Amico 401 Series Instruction Manual

Operation & Maintenance Instructions
400 Series Power Controller
www.amico.com

1 Amico Accessories Inc.
Contents
Preface 4
Section 1: Safety Precautions
Hazards and Other Symbols 5
Warnings and Cautions 6
Conditions of Acceptability 7
Section 2: System Overview
Application 8
Power 8
Charging 8
Monitoring 8
Buzzer 8
Communication/Software 9-11
Intended Use 12
Section 3: System Description
Enclosure 12
Power Supplies 12
Motherboard 12
AC Module (Series 451 only) 12
Remote Display 13
Temperature Sensors 13
Fan Control 13
State of Health 13
Section 4: System Connection
Description and Location of Parts 14-15
Diagram of Connections 16
AC Power Input 17
Batteries 17
Battery Connection Diagrams 17-18
Temperature Sensors 18-19
Host Computer 19
Small PCs and All-in-one PCs 19
Laptop 19
Remote Display 19
DC/AC Output Power 19-20
Thermal Sensors 20

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Contents
Section 5: Installation of Software
Host PC Software 20
Section 6: Initial Testing and Error Conditions
Remote Display 21
Battery 21
Main User’s Interface 21
AC Power 21
System Communication with the Host 21
Sleep Mode 22
Error Conditions 22
Over Temperature 22
Overload 23
Charger Time Out or Bad Battery 23
System Reset 23
Section 7: Operation
Turn On 24
Sleep Mode 24
System Set Up 25
401 Series Setup 26
GUI Setup 27
Email Setup 28
Test Email 29
Sleep Mode Activation 29
Buzzer 29
Upload EEPROM Data 30
CartTrac (Optional) 30
Charging 31-32
Discharging 32-33
Section 8: Field Diagnostics
System Status at a Glance 34
Advanced Functions Description 35
Pull Down Menus 35
Gauge and LED Indicators 36
Thermal Sensors 36
Battery Power 36
Load Power 36
AC Module Enable 36
System Diagnostics 37
Event Log Screen 38

3 Amico Accessories Inc.
Contents
Section 9: Maintenance
Maintenance Screen 39
General Maintenance 40
Battery Maintenance 40
Section 10: Potential Hazards, Interference and Avoidance 41
Section 11: System Specifications
Classification 42
Identification, Marking and Documents 42
Input 42
Input/Output: DC Battery 42
Output: AC & DC Load 43
Output: Fan 43
Output: Temp Sensors 43
Input/Output: USB 43
Output: Remote Display 43
General 43
Environmental 43
Mechanical 44
Battery Profiles 44
Features 44
Section 12: TUV Certification Statement 45
Appendix A: Dimensional and Mounting Information 45
Warranty 46

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Preface
IMPORTANT, PLEASE READ CAREFULLY
Thank you for your purchase with Amico Accessories Inc.
This unit is designed for long lasting performance, provided that the end user complies with assembly and maintenance
procedures. This Manual is your guide to ensure that you get the best performance out of the equipment. Amico
Accessories Inc. is not responsible for any damage as a result of (but not limited to) abuse and other problems that may
be a direct or indirect result of failure to comply with the instructions provided in this manual.
Please Note These Key Words and Symbols:
WARNING Steps where extra care should be taken to prevent injuries and damage.
NOTE Steps that point out helpful information.
Medical Facility Responsibilities
Preventive maintenance checks must be performed regularly to maintain the quality and performance of this product.
Any parts that may be broken, missing, worn, distorted or contaminated in any way should not be used and all affected
parts should be replaced immediately. Should the necessity of any repair be suspected, please contact your local
distributor or call 1.877.264.2697.

