EnerMatic Controller
Power Supply Charger Interface

Release 1.0 March 8, 2005
Copyright ©1989 through 2005. All Rights Reserved - Ample Technology

Introduction

The EnerMatic Controller can be ordered with an interface module for the 55A Power Supply/Charger modules. With this interface module installed, the EnerMatic Controller performs the functions of the Smart Charge Manager, providing multi-step regulation with battery temperature compensation.

Setpoints and other charging parameters are programmable via the terminal interface described in other manuals.

The system may be 12 or 24 Volts.

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Figure 1 - Charge Interface Location

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Figure 2 - 12 Volt Wiring

Charger Interface Assembly

The Charger Interface Assembly is a small module which plugs into the main EnerMatic PCB. The location of this module is shown in Figure 1, above. Note that TB7 is toward the right side of that module. Pin 1 is at the top.

Signal Names and Functions

12V Wiring

Wiring for 12V operation is shown in Figure 2 above. Small signal wires can all be #16 AWG. Larger wires are required for the positive and negative leads from the charger to the batteries. Consult a wire table which gives appropriate sizes versus length.

Wires are shown from the charger to the batteries. In most cases there will be positive and negative distribution posts which collect wires rather than directly onto battery posts. The voltage sensing wires should connect directly to the batteries, however.

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Figure 3 - 24 Volt Wiring

24V Wiring

Read the section above for 12V wiring.

For 24V operation, two 12V Power Supply/Charger modules are connected in series. Typically, the 12V tap on the two chargers is connected to the 12V junction of the 24V battery bank.

A common failure mode for 24V systems is a gradual unbalance in state-of-charge between the top 12V battery and the bottom 12V battery. A gradual decline in capacity is observed, and the unbalance can be detected by measuring the voltages of top and bottom batteries.

To avoid this common failure mode, a balancer circuit is used to ensure that the top 12V battery is charged exactly like the bottom 12V battery.

Current Limiting

NOTE: The shunt shown in the drawing is an option. It is required if charger current limiting is required. A 50 Amp shunt is sufficient for one 55 Amp module since the shunts can tolerate a 100% overload. If two 55 Amp units are operated in parallel, then a 100 Amp shunt is required. Current limit on the EnerMatic is set as a percentage of the shunt value, rather than directly in Amps.

If the shunt is not used, then the negative wire from the charger connects directly to the negative distribution point.

Stacking for more Amps

Control signals are available to operate two chargers in parallel. A second unit can be wired in parallel to the first unit, however, the second unit will use the second control signal.

In 24V systems, two additional chargers are required.

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

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