAYS 3KW RECTIFIER CURRENT DRAW 208VAC 15 3A 230VAC 13 9A ...

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