5 Amico Accessories Inc.
Section 1: Safety Precautions
Hazards and Other Symbols
The following symbols are relevant to either this manual or the Power System.
SYMBOL TITLE DESCRIPTION
ALTERNATING CURRENT
DIRECT CURRENT
ATTENTION Attention: consult ACCOMPANYING
DOCUMENTS
ELECTRICAL HAZARD Indicates an electrical hazard may exist
i
Follow Operating Instructions
Note: On ME EQUIPMENT
“Follow instructions for use”.
Low Battery Symbol used for indicating low battery on
the remote display device.
Powered by DC Symbol used for indicating that the
Power System is currently powered by
DC [battery]. Used on the remote display
device.
Powered by AC Symbol used for indicating that the Power
System is currently powered by AC [wall
power]. Used on the remote display
device.
Earth Ground

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Section 1: Safety Precautions
i
All operating instructions should be thoroughly reviewed prior to the use of the system. Warnings and
instructions should be followed while installing or operating the Power System.
Definitions:
CAUTION: Indicates a hazardous situation, which if not avoided, may result in minor or moderate injury or product or
property damage.
WARNING: Indicates a potentially hazardous situation, which, if not avoided, could result in serious injury or death.
CAUTION:
The AC power conductors must be assembled to a certified plug assembly by a qualified technician. For
compliance to the safety and EMC specifications, the plug assembly must meet the requirements dictated within
this operations manual.
Appropriate airflow is required at both the inlet and exhaust vents of the Power System. Adequate open area
cross section to the Power System should be provided for room ambient air to the inlet and outlet of the Power
System. There should be no blockage of air around the fans and vented ends of the power supply. Fan guards
are recommended to protect the function of the external fans and to prevent dust accumulation. Fan guards are
recommended to be checked and cleaned occasionally to provide optimal air flow.
WARNING:
DO NOT allow untrained technicians to install, modify or otherwise handle this equipment. This equipment is
intended to be installed into an Original Equipment Manufacturer’s product in a controlled setting with precise
work instructions and trained assembly personnel.
DO NOT operate the Power System without the covers completely installed and the connectors attached properly.
The covers provide safety from potentially dangerous voltages.
Do not connect or disconnect the Power System while power is applied. Do not open or in any other manner
change the access to the internal portion of the Power System while power is applied.
Do not allow the Power System to come in contact with fluids. Do not operate the Power System if wet.
Warnings and Cautions

7 Amico Accessories Inc.
Conditions of Acceptability
CAUTION: When installed in an end-product, consideration must be given to the following:
• Appropriate airflow is required for this unit to operate correctly under normal and fault conditions. Suitable
spacing should be provided for the fans and vented ends to allow air flow in and out of the Power System.
When installing the Power System, the cubic area needed for air flow should be taken in consideration and
thermal testing must be performed as part of the end-product acceptance. There should be no barriers to the
fans and the vents of the Power System.
• Suitable fire enclosure must be provided as part of the end-use system investigation. The component shall be
installed in compliance with enclosure, mounting, packing, casualty and segregation requirements of end-use
system requirements.
• Leakage testing must be performed on end-use system.
• IEC 60601-1-4 not performed and must be considered for end-use system.
• Clause 15b limitation of Voltage and/or Energy must be performed on end-use system.
• The AC Line input cable and IEC connector are supplied by the user. Although not strictly required, it is strongly
recommended for additional protection that a fused IEC Input Module (or other external fuse arrangement) is
used with the Power System. The recommended fuse type is 10 A 250 VAC. Both Line and Neutral conductors
should be fused. The AC voltage input earth ground complies with bonding impedance requirements when it is
attached to a standard AC wall outlet. There is no required or provided earth ground bonding when the end-
use system is mobile.
• DC output short circuit and reverse polarity testing shall be considered on end use equipment.
• The DC voltage output cables are supplied by the user. The DC outputs from the Power System do not need to
be fused due to internal current limiting. If the user wishes to install fuse(s) for additional protection, fuse type
and sizing should be based on end-use requirements.
• The Battery Cable is supplied by the user. There is no requirement for fusing the Battery Cable since the Power
System includes a replaceable internal fuse. If external fusing is desired, careful consideration should be given
to fuse specifications for end-use requirements.
• Equipment has not been evaluated as AP/APG equipment. Must be considered as part of the end system
equipment.
• Component shall be properly bonded to the main protective earth termination in the end-use system and
comply with end-system bonding impedance requirements when it is attached to a standard AC wall outlet.
There is no required or provided earth ground bonding when the end-use system is mobile.
• Complies with requirements for US for outside the patient environment. For use within the patient
environment, evaluation must be performed as part of end system equipment.
This product contains electrical components. Observe local, state and federal guidelines for proper
disposal. The end product manufacturer should be contacted for procedures. For further information on
disposal, contact Amico Accessories Inc. at 1.877.264.2697.
Section 1: Safety Precautions

