AMPLE POWER SARV3 Smart Alternator Regulator

Transcription

1 AMPLE POWER SARV3 Smart Alternator Regulator Using a microcomputer, the V3 is packed with features you'd expect from Ample Power. You certainly don't want to try this with the competition, but you can short the field output of the V3 and it will live to tell you about it...even if you forgot to fuse the B+ line! In fact it tells you immediately by flashing its red LED 3 seconds on, and 6 seconds off. What's New? The SAR-V3 has all the features that have made the SAR-V2 so popular, and incorporates the following new features. Much improved field short circuit protection...no more worries about losing the regulator when the alternator brushes short. Dual alternator current limit inputs permit throttling the horsepower drawn by the alternator. This feature lets even small engines use a large alternator, by reducing alternator output when watermaker pumps or other loads are run. Dual current limit is standard on the V3...it was optional on the V2. The Next Step has no current limit capability. Battery equalization can be enabled and will be automatically terminated at the appropriate voltage or time. No adjustments required...set the dip-switches for your battery type and you're done!

2 Both error and status signals are now available for use with remote indicators or audible alarms. A new yellow LED shows when the parallel solenoid is actuated. The regulator stays partially active all the time and will open and close the parallel solenoid as appropriate to maintain a second battery. With the V3 there's no need to purchase another product to keep the starter battery charged when a battery charger or solar panels are being used instead of the engine. Even without the engine running, the SAR-V3 will flash the red LED should too high a voltage be applied to the battery. A pluggable terminal block permits wiring the harness prior to mounting the SAR. Smart Discharge Detection What if the regulator is in float, and the alternator can't keep up with demand? The SAR-V3 is smart enough to sense this condition and go into the absorption state so that a full charge will be returned when the load demand lessens and the alternator can once again continue charging. Charge State Indicator An LED keeps the user informed about the progress of charging. The green LED flashes on/off codes indicating the charge step at the moment. A terminal is provided that can drive a remote indicator. Error Indicator A red LED only flashes when faults are detected, such as loss of sense input, or over-voltage on the battery. Other faults such as shorted field driver or shorted field are reported. Errors are identified by the duration of on and off times for the red LED. This mechanism permits rapid troubleshooting of the charging system. Easy to Adjust The SAR-V3 has no set-point adjustments...just choose your battery type on the dip-switches. There are two current limit potentiometers corresponding to two input signals that activate current limiting. Performance Enhancements The SAR-V3 improves on earlier design performance with these important additions: an output to drive a parallel solenoid which connects the house and starter batteries during charge an input signal to limit the absorption voltage when halogen lights are on

3 an input signal that holds the regulator at the absorption set-point (compatible with Energy Monitor II) two alternator drive capability. Parallel Solenoid Signal The SAR-V3 has also been designed to provide a new level of system integration. The unit drives a parallel solenoid to simplify charging a starter battery at the same time a house battery is charged. This parallel signal is active even when the engine isn't running. With the parallel solenoid driver, the SAR-V3 is ideal for motorhomes and fifth-wheel homes. The loads which are normally drawn from the starter battery can stay connected as wired...the standard solenoid will supply 85 Amps continuously, (400 A intermittent). The same parallel solenoid can even be used with a manual parallel switch to connect the house and starter batteries. Temperature Sensing To provide an ideal charge regimen, the SAR-V3 senses battery temperature and compensates the various set-points. Temperature compensation corrects the output voltages from -4 to 140 Fahrenheit (-20 to 60 C). Above 140 F, the regulator cuts off completely to prevent thermal runaway. The SAR-V3 continues to operate below -4 F, but does not continue to increase battery voltage. Depending on the battery type, the battery voltage can range from 15.9 Volts on an extremely cold battery to 13.5 Volts on an extremely hot battery. Charge profiles follow time-proven regimens customized for each battery type. Absorption Hold The SAR-V3 interfaces to the Energy Monitor II and will stay in the absorption voltage until the Monitor releases it to float. The interface can also be used with a switch to hold the regulator in the absorption state or force it into the float state. Halogen Lamp Protection While batteries need a voltage higher than 13.8 to charge fully, the higher voltage will take its toll on halogen lights, reducing their life considerably. The SAR-V3 includes an input that locks the set-point to 13.8 Volts when desired. This naturally slows the charge process but the locking feature can be used when long hours of motoring at night are expected. On motorhomes, the LOCK input can be connected to the headlights so that the regulator is locked out of high voltages whenever the headlights are on. Dual Alternator Rated

