Bolt-In System$^{tm}$ with EnerMatic Controller
Installation and Wiring Instructions

Ample Power Models BIS-12, BIS-24 and BIS-32 July 5, 2005
Copyright ©1989 through 2005. All Rights Reserved - Ample Technology

Introduction

This manual covers the Bolt-In System, Version 2, (BIS V2), which uses the EnerMatic Controller, (EMC), as the heart of the instrumentation, control and regulation functions.

Another manual covers the User Interface via a terminal or terminal emulator program running on a PC. Yet another manual covers the Systems Navigator, Remote Display, (SYSNAV-RD) unit which provides a User Interface to the EnerMatic Controller in lieu of or in conjunction with the terminal interface.

An alternator is controlled by Smart Alternator Regulation, including temperature compensation and current limiting. The alternator regulation circuits are integrated within the EMC.

Smart Charge Management is also provided by a module which plugs onto the main EnerMatic Controller printed circuit assembly.

Solar and wind/hydro control are also provided by the EMC ...complete energy management in a simple Bolt-In system.

Major Components

The EnerMatic Controller is the central component to the Bolt-In System.

There are also shunts, sensors, and relays to control solar, wind, and hydro sources. The battery shunt, alternator shunt, and battery temperature sensor are included with the BIS.

Also included are positive and negative distribution busses and a charger shunt. A solenoid is included to parallel house and starter batteries.

All of the components are pre-wired to minimize installation and wiring efforts at the time of user installation.

The EnerMatic Controller interfaces to:

Interface to these external components is made with four pluggable terminal blocks, discrete spade lugs, and two DB-9 RS-232 connectors.

Alternator Current Limit

Alternator current limit is set on the EnerMatic controller. See that manual for specific instructions.

Alternator/Regulator Troubleshooting

The Technician Check Out Menu allows the field circuit to be turned on and off by menu control, thus testing the field driver. The engine does not need to be running for this test. The voltage applied to the field can be measured at the terminal on the EnerMatic and at the alternator.

Applying the EnerMatic Controller

The EnerMatic Controller automates monitoring, controlling, and regulation of the energy system. It does require set up, and besides wiring the system correctly, there are other considerations for a successful installation. This section discusses those issues.

Internal Error Detection

The EnerMatic Controller detects many abnormal conditions such as high battery voltage, high load current. Set reasonable limits for those and enable their detection to activate the error output.

The Error LED

The Error LED illuminates to signal an error condition. The cause for the error can be determined by looking at the various status reports available from the terminal interface.

Battery Banks

The EnerMatic Controller monitors three battery banks, B1, B2, and Auxiliary. B1 is the house or energy battery. B2 is usually the starter battery, and Auxiliary is any other battery.

Battery voltage, current and temperature are monitored for B1, while only voltage is measured for the other two.

All voltage channels are configured in hardware to be 12V, 24V, or 32V. They can be configured differently by special order, but otherwise are configured identically.

Shunt Ratings

The standard shunt is rated for 400 Amps. It can tolerate 100% overloads without failure, however extended overloads may distort the accuracy of readings.

Current is measured with a resolution of 1 part in 4096, so resolution is slightly less than 0.1 Amps with a 400 Amp shunt.

The EnerMatic Controller will operate with any shunt which produces 50 milliVolts full scale. The Amp rating of the shunt must be programmed for the controller to calculate current based on the drop across the shunt. Resolution in Amps will change. For instance with a 600 Amps shunt, resolution will be about 0.15 Amps.

Note that both shunts are designed to measure in the negative side, which means the alternator needs to have an isolated ground.

Installation Checkout Menus

The User Interface provides a set of checkout functions which allow controlling and sensing all circuits. Use these functions and verify that all work before trying to start the engine.

Terminal Interface

The EnerMatic Controller will mate to a standard PC serial port using a straight-thru, 9-pin cable with one end male and the other end female. Cables can be patched together to form any length, although a single cable will be best for a permanent connection.

Baud rate is 19,200, 8 data bits, 1 stop bit, no parity and no flow control.

If power is applied to the EnerMatic Controller before the terminal interface is operating, the start-up message from the Controller will be missed.

Other Documents

Be sure to read and follow directions in the Getting Started Guide, and the User Interface Manual.

The AC charger is managed by a plug-in module on the EnerMatic and is covered by the EnerMatic Controller Power Supply/Charger Interface Manual.

A manual describes the Remote Access Protocol, RAP, which is used to communicate with the EnerMatic Controller via the network port. If the EnerMatic Controller is connected to another computer which wants to read a given set of parameters, then RAP is the general method, rather than the terminal interface.

Terminal Block Descriptions

The EnerMatic Controller has terminal blocks labelled TB1 thru TB4 There are also connections for high current signals. These are described later. Pins on terminal blocks which are not used are omitted from the listing below. No wires should be connected to unused terminals.

Mounting the EnerMatic Controller Assembly
The EnerMatic Controller is protected against ambient humidity, but must be mounted in a dry location free of moisture, dust, and other environmental insults. The EnerMatic Controller will operate in temperatures to 70$^\circ$C (158$^\circ$F).

Wiring Diagrams
The wiring diagrams show the only way to wire the EnerMatic Controller. Do not wire it in any other way, such as combining ground wires or battery positive wires. For safety purposes, always use fuses where shown.

Signal Names and Functions
Battery voltage set-points are specified for each voltage system, 12 or 24 volts, as 12 / 24 volts, respectively. Systems for 32 Volts are also available.

TB1, EnerMatic Controller Assembly

TB2, EnerMatic Controller Assembly

TB3, EnerMatic Controller Assembly

TB4, EnerMatic Controller Assembly

High Current Connections

High current connections are made using push tabs. There are three tabs on the right side of the EnerMatic Controller which connect to the alternator.

The name of each tab is given on the wiring diagram.

Push Tabs, Right Side

Installation and Warranty Support

For questions regarding installation, operation, or warranty service contact PowerTap, Inc. who is the authorized warranty service agent for all Ample Power products. Their phone number is 206-789-4743, and their fax is 206-789-9003.

Email support is available from support@amplepower.com. See also the following websites for more troubleshooting suggestions.

http://www.amplepower.com
http://www.amplepower.net
http://www.pwrtap.com

Wiring Diagrams

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

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