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Application
The 400 Series DC Controller is a Medical Grade Power Management System designed for use with both Sealed Lead
Acid [SLA] Absorbent Glass Matt [AGM] and Lithium Iron Phosphate Batteries in Mobile Point of Care [MPOC] products
for Hospitals and Long Term Health Care facilities. The product uses microprocessor based technology for intelligent
charging, reconditioning, state of charge monitoring and DC power control. It is designed, manufactured and certified
to EN 60601 Medical Safety Standards. There are two models in the 400 Series: Model 401 and Model 451. The Model
401 provides 19.5 V, 12 V, and 5 V DC outputs. The Model 451 provides the same DC outputs as the Model 401 but
also includes a 115 VAC output. The hybrid design of the Model 451 provides True Sine Wave AC output together with
multiple regulated DC outputs to power any combination of equipment, without the need for external converters. Both
models can be customized to user needs and other battery chemistries can be included with simple firmware upgrades.
Power
The 400 Series DC Controller uniquely combines the “By-Pass” feature of AC Systems with the high efficiency and
long run times of traditional DC Systems. It uses an automatic transfer of load to ensure smooth uninterrupted supply
switching from AC Wall power to DC Battery power.
The 400 Series DC Controller has the capability of powering multiple DC and AC devices (AC with Model 451 only) up to
a combined load of 200 watts while simultaneously charging the battery.
Charging
The 400 Series DC Controller is optimized for battery capacities in the range of 10 Ah to 100 Ah, and has the capability to
charge at up to 25 Amps. It uses an intelligent multi-stage charging algorithm to adhere to the battery manufacturer’s
specifications and maximize battery life while maintaining safe operating conditions. Presently there are numerous
preset charging profiles for both Lithium Iron Phosphate and Sealed Lead Acid batteries. Other battery chemistry
profiles may be added in the field with a simple firmware upgrade.
Monitoring
The system has an on-board microprocessor that monitors multiple sensors for use with the State of Charge [SOC]
predictions; DC voltage, DC current, ambient temperature, battery temperature, total charge, discharge amp hours since
activation and battery experience. A key monitoring feature is Event Logging which logs key information each time the
battery experiences a specific event. Using the power system’s memory, up to 2000 events can be logged and used for
diagnostics and maintenance scheduling. Using the host system’s memory, the total number of events is limited only by
the host system’s available storage capacity.
Buzzer
The buzzer is audible at a frequency of 2.4 kilohertz nominal at an audible intensity of typically 92 decibels at 10
centimeters. The buzzer may be enabled or disabled by the user. If disabled, the buzzer will not sound for ANY
circumstance. The buzzer, if enabled, will notify the user if the battery power goes below a pre-established state of
charge voltage threshold indicating an imminent need for charging and/or discontinuing computer usage.
Section 2: System Overview

9 Amico Accessories Inc.
Main User’s Interface
Communication/Software
Communication between the Power System and the User’s CPU is accomplished with a standard USB cable. Once
the Power System is recognized by the CPU, a device driver will be installed on the CPU allowing ports to open for
communication. The communication driver is included with the GUI software and will normally install automatically. In
the event that the device driver does not install correctly, please contact IT for further assistance.
The system communication software includes two user interfaces; the Main User’s interface and the Advanced
Functions interface. These interfaces are provided on the display on the host computer. The information provided in
these interfaces is ported to the host computer via a standard USB connection between the 400 Series Power Monitor
and the host computer.
The Main User interface can be resized using the standard window resizing feature.
If this display is terminated by selecting the “x” in the upper right hand corner; the software will continue to run. The
software logo icon is displayed in the notification area of the windows toolbar.
The 400 Series communicates with the host computer and provides a graphical interface to the user through the host
computer display. Although this communication provides useful and extensive features, it is technically optional as the
system will operate without this communication link. It is strongly advised, however, that these features and the link be
used to take full advantage of the capabilities of the system.
Section 2: System Overview

