NewMar ULM-100 User manual

P.O. Box 1306

Newport Beach

California 92663

Phone: 714-751-0488

Fax: 714-957-1621

E-Mail: [email protected]

www.newmartelecom.com

Unity Low Voltage

Disconnect & Monitor

Installation/Operation Manual

Model: ULM-100

Table of Contents Page Table of Contents Page

1.0 Overview 2 5.14 LVD Level Mapping 4

2.0 Materials Provided 2 5.2 Meter 4

3.0 Mounting 2 5.21 Voltage Monitoring 4

3.1 Rack Ears 2 5.23 Backlighting Adjustment 4

4.0 Wiring 2 5.24 Temperature Monitoring 4

4.1 Rectiﬁer Input 2 5.25 Meter Power Source Selector 4

4.2 Battery Input 2 5.26 Restore to Factory Settings 5

4.3 Load Output 2 5.3 Battery Circuit Breaker 5

4.4 Alarms 3 5.4 Alarm LED 5

5.0 Operation & Adjustments 3 6.0 Connecting Rectiﬁer Types 5

5.1 Low Voltage Disconnect 3 6.1 Unity Rectiﬁer Shelf (URS) 5

5.1 Manual/Auto Selector Switch 4 6.2 Power Modules (PM Series) 5

5.12 LVD Adjustment 4 7.0 Troubleshooting 6

5.13 LVD Alarms: Pre-Disconnect & Disconnect 4 8.0 Speciﬁcations 6

9.0 Outline & Mounting Drawing 7

M-ULM100

030315

P.O. Box 1306

Newport Beach

California 92663

Phone: 714-751-0488

Fax: 714-957-1621

E-Mail: [email protected]

www.newmartelecom.com

1.0 Overview

This 1RU assembly contains numerous DC control and monitoring features that integrate power and distribution

components into a highly functional system. Built in features include: low voltage disconnect, digital monitor of voltage

and amperage, battery disconnect breaker, and alarm contacts. The digital display monitors bus voltage, battery

voltage, system output current, and low voltage connect/disconnect set points. Alarm contacts actuate on low voltage

and battery disconnect conditions. Rear panel bus bars provide ample terminal landings for easy integration with rack

mount rectiﬁers, distribution panels and batteries.

Figure 1: Overview - Front Panel

2.0 Materials Provided

Qty. Description

2 Mounting ears for 19” rack mounting (Note: Contact Newmar Technical Support for 23” rack mount ears)

6 6-32 x 3/8” Phillips head screws, black-mount the two mntg. ears

1 Molex pigtail alarm connector/wire assembly (six wires)

10 ¼-20 Hex Head bolt for rectiﬁer, battery input & load connection

10 ” split lock washer - one per 1/4-20 Hex Head bolt above

1 Installation/Operation Manual

3.0 Mounting

3.1 Rack Ears: One pair of rack ears for 19” rack mounting are provided. Optional 23” rack mounting ears are available

- please contact Newmar for p/n 699-3918-0, qty.2. Two mounting options are available: Flush mount and 6” off-set or

‘center mount’.

4.0 Wiring

Figure 2: Wiring - Rear Panel

See Table 1 for Recommended Wire Size

4.1 Rectiﬁer Input: Three sets of landings for ¼” ring lug terminals are provided for rectiﬁer Hot and RTN input connections.

Maximum total rectiﬁer current is 100 Amps. See section 6.0 for more information on connecting Newmar rectiﬁers.

4.2 Battery input: One pair of landings for ” ring lug terminals are provided for connecting the battery. The ULM-100

incorporates a 100 Amp battery breaker on the front panel however for long battery cable runs we recommend a fuse or

breaker wired on the battery hot side, located as close to the battery as practical.

4.3 Load output: One pair of landings for ” ring lug terminals are provided for connecting the load or feeding a

distribution panel such as Newmar model DST-FB, DST-10, DST-20A or FDP fuse panels. Maximum load current is 100 Amps.

Temperature

Sensor

P.O. Box 1306

Newport Beach

California 92663

Phone: 714-751-0488

Fax: 714-957-1621

E-Mail: [email protected]

www.newmartelecom.com

Table 1: Wire Size Chart

Amperage Minimum Wire Size in AWG

1-10A #16

11-20A #14

21-30A #12

31-35A #10

36-50A #8

51-70A #6

71-90A #4

91-100A #2

4.4 Alarms: Pre-disconnect & Disconnect- Two sets of Form C alarm contacts are provided for the following: Pre-LVD

Disconnect & LVD Disconnect. Wiring is via the Molex six conductor alarm wire pigtail included with the ULM-100. See

section 5.12 & 5.13 for information on setting Pre-disconnect and LVD activation thresholds.