4 The SAR-V3 Regulator is rated to drive the fields of two alternators in parallel. No additional circuitry is required if both alternators are mounted on the same engine. When the alternators are mounted on separate engines, a Dual Alternator Controller, DAC, is available which permits either or both engines to be run without applying field power to an alternator that isn't rotating. Features at a Glance Fast, Full, Multi-Step Charging Automatic Compensation for Battery Temperature Adjustable Dual Current Limits Automatic Equalization Termination `Smart' Error Lamp Output Identifies Problems `Smart' Status Lamp Indicates Charge State Dip-switches select Charge Set-points Compatible with all Battery types Synchronizes operation with Energy Monitor II, H1 unit Lockable at 13.8 (27.6) Volts Easy Installation with pluggable terminal block Precision Reference Control Over Time and Temperature Field Driver is Short Proof Signals available for remote error and status indicators Voltage runaway indication even without engine running Operates parallel solenoid for cross charging house and starter battery for any charge source, (battery combining function). Dimensions and Mounting The SAR-V3 Regulator is 148 mm long by 171 mm wide. It stands 42 mm off its mounting surface. It can be mounted in any orientation. The housing is marine grade aluminum which has been clear anodized and screen printed. Regulator Comparison...SAR V3 and Next Step, NS2 Introduction The NS2 is the latest Ample Power Regulator. It was designed as an entry level regulator but with a series of options. With all the options, the NS2 has the functionality of the SAR V3, however the optional serial port is required for many of those functions. A computer with a serial port is also necessary.

5 For those with a computer, the NS2 with options is easier to use. For instance, current limit in the V3 is set by a potentiometer and requires an ammeter to measure alternator or battery current. With the NS2, current is programmed as a percentage of alternator maximum. The table below lists functions and their implementation on the two regulators. Equalization AGM and liquid electrolyte batteries require periodic equalization. A cruising vessel which can't rely on shore power for this purpose should select the V3, or go with all the NS2 options. The V3 can equalize via an internal jumper selection and an external input to start the equalization cycle. The NS2 requires a computer to start the cycle. Those comfortable with a computer will be best served with the NS2. Regulating Two Alternators The V3 can drive the field of two alternators directly. If the two alternators are on separate engines then a Dual Alternator Controller, DAC is required. The V3 and DAC combination work well in power boats where the two engines are side by side. In multi-hull vessels, where the engines are a great wiring distance from each other and the house battery bank, problems with RFI noise and regulator stresses from transients on the field wire make the V3/DAC method less than optimum. The NS2 addresses this problem by utilizing an Alternator Driver Module. The NS2 itself is located near one engine, and the Driver near the other engine. High power field connections are short and thus RFI and transient problems are much less. Wiring is also simpler. Regulator Setpoints The V3 has a dipswitch to select the type of battery in the system. It bases absorption time on the battery selection and other dynamic measurements. In most cases the V3 does an excellent job of delivering a fast full charge. The NS2 provides potentiometers for absorption and float voltages, and absorption time. They can also be set via the computer and saved in nonvolatile memory. The NS2 should be selected if you want to use non-standard setpoints. Regulator Size The NS2 is about 1/4 the size of the V3. Communications

6 The NS2 can communicate using a subset of the Remote Access Protocol, RAP. With the optional serial port, the NS2 will be compatible with future displays offered by Ample Power and others. Feature SAR V3 Next Step NS2 Battery Combiner Mode Standard Standard Temperature Sensor Standard Standard Equalization Standard Optional Serial Port Absorption Lock Standard Optional Serial Port Adjustable Setpoints Dipswitch, 8 types Yes Two Alternator Drive Standard Optional 12/24 Volts One or Other Works on Either 32/36/48 Volts No Yes Computer Interface No Optional Serial Port Firmware Upgrade Replace Chip Re-program Flash Pluggable Terminal Blocks Yes Yes Short Circuit Protection Electronic + Fuse Fuse Read Battery Voltage No Optional Serial Port Read Battery Temperature No Optional Serial Port Duty Cycle Current Limiting Standard Optional Serial Port English Status Messages No Optional Serial Port Remote Status LED Standard No English Error Messages No Optional Serial Port Remote Error LED Standard Optionl

7 Smart Alternator Regulator Installation and Operating Instructions Ample Power Models SARV3-12P and SARV3-24P February 1, 2000 V3 Mounting the Regulator The regulator is protected against ambient humidity, but must be mounted in a dry location free of moisture, dust, and other environmental insults. The regulator will operate in temperatures to 60 C (140 F). Wiring Diagram The wiring diagram above is the only way to wire the Smart Regulator. 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. NOTE: For those familiar with earlier regulators such as the SAR- V2 or Next Step Regulators, note that all inputs and outputs on the SAR-V3 are active on a positive signal. That means the PARALLEL solenoid, the ERROR LAMP and the STATUS LAMP are wired to their respective devices with the other end of the device returned to Negative Distribution. All inputs at the terminal block are activated when they are connected to battery voltage. Leave unused optional terminals unconnected. Signal Names and Functions Battery voltage set-points are specified for each voltage system, 12 or 24 volts, as 12 / 24 volts, respectively. PARALLEL, (optional)... an output that has a positive voltage when the regulator detects that the house battery is being charged. The maximum load is 1.5 Amps. ON / OFF, (required)... an input that that turns the alternator field circuits of the regulator on when battery voltage is applied. Typically it is connected to the ignition switch. Typical draw is Amps. NOTE: On gasoline engines DO NOT connect at the spark coil... connect at the ignition switch. GROUND, (required connect this wire first)... the reference ground for the regulator. All battery voltages are referenced to this connection. 1 B, (required)... the power input source for the alternator