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The Advanced Functions screen provides a variety of detailed information to be used for evaluation of the power
system and the components attached. It also allows for the System Setup of the different types of batteries, the length
to scheduled maintenance and other onetime set up parameters.
This Advanced Functions screen is used by the user’s IT department or other skilled technician as described in this
manual. This advanced functions screen provides further information besides the main user interface. It displays the
temperatures of the controller and the batteries, the actual current and voltage draw or charge, display the battery
information, the firmware and GUI version, and features to test several controller functions.
The Main User’s interface is also available through a remote display mounted directly to the cart. It is constructed to
mimic the display as viewed on the host computer’s display. It is essentially identical however it does not include the
time to charge/discharge information or the AC Module indication of the Series 451 like computer’s display.
Advanced Functions Interface
Section 2: System Overview

11 Amico Accessories Inc.
The Main User’s interface provides a variety of information to the user [typically the Nurse] relating to
1. The current connection,(Power Source) as AC or DC
2. Indication that the unit is charging the battery
3. Indication that the battery charge is low
4. Indication that the unit is being shut-down due to insufficient battery charge
5. Indication that the unit is recovering a severely discharged battery
6. The current charge status of the battery (SOC)
7. The status of the battery charge to either (1) the time remaining until discharge or (2) the time remaining to Full
Charge
To completely exit the software and turn off the 400 Series interface to the CPU, the user must select the “Software Exit”
tab beneath the “File” pull down menu on the Advanced Functions display screen. This will turn off the software and
remove the icon from the notifications toolbar.
Section 2: System Overview

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Section 2: System Overview
Section 3: System Description
Intended Use
The Series 400 Power System is intended for use within mobile powered carts or similar applications. The system
provides a sustainable and rechargeable source of energy for mobile applications. The system is intended for indoor use
within a Hospital or Long Term Healthcare environment. The system is not intended to experience significant vibration
or physical shock. The system is intended to be placed within a protective enclosure provided by the cart manufacturer
that will, among other things, eliminate its exposure to liquids or materials that may unintentionally be dropped onto
the system. It is recommended that the OEM provides ventilation on their enclosure to allow ample airflow and cooling.
Enclosure
The 400 Series Enclosure safely houses the components (Motherboard, Power Supplies and optional AC Module). The
enclosure is made out of steel and is earth grounded when connected to a wall outlet or other grounded AC source of
power [AC input source interface is provided by the cart manufacturer].
The 400 Series Enclosure includes ventilation for efficient cooling. There are two cooling fans to push ambient air in
and slotted vents around the perimeter that allow hot air to vacate. Avoid blocking the ventilation areas and fans.
Insufficient air flow can cause overheating and can reduce performance.
The 400 Series Enclosure can be mounted in any orientation. There are 6-32 threaded inserts provided on two surfaces
for secure mounting. The user is to provide the mounting screws (refer to installation drawing in this manual for
mounting hole locations and maximum screw lengths).
Power Supplies
The two internal power supplies are modular and are mounted to the Motherboard. They provide power for battery
charging and driving the loads when AC Power is present. The supplies feature active Power Factor Correction [PFC];
universal input from 100-240 VAC, 50-60 Hz; and are fully approved [independently] to IEC 60601 Medical Safety
Requirements.
Motherboard
The Motherboard is the main system element, the primary circuit board, containing the intelligence and the logical
connections by which the other components of the system communicate. It is also the location of onboard memory
used to store State of Charge (SOC), monitoring of events, thermal sensing, and the operational firmware.
The Motherboard has internal connectors to interface with the power supplies and optional AC Module. The
Motherboard also contains multiple connectors for AC Input, DC Outputs, interfaces to the host computer via a
Universal Serial Bus (USB), Remote User Interface (Display), temperature sensor(s), I2C BUS, fuse holder, and optional
external fan.
AC Module (Series 451 only)
The optional AC Module provides up to 200 W of 115 VAC power in addition to the multiple DC outputs of the Model
401. The AC Module is internally mounted to the Motherboard.