5.0 Operation & Adjustments

Figure 3: LCD Menu

5.1 Low Voltage Disconnect: The ULM-100 incorporates a 100 Amp solid state LVD circuit which automatically removes

the battery when battery voltage drops to a pre-set DISCONNECT threshold (or when manually activated- see section

5.11) and automatically re-connects the battery when battery voltage rises above the selected CONNECT threshold (see

Speciﬁcation 8.0 for default LVD thresholds and adjustment ranges)

P.O. Box 1306

Newport Beach

California 92663

Phone: 714-751-0488

Fax: 714-957-1621

E-Mail: [email protected]

www.newmartelecom.com

5.11 Manual/Auto selector switch: The LVD selector switch sets the way the LVD circuit functions.

• Manual connect - Battery always online

• Automatic - LVD function enabled (factory default)

• Manual disconnect - Battery always ofﬂine

5.12 LVD Adjustment: The ULM-100 offers easy adjustment of both dis-connect and re-connect LVD settings without the

need for an external, adjustable power supply. These thresholds can be selected from the SETTINGS page using the menu

knob, the default factory setting for the particular item is also displayed. A press on the menu knob will save the settings

and is retained even after powering down the unit. LVD threshold adjustment can be made while the system is operating.

5.13 LVD Alarms: Pre-disconnect & disconnect - Two external alarms can be triggered by the ULM-100: the Pre-disconnect

(‘PRELVD’) and the LVD dis-connect (‘LVDDISCON’). The LVD Pre-disconnect alarm is a warning to an impending battery

disconnect. It is triggered by an adjustable voltage thresholds set above the LVD dis-connect threshold and below the

re-connect threshold. The LVD dis-connect alarm is automatically set using the LVD dis-connect threshold (see 5.12). Both

alarms will trigger the LED Alarm light.

5.14 Voltage Level Mapping - 12 VDC example shown

12.5v NORMAL VOLTAGE

12.3v LVD RE-CONNECT (ADJUSTABLE)

11.6v PRE-LVD ALARM (ADJUSTABLE)

11.0v LVD DIS-CONNECT (ADJUSTABLE)

Normal Voltage - Typical system voltage with rectiﬁers supplying load(s), batteries not deeply discharged.

LVD Re-Connect - Level at which the battery will be re-connected after a dis-connect event when AC power is restored.

Pre-LVD Alarm - Level at which the pre-LVD alarm contact triggers as an early warning for a low battery disconnect. (See

Speciﬁcation Section 8.0 for factory default.)

LVD Dis-Connect - Minimum allowable battery voltage level has been reached and will disconnect battery to prevent

damage. Will also trigger LVD alarm. (See Speciﬁcation Section 8.0 for factory default.)

5.2 Meter

Figure 4: LCD Home Screen

5.21 The home screen shows DC voltage, DC current and Ambient temperature in degrees Celsius. The display always

returns to the home screen after 30 seconds of inactivity. A push of the menu button will display the alarm screen and

rotating the knob will send it to adjacent display pages.

5.22 Plant Current Monitoring: The total current being produced by the rectiﬁer(s) connected is displayed on the main

screen. This includes current drawn by the load and battery charging current.

5.23 Back Lighting: The ULM-100 allows the user to adjust LCD backlight level to match environment lighting or suit user

preferences. Changes can be made in the settings menu and is adjustable from 20% to 100% levels.

5.24 Temperature Monitoring: Ambient temperature is displayed on the home screen in Celsius and on the temperature

screen in both Fahrenheit and Celsius. The sensor is located on the front panel next to the alarm LED.

5.25 Meter Power Source Selector: The LCD meter can be powered from the rectiﬁer side or the battery side by using the

selector switch. Powering the meter from the rectiﬁer side(default) causes the ULM-100 to completely shutdown during a

Low battery voltage disconnect thus reducing battery drain. Powering from the battery side will allow the LCD meter to

continue operating even with a an LVD disconnect event.

P.O. Box 1306

Newport Beach

California 92663

Phone: 714-751-0488

Fax: 714-957-1621

E-Mail: [email protected]

www.newmartelecom.com

5.26 Restore to Factory Settings: The ULM-100 comes with default factory settings that will work for most applications.

This feature will clear all user setting changes back to factory settings. This is particularly useful in the event the ULM-

100 contactor begins cycling. Example: Connect and Disconnect thresholds set too close toghether. The ‘Restore Setting’

feature can be activated in the settings menu.

