Sure Power 3104 User manual

PROPRIETARY
THIS DRAWING IS THE PROPERTY OF SURE POWER INC. and shall not be
copied, reproduced, lent, or disposed of, nor used for any purpose other than
that for which it is specifically provided without the written permission of
SURE POWER INC.
MODEL NO: 3104
INTERCONNECT CONTROLLER
12V,300A
SPECIFICATION OUTLINE
12
006
1
001 3875 PRODUCTION RELEASE 6/19/03 BF
F04-019-006
REV ECO REVISIONS
DESCRIPTION DATE BY
PROJECT ENGR
ENGR MANAGER
SALES/MRKTG
DRAWN
DRAWINGS IN THIS DOCUMENT ARE NOT TO SCALE
INTERPRET GEOMETRIC DIMENSIONS AND
TOLERANCING PER ASME Y14.5-1994
A
PPROVALS DATE
TOLERANCES ARE: .X
X
.XX
X
± .03
± [X.
X
[X.X
X
± 0.8
± ] ]
UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN INCHES
[
MM
]
REV DRAWING NO.CAGE CODE NO.
55
1
56
SIZE
A
SCALE: NONE FILE:
TITLE
SHEET OF
002 3949 ADD TERMINAL LABEL TO PART 11/19/03 BF
003 4783 ADD DIMENSION TOLERANCES 6/15/06 BF
3104
3104-006
005 4907 Connect 12V Alarm to Batter
y
+ Side 4/18/07 JT
004 4787 ADD HEATSHRINK TO TERMINAL POST 7/7/06 BF
006 5343 Add Disconnect Volta
g
e
(
VD
CO
N
)
Note 12/10/08 JT
JZD 12/4/08
3104
INTERCONNECT/CONTROLLER

122
- SEE SHEET 1-
REV ECO REVISIONS
DESCRIPTION DATE BY
REV DRAWING NO. CAGE CODE NO.
55
1
56
SIZE
A
SCALE: NONE FILE:
TITLE
SHEET OF
F04-019-006
006
MODEL NO: 3104
INTERCONNECT CONTROLLER
12V,300A
SPECIFICATION OUTLINE
3104
3104-006
OVERVIEW
The 3104 is a 300A integrated solenoid and control module for 14V systems. The unit features a bi-stable solenoid that can
remain open or closed without a coil current draw. The unit can be utilized in four different modes of operation based on settings
of jumpers external to the unit.
1. Unidirectional Battery Separator:
This mode is used to charge two batteries from one power source. In this mode, the unit monitors the “main” battery. When
the main battery voltage is above the connect threshold, the solenoid connects the two batteries together. When the main
battery voltage drops below the disconnect threshold, the solenoid is opened.
In this mode, the connect threshold is usually set to a voltage that is only reached when the charging system is operational.
This will cause the solenoid to only close when the charging system is operational, charging both batteries.
The RCM pin must be grounded in a battery separator application.
The disconnect voltage may be set one of two ways:
a. Near the full charge resting voltage of the batteries. This will cause the solenoid to be opened shortly after the
engine is stopped. This will preserve 100% of the starting battery capacity for engine cranking.
b. Below the full charge resting voltage of the batteries. Setting the disconnect voltage lower will result in delaying the
opening of the solenoid until some of the charge is removed from the starting battery. This will result in a longer life
in the auxiliary battery and the ability to carry the auxiliary load for a longer period of time.
In this mode, the manual override can be used to provide jump-starting from the auxiliary battery.
2. Bi-directional Battery Separator:
This mode is used to charge two batteries from two sources. In this mode, both batteries are monitored. If either battery is
above the connect threshold the unit will close the solenoid. If the batteries are below the disconnect threshold the unit will
open the solenoid. The voltage settings for the bi-directional battery separator remain the same as the unidirectional battery
separator.
The RCM pin must be grounded in a battery separator application.
3. Low Voltage Disconnect (LVD):
In this mode, the unit monitors the battery voltage. When the battery voltage drops below the disconnect voltage, the unit
opens the solenoid, removing power from the load. The solenoid closes, powering the load, when one of the following
conditions is met:
a. The ISW input is grounded momentarily.
b. If the RCM pin is grounded and the battery voltage is above the connect threshold.
c. If the engine is running and Lockout feature is applied (see DISCONNECT LOCKOUT description).
In this mode, the connect threshold is usually set to a voltage that is only reached when the charging system is
operational. The disconnect threshold is set to a voltage that leaves sufficient charge in the battery to crank the
engine.
4. Isolator / Interconnect Mode:
This mode is used to charge two batteries from one power source. This mode
provides the advantages of both the isolator charging system and the battery
interconnect.