13 Amico Accessories Inc.
Remote Display
The Remote Display is the remote user interface (RUI) representing the information necessary for normal operation of
the power system and cart. The RUI displays, among other items, a gas gauge representation of the charge state of the
battery.
Temperature Sensors
The Controller utilizes digital temperature sensors to maintain safe operation and control cooling. There are multiple
internal sensors, and connections for external sensors. The external sensors are used to measure the temperature at
the post of each SLA battery. The system will alert the user if a temperature sensor is not installed or is damaged within
5 minutes after the start of a charge cycle if SLA batteries are used. The sensors allow the controller to shut down if it
detects an over temperature of the battery. Lithium Iron Phosphate batteries do not require temperature sensors.
Fan Control
The system provides two 80 millimeter (mm) fans that are temperature controlled and variable speed. They operate
continuously when the battery is being charged, and operate when the temperature is elevated under all conditions.
A connector is provided for an optional 12 V external fan. This may be used to cool other electronics in the system. The
external fan operates in the same manner as the internal fans. External fans must be limited to a maximum of 3 Watts
/250 mA.
Fan performance has been selected to provide the most optimal cooling while minimize power consumption and noise.
State of Health
The system continually calculates, in the background of the host CPU, the State of Health (SOH) of the battery(s). This
calculation compares a theoretically ideal battery with the current state of the battery. It provides this calculation based
on a relatively complex algorithm that compares charge and discharge rates from the battery in the system with an
ideal battery.
The SOH parameter provides the user the relative life left in the battery as a percentage. A battery with a SOH indication
of 70% would be representing that the battery can sustain 70% of the energy of an ideal battery and therefore will
provide roughly 70% of the duration of an ideal battery if all other parameters [load, temperature...Etc] are equivalent.
Remote Display
Section 3: System Description

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Section 4: System Connection
The system connection is through bulkhead connections on the Power System enclosure. The external fan connector
is located on the far left followed by the AC Input Power connector, fuse connection, Battery Input, I2C connector (I/O)
for battery temperature sensors, the USB connector, Remote Display (RUI) connector (CAT5), and the DC load output
connector. For the 451 Model only, the AC Output connector is available above the DC output connector on the right
side.
Series 451
Hybrid
Power
Management
System
Call or visit us at:
203-653-1447
[email protected]
H-E-Systems.com
1Auxiliary Fan Port:
Thermally controlled, variable speed
fan output
2Ground Terminal:
For secure grounding to mobile devices
3AC Input:
100 VAC~250 VAC, 50/60 HZ input
430 Amp Battery Fuse:
User replaceable fuse
5Battery Connection:
Connect multiple batteries in parallel
6I/O Port:
Digital communication bus
7USB Port:
USB port for connection to local CPU
8RUI Port:
Remote user interface / fuel gauge
9DC Output:
5 VDC, 12 VDC and 19.5 VDC outputs
10 AC Output:*
120 VAC, 60 HZ, true sine wave output
* DC only system also available.
54 7
10
1
8
9
2
3
6
DESCRIPTION AND LOCATION OF PARTS:
10.25
6.00
.75
2.40
8.375
3.875
9.000
1.375
4X 6-32UNC THREADED
MOUNTING HOLES
4X 6-32UNC THREADED
MOUNTING HOLES
Hoffman Engineered Systems | 8 Riverbend Drive | P.O. Box 17002 | Stamford, CT 06907
One system.
Two power sources.
The 451 Hybrid Power Management System features:
nMost energy efficient power conversion in the industry for DC and AC outputs.
nFast, safe and reliable charging for all current and future battery chemistries.
nProprietary battery-charging algorithms provide maximum run-time and battery life.
nIndustry’s most accurate measurement of battery status and state-of-health.
nReal-time battery state-of-health information for maintenance and replacements.
n19.5 VDC, 12 VDC, and 5 VDC simultaneous outputs for virtually any technology.
n120 VAC true sine wave output.
nAdvanced software provides control and display of all operating parameters.
nIEC 60601-1 certified.
nPatent pending.
5.7 lbs
DESCRIPTION AND LOCATION OF PARTS
1Auxiliary Fan Port
Thermally controlled, variable speed fan output
6I/O Port
Digital communication bus
2Ground Terminal
For secure grounding to AC power source
7USB Port
USB Port for connection to local CPU
3AC Input
100~240 VAC, 50/60 Hz input
8RUI Port
Remote user interface/fuel gauge
430 Amp Battery Fuse
User replaceable fuse
9DC Output
5 VDC, 12 VDC and 19.5 VDC outputs
5Battery Connection
Connect single or multiple batteries in parallel
10 AC Output
120 VAC, 60 Hz, true sine wave output
Description and Location of Parts