5.3 Battery Circuit Breaker: The Hot side of the battery input goes to a front panel mounted 100 Amp circuit breaker

labeled ‘BATTERY’. This circuit breaker incorporates auxiliary contacts which will alert the user via the LCD display (‘Battery

ofﬂine’) and red ‘Alarm’ LED, should the breaker trip or be placed in to the OFF position inadvertently.

5.4 Alarm LED: This red LED will illuminate when any of the following conditions occur:

• Battery circuit breaker in OFF position

• LVD Pre-disconnect threshold crossed (see section 5.13 for more info)

• LVD activation- manually or automatically

6.0 Connecting Rectiﬁer Types

The ULM-100 will accept any ﬁltered rectiﬁer input (s) providing total rectiﬁer amperage does not exceed 100 Amps. See

Figure 5 and 6 for wiring examples of Newmar Unity Rectiﬁer Shelf (URS) and Power Modules (PM Series).

6.1 Unity Rectiﬁer Shelf (URS): The URS has two sets of output terminals. Both are marked ‘OUTPUT/BATTERY’. One set uses

a barrier style terminal block with # 6 screw terminals located near the optional UFP-5 fuse panel location and the other

is a european style terminal block on the opposite end of URS rear panel which will accommodate up to 8 AWG wire size.

The ULM-100 Rectiﬁer Input can be connected to either one of these two sets of output terminals.

UFP-5 Note: If using the optional Unity UFP-5 GMT Fuse Distribution Panel, the UFP-5 Hot & RTN/GND input leads will have

to be extended with a pair of 14 AWG wires and crimp butt connectors. Connect extended UFP-5 input wires to the ULM-

100 LOAD terminals.

Figure 5: ULM-100 and Unity Rectiﬁer Shelf (URS) with Optional UFP-5 Wiring Diargram

6.2 Power Module (PM Series): One or more Newmar PM Series Power Modules can be connected to the ULM-100 Rectiﬁer

Input (100 Amps max. total). Use the ‘Vout’ or diode isolated terminal when connecting 2 or more PM’s in parallel. Figure

6, ULM-100 and Power Module wiring diagram - next page.

P.O. Box 1306

Newport Beach

California 92663

Phone: 714-751-0488

Fax: 714-957-1621

E-Mail: [email protected]

www.newmartelecom.com

7.0 Troubleshooting

• Meter Display Errors: In the event the LCD display gets out of sync with the micro-controller and displays incorrect

information, a simple ﬁx is to power cycle the LCD. To power cycle the meter without disconnecting the load: ﬁrst ensure

the rectiﬁers are on, slide the breaker to OFF position then slide the meter power to ‘Battery’ then back to ‘Rectiﬁer’. This will

brieﬂy disconnect power to the meter and allow a safe power cycling and clear the display error. Turn on battery breaker.

• LVD Stability Issues After Settings Change: If the LVD contactor cycles frequently after making changes to the LVD

default settings, the ULM-100 can be restored to factory settings to aid in troubleshooting (see 5.26 and the menu diagram

for details).

8.0 Speciﬁcations

Electrical

Nominal System Voltage: 12, 24 or 48 VDC

Voltage Range: 8 to 65 vdc

Grounding: Positive or Negative (polarity insensitive)

Maximum Continuous Current: 100 Amps DC

Battery Breaker: 100 Amps with handle guard

Low Voltage Battery Disconnect: 100 Amp, solid state (FET)

Factory Default:

LVD Set Points 12 Volt 24 Volt 48 Volt

Disconnect 10.4V 21.0V 42.0V

Connect 12.0V 24.5 49.0V

Factory Default LVD Pre-Disconnect Alarm Threshold (Adjustable):

System Voltage 12V 24V 48V

LVD Pre- Disconnect 11.2V 22.8V 45.5V

Figure 6: ULM-100 and Power Module

Mechanical

Chassis: Aluminum with vinyl lamination, black powder

coat front panel

Terminals: Plated copper. Landings for up to three

rectiﬁer inputs, with separate battery & load

terminals

Rack Size: 19”, 1U

Cooling: Convection

Dimensions: 1.75” H x 19” W x 11” D

Weight: 6.25 Lbs.

Environmental

Operating Temperature range: 0 to +60°C

* Fuse Hot near

battery on long

cable runs

P.O. Box 1306

Newport Beach

California 92663

Phone: 714-751-0488

Fax: 714-957-1621

E-Mail: [email protected]

www.newmartelecom.com

9.0 Outline & Mounting Dimensions

Table of contents

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