8 field current, PARALLEL, ERROR LAMP, and STATUS LAMP. Amperage draw on this wire is rated at 15 Amps maximum. To completely deactivate the regulator, a suitable switch (not shown) can be inserted into this line. FIELD, (required)... an output that is driven positive by the regulator to make the alternator charge. Voltage at this point depends on how much current the alternator should produce and varies from zero to battery voltage. ALT.GND, (required)... the return line for field current. NOTE: Do not jumper this wire to the GROUND tab. LOCK, (optional)... an input, when connected to battery voltage, that locks the regulator set-point at the battery gassing voltage. Used to prevent higher voltages when halogen lights are used. Refer to the LOCK Input section for the operating description. BAT.VOLTS, (required)... the sense wire for battery voltage. Any erroneous voltage drop in this wire from the battery can cause overcharge. T- (BLK), (recommended)... ground side of the temperature sensor, which is supplied with the regulator. T+ (RED), (recommended)... positive side of the temperature sensor. Voltage at T+ (RED) is 2.98V 25 C (77 F), and varies plus and minus with temperature at the rate of 0.01V per degree C. Some battery manufacturers require temperature sensing of the battery for warranty purposes. Under all cases except for temporary troubleshooting, we recommend using the temperature sensor at all times. ABS, (optional)... a positive voltage applied at ABS will lock the regulator at the absorption set-point. This is typically used with the Ample Power Energy Monitor/Controller. Refer to the ABS Input section for the operating description. Figure 2. Internal Settings Locations Status Indicator The green Status Indicator and the external STATUS LAMP, if wired, shows the charging state of the regulator. Status is shown by flashing the green Status Indicator with On and Off times in seconds as shown in Table 1 below. Table 1. Green Status Indicator Status On Off ON/OFF Input Off 3 3 Bulk Charge 2 1 Gas Charge 6 1 Absorption Charge 1 1 Step to Float 1 6 Float Charge 2 2 Gas Lock 3 1 ABS Hold 1 3 Equalization Charge 6 6 ERROR LAMP, (optional)... an output that has a positive voltage blink rate identical to the red Error Indicator. Refer to the Error Indicator section. Maximum current permitted from this output is 0.05 Amps. STATUS LAMP, (optional)... an output that has a positive voltage blink rate identical to the green Status Indicator. Refer to the Status Indicator section. Maximum current permitted from this output is 0.05 Amps. LIMIT, (optional)... an input that activates the regulator s duty-cycle current limiting when battery voltage is applied to this connection. This duty-cycle current limit is adjusted with potentiometer R11 (Refer to Figure 2). Refer to the Current Limiting section for the operating description. EQL, (optional)... an input that activates either the regulator s equalization mode or a second duty-cycle current limit, depending on the internal jumper P1. This input is activated when battery voltage is applied to EQL. The duty-cycle current limit is adjusted with potentiometer R12 (Refer to Figure 2). Refer to the Equalization section for the operating description. 2 Error Indicator The red Error Indicator and the external ERROR LAMP, if wired, reports abnormal conditions. Errors are identified by On and Off times of the red Error Indicator as shown in Table 2 below. They are listed in the order that errors are displayed if there are multiple errors. All errors, except the last one, attempt to shut off the field drivers until the error condition subsides. Note: The last error can also be a warning that voltage getting to the regulator on the B input is insufficient to fully drive the field output. Table 2. Red Error Indicator Error On Off Voltage Runaway 6 3 Field Short Circuit 3 6 Bat. Volts disconnected 3 1 Can t turn field off 1 1 Bad Temperature Sensor 6 6 Over Temperature 3 3 Can t turn field on 1 3 Missing GROUND connection 6 0.5

