Fan Replacement
If the fan fails to operate when the charger is on and a load is applied, it may be in
need of replacement. Replacement fans are available from NEWMAR. (For models
PT-70CE and PT-24-35CE specify part number 999-1205-0; for all other models
specify 999-1208-0; Refer to Replacement Fan with PCB connector.)
To remove the fan for replacement:
1) Disconnect the charger from the a.c. power source.
2) Remove the drip shield by grasping it on either side and pulling firmly upward.
3) Snap off the filter retainer and remove the filter.
4) Using a phillips screwdriver remove the four fan retainer screws holding the fan
assembly in place and lift it out, taking care not to pull excessively on the fan power
leads which are attached to the internal PCB.
5) Grasp the connector at the end of the leads firmly between two fingers and snap
it out of the connector receptacle on the PCB.
6) Remove the fan from the fan plate.
Installing the new fan is simply the reverse of the above procedure.
NOTE: When installing the new fan, position it so that the direction-of-flow arrow
molded into the top of the fan housing points into the charger.
V) APPLICATION NOTES
A) Start Up
1) Before powering up your charger, check for tight electrical connections to each
battery in your system. Switch off any d.c. loads on the batteries. Apply a.c. power.
Observe the d.c. ammeter on the front panel. This meter displays the total d.c.
output of the charger, through all banks. It will give some indication of the overall
state of charge of your batteries. If the meter is reading mid-scale or higher, it is an
indication that the batteries are in a relatively low state of charge. The charger,
sensing this, is supplying high current to the batteries. If the meter needle is at or
near the bottom of the scale the batteries are at or nearing full charge.
2) Apply a load to the charger by switching on some lights, a pump or some other
d.c. appliance. Observe the charger meter. It should read approximately the same
as the expected current draw of the appliance. As current is demanded from the
battery system, the charger will automatically increase its output in response to the
increased load demand. When load current exceeds 10-20 % of the charger’s rated
capacity, the charger will go into the absorption mode and remain there until current
drops below 5-15 % of capacity or until the time-out circuit cycle is complete.
Note: The Phase Three Charger is self-limiting and will rarely blow an input fuse. If
the input fuse should blow upon first application of power, disconnect a.c. power to
the charger and consult the TROUBLESHOOTING section of this manual.
If the input fuse does need replacing, be sure to replace it with the same type and
value for continued protection. The fuse value is specified on the lower left hand
corner of the charger front panel.
B) Constant Versus Occasional Use
In general, it is recommended that the charger be left connected continuously to the
a.c. distribution system so that it will be in operation whenever a.c. is available. This
will maintain batteries at peak voltage and will automatically compensate for the
natural self-discharge of the battery system. When a load is applied to the battery
system the charger’s output will automatically increase to supply the current which
would otherwise draw battery voltage down. Repeatedly allowing batteries to
become completely discharged before recharging will greatly shorten their
life. Leaving the charger on continuously will prevent this.
While the output regulation of the charger will minimize battery gassing and water
loss, monthly checks of the electrolyte level (for wet lead acid batteries) are still
strongly recommended. Some water loss is an inevitable aspect of the charging
process, and maintaining the correct electrolyte level in your batteries is the most
important thing you can do to assure their maximum performance and long life.
C) Proper Load Sizing
The Phase Three Charger is rated for continuous duty (e.g., the PT-40CE can deliver
up to 40 amps continuously, 24 hours a day, seven days a week). While the charger
cannot be damaged by overloads that exceed this continuous rating, excessive
load demands may draw battery voltage down faster than the charger can resupply
it. If battery voltage continues to drop and the output current is at maximum while
the charger is in service, check to see that your average d.c. loads are not exceeding
the charger’s rated output. If they are, you may wish to consider adding another
charger in parallel to provide sufficient power for your requirements. (See section
III) E) Multiple Unit Parallel Wiring.)
D) Operation With Engine
It is perfectly acceptable to allow the charger to remain on when the engine is
started and while it is running. The current limit feature of the Phase Three Charger
will protect against any damage due to the high current demands of engine cranking.
Output diodes will prevent any back-feed of current into the charger from the
alternator while the engine runs.
As the alternator starts to charge the battery, the charger output will decrease.
When the battery voltage exceeds the rated output voltage of the charger it will shut
off and stay off as long as the batteries are in this high state of charge. If the battery
voltage should drop below the charger’s rated output voltage it will automatically
return to service.
E) Operation as a d.c. Power Supply (stand-alone d.c. power source) or Radar
Rectifier
Most battery chargers are not suitable for powering electronic devices directly, without
a battery attached to the output, as the high ripple and pulsing d.c output ( i.e.,
rectified a.c. output) can interfere with the operation of the device. The Phase Three
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