Ample Power Bolt-In System
Installation and Operating Instructions

Ample Power Models BIS-12 and BIS-24 ...Preliminary April 7, 2004

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Introduction

The Bolt-In Electrical System, BIS, has been designed to eliminate a myriad of small interconnecting wires that are necessary when components of a complete electrical system are mounted and wired as sub-assemblies.

The BIS has circuits to perform the following electrical system functions:

External Wiring Overview

The BIS contains shunts and distribution bars for positive and negative connections to external devices. A single distribution post is provided for connection to the starter battery. Wires to the distribution bars and post are typically #00, but may be smaller or larger depending on the wire lengths. A wire capacity table can be found in the Ample Power Primer.

Also contained in the BIS is a printed circuit board, PCB, with control relays and other circuits to integrate the electrical functions. There is a 12-pin terminal block on the PCB which provides termination for small external wires.

There is also a 6-pin terminal block mounted on the base plate. It has signals representing the Amps produced by the main engine, or the Ample Power Genie. The optional Start/Stop Controller for the Ample Power Genie can optionally use the Amps signal to shunt off the engine if alternator Amps goes to zero.

Mounting the Bolt-In System

The BIS is protected against ambient humidity, but must be mounted in a dry location free of moisture, dust, and other environmental insults. The BIS will operate in temperatures to 70$^\circ $C (158$^\circ $F). It may be mounted in engine rooms which are adequately ventilated, however, minimizing wire length to batteries and inverters is important. Less important is the wire length to the alternator(s).

Major Positive Wires

On the left of sheet 1, shown above, are the major wires from external positive points. On the far left is a High Side Current Sensor, HSCS, used to monitor alternator current from the Genie diesel battery charger. HSCS units are able to very accurately measure current in the positive or high side of the circuit. Electronics making this possible are potted into the base of the shunt.

Another HSCS is provided for the main engine alternator, located at the right end of a positive distribution bar. The positive distribution has three bolts to make connections to external devices. Multiple lugs can be stacked up on the bolts to support a great many devices.

While it isn't necessary to wire the positive wires in the order shown, it is good practice to label all wires clearly to make troubleshooting easier should that be necessary.

Major Negative Wires

Major negative wires are shown in the lower center of Sheet 1 above. A shunt is provided to measure battery current for Amp-hours consumed and remaining. A second shunt on the right side of the negative distribution bar is used to measure battery charger current which can be limited by setting the limit value in the Energy Monitor/Controller menu. Current limiting is useful to prevent dockside breakers from being overloaded when the batteries are deeply discharged and the charger would consume too much power if not limited.

There are three bolts available to connect negative wires from external devices. It is permissible to stack multiple lugs onto the bolts if necessary.

TB1, Printed Circuit Board

A printed circuit board is mounted on the right wall of the BIS. It has relays for solar and wind control, as well as dual alternator control. Other electronic circuits are provided for integration purposes. The PCB is conformal coated to resist moisture penetration.

NOTE: Pin 1 on TB1 is at the bottom of the PCB. Recommended wire gauge is shown within parenthesis at the end of the description on the drawing.

Externally Mounted Devices

Sheet 2 above shows the wiring for externally mounted alternators and other components.

Included with the BIS are two Terminators which should be mounted on the alternator(s). The terminators reduce electro-magnetic interference, and also suppress transients which may damage electrical equipment.

NOTE: For safety the main battery must be fused. The fuse is equally effective in either the positive or the negative lead on the battery, assuming that it is located close to the battery. While most other fuses will be connected to positive leads, it makes sense to fuse the negative side of the battery for the following reasons:

Only fuses rated for DC circuits should be used. With a properly fused battery, all other major wires will be protected from short circuits. Small individual wires will still need fuses or breakers in-line.

Smart Alternator Regulator, V3

The Smart Alternator Regulator, V3 is built into the BIS. For a full description of the SARV3, refer to the data sheet and manual.

Current limiting is enabled on the SARV3 when the ignition input for the Genie is activated. This is required to prevent the Genie engine from being overloaded.

The ABS input to the SARV3 is activated by the Energy Monitor/Controller.

Temperature information from the battery temperature sensor is provided to the SARV3.

Energy Monitor/Controller

An Energy Monitor/Controller, EMON, is provided with the BIS. It is typically mounted at the Nav station or nearby. Connection between the BIS and the EMON, is made with a standard 25 pin computer cable. Connectors are male/female so that extensions are possible using additional cables.

The EMON controls the AC battery charger with it's Vref and Iref signals. These signals are programmable using the keypad on the EMON. Setting the value of these signals is done under the PROGRAM/CHARGER menu. Using that menu you will set the float, gassing and absorption setpoints according to battery type. As mentioned earlier, current limiting can be set to reduce battery charger current, avoiding dockside breakers from opening.

For more information see the EMON manual.

Energy Monitor/Controller Wiring

There are two connectors and one terminal block on the back plate of the Energy Monitor/Controller furnished with the BIS. The DB25 connector is used to mate with the BIS.

The DB9 connector on the back plate is a serial communications port which can be used to log data collected by the EMON.

The 8-pin terminal block provides some signals generated by the SARV3 and the EMON.

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Troubleshooting

First, look at the Signal Names and Functions section above and make sure that all required wires are in place and properly connected.

To help diagnose voltage set-points, remove the T+ (RED) connection to disable temperature compensation and prevent a faulty temperature sensor from affecting the system.
NOTE: With temperature sensing, a higher battery temperature will result in a lower battery voltage. Likewise, a lower battery temperature will result in a higher battery voltage.

Record the on and off times of the error and status LEDs. The error LED does report common faults with the wiring.

Finally, if the problem still exists, obtain a copy of the SAR V3 Troubleshooting Guide which is available from the following sources:
BIS Service Center. Take the measurements as directed and send the results to the service center.

Ample Power products are manufactured by Ample Technology, 2442 NW Market St., #43, Seattle, WA 98107 - USA

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