AA Portable Power Corp EMC series User manual

User Manual
Of
Smart Charger (15A) for 51.2V (16 cells) LiFePO4
Battery Pack (110V only, Standard Female plug)
AA Portable Power Corp (http://www.batteryspace.com)
Address: 860 S, 19 th St, Unit A, Richmond, CA, 94804
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Prepared & Approved by Louis (01/10/08)

User Manual for EMC Series Charger
1. Overview
The EMC series chargers are suitable for charging lithium ion
battery packs such as those used in
electric vehicle applications. The EMC series chargers are
designed to work seamlessly with EMS through the CAN interface
or digital input for safe battery charging. Standard safety features
include protection against a short circuit on the charger output
reverse polarity over charging over temperature etc.
2. Technical Parameters

2.1 Specifications
Model: EMCXX---YY (XX: Output Voltage YY: Output Amps)
Efficiency: ≥88%
Input voltage: 110V AC (220V AC available as special order)
Input voltage range: AC 95 ~ 130V / AC 195 ~ 242V
Frequency: 40 ~ 60Hz
Communication: CAN and 12V Digital Input
Vibration: SAEJ1378
Water resistance: IP31
Power factor: ≥0.75
2.1 Operating Environment
Altitude: ≤2000 Meters
Temperature: ---30°C ~ 55°C
Installation Stress: ≤ level 5
Humidity: 5% ~ 70% RH @ Non Condensing keep away from exposure to moisture
Storage environment: ---30°C ~ 60°C @ Keep away from combustible materials
3. Charging Status and Alarm Status Indication
3.1 Alarm Indication
Reverse polarity or low voltage: Red light blinking 20% light on
Charger over heating: Red light blinking 40% light on
Ambient temperature too high: Red light blinking 60% light on
Charging time out: Red light blinking 80% light on
Over Voltage Protection: Red light blinking 100% lights on
BMS alarm/charging interruptions All LED’s blinking
3.2 Charging Status Indication
Shutdown status: Six lights blinking
Charging stage: Percent light indicating pack voltage vs. max charging
--- voltage
Battery presence not detected: Red light blinking 20% light on
Charging complete: All green lights on
4. Functions
4.1 Output short circuit protection.
4.2 Over---temperature protection:
Temperature less than 83°C @ Full charging power
Temperature is 85°C to 95°C @ Power reduced to 50%
Temperature is greater than 95°C @ No output

4.3 Reverse polarity protection: charger will not turn on if the battery pack is connected
backwards (or
less than 5V).
4.4 A switch on the charger marked “Override” is used to select either external or internal
controlled charging.
Override Off @ Use with EMS system either CAN or digital input
Override On @ Charger program based on pack voltage only (recommended for testing
purposes only do not use for normal charging).
4.5 When external control is selected and a CAN signal is used if any cell reaches the recharge
set point (default 3.7V as signaled by the EMS) the charger will automatically enter the final
recharge cycles.
4.6 Recharge cycles. When the EMS detects any cell has reached the recharge set point (default
3.7V) or above the charger reduces the charge current to zero amps for five minutes to allow
the EMS to balance the battery pack. The charge will resume after five minutes at half the
previous charge current and will again charge until it receives a signal from the EMS that a cell
has reached the recharge set point. These recharge cycles continue until the charging current
reaches the minimum charging current to complete the charging process.
4.7 Digital alarm input:
0.0V - 2.0V: Charging stopped
2.5V - 12.0V: Enable charging or resume charging
4.8 When both CAN and the digital control signals are available the charger is controlled by the
CAN communication signal.
5. Connections
5.1 IEC Connector
For EMC chargers which output 10A or less the charger comes with an IEC type connector for
the output. The connections to the battery pack are made as follows:

5.2 Anderson SB50 Connector
EMC Chargers with output greater than 10A come with an Anderson SB50 style
connector for the output. These connectors are labeled “+” and “-”. A mating connector
comes with the charger.
5.3 CAN and Digital Input Controls
A five wire connector connects to the charger for interfacing with the BMS. Three wires
have a white connector attached, these three wires are the CAN interface. The other two
wires are labeled “+12V” and “-12V”, these wires are the digital in ut used to control the
charger from the EMS CPU. Connect the “+12V” to the 0V connection on the EMS CPU
and the “-12V” to the GND connection on the EMS CPU.
The EMS CPU will output a 12V signal from the “0V” terminal whenever a pack normal
situation is detected. During charging if a cell exceeds the maximum voltage limit this
will drop to 0V which will trigger the charger to temporarily pause charging until the
high voltage cell can return to normal voltage. All green LED’s on the charger will flash
when this occurs.

For a CAN communication connection connect the CANH CANL and CAN GND to the
matching connection on the CAN connection on the EMS CPU. The white connector may
be cut off of the cable; however note which wires are which before doing so.

If both the CAN communication and the digital inputs are connected CAN
communications will take priority over the digital input for charge control. CAN
communications requires the optional CAN board be installed on the EMS CPU.

6. Cautions
Make sure charger voltage output matches to the number of cells in the battery pack.
Make sure positive output of the chargers is connected to a positive connection to the battery
pack and the negative output of the charger is connected to a negative connection of the
battery pack.
After a complete charge disconnect the power source from the charger and then disconnect the
connection between the charger and the battery pack.
A BMS system must be used during the charging process either through CAN communication or
through the digital alarm input to prevent over---charging.
7. Troubleshooting
The charger must be installed in a cool well---ventilated area which is free of dust
If the charger is not charging unplug the charger from the AC line and battery pack then check
for poor connections short circuits over heating conditions as well as alarm status from the
Energy Management System.
If charger does not display any LED’s when plugged in and charging does not occur the fuse
maybe blow. Unplug the charger from the battery pack and AC line and check the fuse by

unscrewing the cap with a #2 Philips screw driver. If the fuse is blown replace with an equivalent
size fuse of the same voltage and amperage rating.
If the charger finishes charging too early make sure that the connection from the charge to the
battery pack is good and does not have high resistance.