15 Amico Accessories Inc.
Section 4: System Connection
We recommend, when possible, to connect the battery to the system prior to providing AC power to the system. This
allows the system to reset with a battery attached; a more common configuration.
The diagram on the next page represents the basic system connection. The table and paragraphs that follow provide
details regarding each connection.
Series 401/451
(AC Module shown installed)
Description and Location of Parts

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Section 4: System Connection
DC OUTPUTBAT TERY
1234
5678
1234
8 7 6
5
910
1234
AC INPUT
AC OUTPUT
1 2
3 4
SERIES 451 MOLEX CONNECTOR PINOUTS
AC OUTPUTDC OUTPUTBAT TERYAC INPUT
1
2
3
4
LINE
NC
NEUTRAL
NC
1
2
3
4
BATT (-)
5
6
7
8
9
10
BATT (-)
I2C: SDA
BATT (+)
BATT (+)
BATT (+)
BATT (-)
I2C: GND
I2C: SCL
I2C: 5VDC
12VDC RTN
4
3
2
1
5
6
7
8
12VDC RTN
19.5VDC RTN
5VDC RTN
12VDC
12VDC
19.5VDC
5VDC
1
2
3
4
LINE
NC
NEUTRAL
NC
12
FAN OUTPUT
I2C PORT
1
2
3
4
5VDC
SCK
RTN
SDA
1234
I2C PORT
FAN OUTPUT
1
2
FAN (+)
FAN (-)
QTY
1
2
3
4
5
6
7
8
9
10
1
1
1
1
14
REFERENCE
AC INPUT CABLE CONNECTOR
BATTERY CABLE CONNECTOR
DC OUTPUT CABLE CONNECTOR
4
2
1
1
6
AC OUTPUT CABLE CONNECTOR
CRIMP FOR BATTERY AND DC OUTPUT CABLES
CRIMP FOR AC INPUT AND AC OUTPUT CABLES
RING TERMINAL FOR AC INPUT AND AC OUTPUT CABLES
TEMP SENSOR/ACCESSORY CABLE CONNECTOR
FAN CABLE CONNECTOR
CRIMP FOR TEMP SENSOR/FAN/ACCESSORY CABLES
DESCRIPTION
RECEPTACLE HOUSING, 4 POSITION, SINGLE ROW
RECEPTACLE HOUSING, 10 POSITION, DUAL ROW
RECEPTACLE HOUSING, 8 POSITION, DUAL ROW
RECEPTACLE HOUSING, 4 POSITION, DUAL ROW
FEMALE TERMINAL, TYPE 45750, FOR 16 AWG WIRE
FEMALE TERMINAL, TYPE 45750, FOR 18 AWG WIRE
RING TERMINAL, INSULATED, FOR 18 AWG WIRE
CONNECTOR HOUSING, 4 POSITION, SINGLE ROW
CONNECTOR HOUSING, 2 POSITION, SINGLE ROW
FEMALE TERMINAL, TYPE 71851, FOR 22-24 AWG WIRE
MFG
MOLEX
MOLEX
MOLEX
MOLEX
MOLEX
MOLEX
MOLEX
MOLEX
MOLEX
AMP
MFG PN
39-01-4040
39- 01-2100
39- 01-2080
39- 01-2040
457503111
457501111
54774-2
50-57-9404
50-57-9402
16-02-0102
ITEM
SERIES 451 MATING CONNECTOR PART NUMBERS
SYSTEM I/O
Diagram of Connections