9 Voltage and Absorption Time Set-points The voltage and the time of the absorption cycle are controlled by the internal dip-switch, S1. Refer to Figure 2 for the location of S1. Select a charge profile by setting the battery type switches on S1 according to the following table. Table 3. Battery Type Selection Battery Type Sw 1 Sw 2 Sw 3 Thick Plate Liquid Off Off Off Medium Plate Liquid On Off Off East Penn Gel Off On Off Concorde AGM On On Off Optima Off Off On Exide Gel On Off On Johnson Control Gel Off On On Ample Power Gel On On On What You Should See The regulator is on whenever power is present at B. Without voltage at the ON / OFF input, the regulator is simply controlling the parallel solenoid, and will close the solenoid whenever the voltage on BAT.VOLTS indicates that the main battery is being charged. When the regulator is first turned on via B, the red Error Indicator will glow for 5-8 seconds before extinguishing. Then the green Status Indicator will then start to flash the charge status. If there is a positive voltage on the ON / OFF input, then the alternator should start to charge after the red Error Indicator goes off. Thus, alternator charging can be controlled via the ON / OFF input. ABS Input When battery voltage is applied to this input, the regulator is held at the absorption set-point. Removal of the input signal causes the regulator to begin stepping toward the float voltage. Step-to-float is an intermediate mode where the float set-point is approached in small steps over time. This is done in an attempt to maintain some alternator output and thus keep the tachometer alive. LOCK Input This input locks the regulator at the gassing set-point, which is half-way between the absorption and float set-points. Removal of the signal toggles between stepping to float, or going to the absorption set-point. The first activation and then removal of the LOCK signal causes the regulator to step float. The next activation and then removal of the LOCK signal causes the regulator go to the absorption set-point, initializing the absorption timer. This cyclic behavior repeats. Thus, the LOCK input can be used to completely control the charge state at float, gas or absorption. Input Priorities The EQL signal overrides the LIMIT signal. Both EQL and LIMIT override the ABS and LOCK signals. On the current release, the LOCK signal overrides the ABS signal. Current Limiting Two 20-turn potentiometers with two input signals permit duty cycle current limiting at two independent set-points. Duty cycle current limiting is a mode where the percentage-of-time that the regulator is driving the field is set by the potentiometer. Current limiting 3 is useful to reduce alternator output, and thus reduce horsepower requirements from the engine. Two settings are available. The control inputs are LIMIT, and EQL. Note that the EQL input serves a dual function depending on whether an internal jumper, P1, is in place. See the Equalization section for more information. For normal limiting on a small engine, assert the LIMIT input. The EQL input can be connected to the same switch that enables another load on the engine. For example, a clutch driven pump may require a further reduction in current, so wire the EQL input to the switch that activates the clutch for the water pump. The potentiometer for LIMIT is R11. R12 sets the current limit for the EQL input. Refer to Figure 2 for R11 and R12 locations. NOTE: The EQL input is used here as a second current limit setpoint. See the following section below for information to do equalization. Equalization Equalization is a process where the voltage on the battery is allowed to rise to a higher voltage, typically 16.2 / 32.4 Volts for most batteries, where the applied current is limited to 3-7% of the Ah capacity of the battery. The applied current must be set using R12. The EQL input is used for a second current limit whenever the input signal is activated. To enter the actual equalization mode, the two pins of P1 must be first shorted with a jumper terminal or a switch connected to the two pins, refer to Figure 2. This changes the mode of the EQL input signal to regulate at the equalization voltage set-points as well as current limit. Then the EQL input should be momentarily activated for at least two seconds and then released. A second momentary action will terminate the equalization process. Equalization will terminate automatically whenever the ending voltage or time is achieved. CAUTION: Equalization produces a higher voltage than some normal equipment can tolerate. Turn off equipment that will not tolerate an input of 17 / 34 Volts or more. NOTE: The Smart Regulator does not permit equalization for the gel batteries but does permit equalization of absorbed glass matte batteries at an appropriate voltage. Alternator Requirements The alternator must be an externally regulated model with one brush connected to ground and the other brush fitted with a connection to make the field connection, (P-type). NOTE: Alternators not rated for continuous operation at high current and temperature may fail when driven by the regulator unless current is limited to a safe value. Troubleshooting First, look at the Signal Names and Functions section above and make sure that all required wires are in place and properly connected. We have found that moving a wire such as BAT.VOLTS or GROUND a few feet away from a good Battery Positive or Negative Distribution could result in undesirable regulation due to voltage spikes in the system. To help diagnose voltage set-points, remove the T+

10 (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. Second, if the problem still exists, obtain a copy of the SAR V3 Troubleshooting Guide which is available from the following sources: Regulator Service Center Web: support@amplepower.com Phone: (206) or Fax: (206) The troubleshooting guide was designed to help isolate a majority of the installation problems. Fill out the Troubleshooting Guide to determine if all measurements meet the specified requirements. Finally, if you are unable to remedy the problem, contact the regulator service center with the SAR V3 Troubleshooting Guide completed for referencing. Supplement: Using the SAR with Two Engines and Two Alternators Figure 3. Modifications to the Basic Wiring Diagram for a Two-engine, Two-alternator System Ample Power products are manufactured by Ample Technology, 2442 NW Market St., #43, Seattle, WA USA Visit 4