17 Amico Accessories Inc.
+
-
1
2
+
-
1
2
+
-
1
2
+
-
1
2
RED #16 AWG
RED #16 AWG
RED #16 AWG
RED #16 AWGRED #16 AWG
BLK #16 AWG
BLK #16 AWG
BLK #16 AWG BLK #16 AWG
BLK #16 AWG
+
-
SERIES 400
CONTROLLER BATTERY
B A TT+
B A TT-
+
B A TT-
RED #16 AWG
SERIES 400
CONTROLLER
RED #16 AWG
BATTERY
RED #16 AWG
-
BLK #16 AWG
RED #16 AWG
BLK #16 AWG
BLK #16 AWG
B A TT+
BLK #16 AWG
-
BATTERY
+
RED #16 AWG
BLK #16 AWG
ANDERSON
SB50
ANDERSON
SB50
ANDERSON
SB50
ANDERSON
SB50
RECOMMENDED SINGLE BATTERY CONNECTION
RECOMMENDED DUAL BATTERY CONNECTION
AC Power Input
AC Input Power is applied to the system through a 4-position Molex Connector. A #6-32 threaded hole is provided for
chassis ground termination. AC Power is assumed to be consistent with standard wall power [European or U.S.]. The
screw should not be longer than five sixteenths of an inch (5/16”) long and not powder coated.
The AC Input Voltage earth ground complies with bonding impedance requirements when it is attached to a standard
AC wall outlet. There is no required or provided earth ground bonding when the end-use system is mobile.
The 400 Series Controller does not require external EMI Filtering to meet UL 60601 standards. However at the system
level, it may be beneficial to use an AC Line filter at the entrance to the system enclosure when there are other active
electronic devices within the enclosure. The suggested part is Corcom 10EBH1 or equivalent.
Batteries
Batteries are connected to the power system through a 10-position Molex Connector. Multiple battery installations
must be connected in a “parallel” configuration thereby providing 12 volts to the system.
Refer to the system I/O diagram for connector pin out. Each pin is rated for 10 Amps maximum and 16 AWG wire is
recommended. It is required that all three conductors be used in the battery harness for charging current higher than
15 Amps. Maximum battery charge current for the system is 25 Amps shared over all three conductors. Although
smaller batteries may not need all three conductors, it is still recommended all be used for best performance. It is also
recommended that the configuration minimize wire length and other added resistive effects. It is further recommended
that the resistive effects of wire length or other elements are balanced between batteries.
The wire harnesses to the battery must be tightly secured to the battery terminals using the torque recommended by
the battery manufacturer. Caution: Insufficiently secured DC power connections may result in compromised safety of
the battery, the wiring, the controller, and the system. Required battery fuse replacement is the mini-blade fuse 32V,
30A by LittelFuse part number 0297030.WXNV.
Several recommended battery connections are described in the diagrams below. Please note wire gauge and
connection should be in accordance with UL ratings and specifications:
Section 4: System Connection
Battery Connection Diagrams

www.amico.com 18
Section 4: System Connection
+
-
1
2
+
-
1
2
+
-
1
2
+
-
1
2
RED #16 AWG
RED #16 AWG
RED #16 AWG
RED #16 AWGRED #16 AWG
BLK #16 AWG
BLK #16 AWG
BLK #16 AWG BLK #16 AWG
BLK #16 AWG
+
-
SERIES 400
CONTROLLER BATTERY
B A TT+
B A TT-
+
B A TT-
RED #16 AWG
SERIES 400
CONTROLLER
RED #16 AWG
BATTERY
RED #16 AWG
-
BLK #16 AWG
RED #16 AWG
BLK #16 AWG
BLK #16 AWG
B A TT+
BLK #16 AWG
-
BATTERY
+
RED #16 AWG
BLK #16 AWG
ANDERSON
SB50
ANDERSON
SB50
ANDERSON
SB50
ANDERSON
SB50
RECOMMENDED SINGLE BATTERY CONNECTION
RECOMMENDED DUAL BATTERY CONNECTION
Temperature Sensors
The system configuration, one or two SLA batteries, will determine if one or two temperature sensors are necessary.
Lithium Iron Phosphate batteries do not require temperature sensors. The temperature sensors are connected to the
negative post of each battery, as shown in the figure below.
NOTE: For single battery connections, the “Bat 1” temperature sensor must be used; for dual battery connections,
a “Bat 1” and a “Bat 2” temperature sensor must be used. The sensors are addressed uniquely thereby providing
access to each battery temperature independently. Failure to install Bat temperature sensors if an SLA battery
chemistry is selected will cause the system to Shut Down after 5 minutes.
Button Terminal Temperature Sensor Mount Figure
Black Negative Battery Cable
Battery Button Terminal
(Negative)
Temperature Sensor
(Black Side Faces Up)
3/4" Washer
Lock Washer
Washer
Bolt
Battery Connection Diagrams

19 Amico Accessories Inc.
The battery temperature sensors are controlled using an I2C bus. Each item is specifically addressed therefore the
connection to each can be through any I2C connector. In the above diagram, therefore, any I2C connection can be
interchanged with any other without any functional effect.
Host Computer
The host computer connects to the Power System through a standard USB connection. When connecting the system to
the host computer it may take up to 30 seconds for Windows to recognize the device, allow drivers to install, and then
begin communication. If this does not occur, please contact the manufacturer.
It is recommended to run the GUI software on the host PC to take advantage of the battery management features. In
addition, using any available power saving features on the PC and Monitor may improve battery run times significantly.
Small PCs and All-in-one PCs
Small PCs and All-in-One PCs are compatible with the 400 Series Controller. Small PCs and All-in-One PCs provide the
best economic space and best power consumption.
Laptop
If the host computer is a laptop and its associated internal laptop battery is left installed, the 400 Series may not
operate correctly. The time estimations for charging and discharging will be effected by the requirement to charge and
discharge the laptop battery.
While calling for charge current to charge the laptop battery, the 400 Series System will over-estimate the current
necessary to support the loads (which include the battery) attached to the system and will not factor in the reduced
current needed after the laptop battery reaches full charge. This will result in a significant error during the discharge
cycle as the laptop battery requires intermittent recharging from the 400 Series System batteries.
If the laptop battery is in place, the 400 Series System will estimate the time remaining to discharge accurately. However
during charge the presence of the laptop battery will affect the 400 Series System ability to predict charge time due to
the unanticipated draw from the laptop battery.
It is strongly recommended that the user remove the laptop’s battery prior to use with the 400 Series System. The time
available to the PC is unchanged since the 400 Series System battery depletion will be similar regardless of the laptop
battery’s presence; the system will require the 400 Series System batteries to be recharged regardless of the state of the
laptop battery.
The 400 Series System will gracefully turn off the laptop without the presence of the laptop battery when the batteries
are nearing full depletion. The laptop battery is not necessary for added protection of the user’s data.
Remote Display
The remote display (RUI) uses a standard Category 5 connection (CAT5) to the system; straight through type; not patch
type. This is used for the convenience of a standard cable; the system is not compatible for use within a networked
system.
DC/AC Output Power
For Models 401 and 451, DC Output Power is provided through an 8 position Molex connector. Refer to the System I/O
diagram above. There are two 12 VDC outputs and returns; both must be used to split the load if current will exceed
10 Amps. There is also a 19.5 VDC output and a low power 5 VDC/ 2 A output. The combined total power for all three
outputs is 200 watts. Outputs may be used simultaneously as long the total power is not exceeded.
Section 4: System Connection