123
- SEE SHEET 1-
REV ECO REVISIONS
DESCRIPTION DATE BY
REV DRAWING NO. CAGE CODE NO.
55
1
56
SIZE
A
SCALE: NONE FILE:
TITLE
SHEET OF
F04-019-006
006
MODEL NO: 3104
INTERCONNECT CONTROLLER
12V,300A
SPECIFICATION OUTLINE
3104
3104-006
UNIT CONNECTIONS
The unit has 12 connections, 10 through a locking header:
1. Start Battery connection:
This is the high current connection to the start / main battery. This connection is made directly to the solenoid. Ring terminal
sizing must accommodate the M10 lug on the solenoid. Product labeling refers to this as the START connection. The unit is
powered from the start battery connection or the auxiliary battery connection, drawing power from whichever has the higher
voltage. The voltage on this connection is compared to the voltage on the auxiliary battery connection to determine if the
solenoid closed as intended.
2. Auxiliary Battery/ Load connection:
This is the high current connection to the auxiliary battery (battery separator mode) or load (LVD mode). Ring terminal sizing
must accommodate the M10 lug on the solenoid. Product labeling refers to this as the AUX connection. The unit is powered
from the start battery connection or the auxiliary battery connection, drawing power from whichever has the higher voltage.
The voltage on this connection is compared to the voltage on the start battery connection to determine if the solenoid closed
as intended.
3. Locking header connector:
Start Battery (SBAT) – Pin K
This connection is the sense connection for monitoring the start / main battery voltage. This connection is referred
to as the SBAT connection. This connection is used in all of the operational modes to determine solenoid
operation.
Auxiliary Battery (ABAT) - Pin J
This connection is the sense connection for monitoring the auxiliary battery voltage. This connection is referred to
as the ABAT connection. This connection is used in the bi-directional mode to monitor the auxiliary battery voltage.
Unless Pin A of the connector is grounded, this input is ignored.
Lockout (LOCK) – Pin B
This is the disconnect lockout input. To close the solenoid if it is open and prevent the solenoid from opening,
ground this input.
Re-Connect Mode Jumper (RCM) – Pin D
This pin must be grounded in a battery separator application and for automatic reconnect in an LVD application.
This is the jumper to set the reconnect mode of the unit. With the RCM jumper left unconnected, the load can only
be reconnected by grounding the Switch input. With the RCM jumper connected to ground, the load will also be
reconnected if the voltage rises above the connect threshold for 2.5 seconds.
GND - Pin H
This is the unit ground connection.
Switch input (ISW) - Pin G
This is the input for operator override. To toggle the solenoid to the opposite state, ground this input. This
connection is referred to as the ISW input.
LED output - Pin F
This is the LED drive output. This output indicates the status of the
unit. This output is a 20mA ±5mA current source. The LED is
powered when the solenoid is open and off when the solenoid is
closed.

124
- SEE SHEET 1-
REV ECO REVISIONS
DESCRIPTION DATE BY
REV DRAWING NO. CAGE CODE NO.
55
1
56
SIZE
A
SCALE: NONE FILE:
TITLE
SHEET OF
F04-019-006
006
MODEL NO: 3104
INTERCONNECT CONTROLLER
12V,300A
SPECIFICATION OUTLINE
3104
3104-006
Delay Mode Jumper (DMD) - Pin E
This is the jumper to set the length of the disconnect delay. Left unconnected this terminal sets a 10s disconnect
delay. This terminal sets a 5 minute delay when connected to ground. This input is only checked when power is
initially applied.
Alarm Output (ALRM) - Pin C
This output is for an optional alarm. The output will be pulled low and sinks current when the unit is in the delay
pending a solenoid open. The output remains low if the solenoid opens and turns off once the solenoid is closed
again. In LVD mode, the operator can either tie the other side of the alarm to the battery side or load side of the
solenoid to have the alarm remain on or shut off with the loads. This output is limited to 50mA ±5mA.
Bi-directional Mode Jumper (BMD) - Pin A
This is the jumper to set unidirectional or bi-directional mode. Left unconnected this terminal sets unidirectional
mode. Connected to ground this terminal sets bi-directional mode. This input is only checked when power is
initially applied to the unit.
FUNCTIONAL DESCRIPTION
Note: All values are approximate; see device specification section for exact values and tolerances.
When power is applied to the unit, the unit will default to the open state. The mode jumper inputs are read at this time. The unit
then operates in automatic mode.
AUTOMATIC MODE:
1. BMD pin not grounded:
If the BMD pin is not grounded, the state of the unit is dependent upon the voltage on the SBAT terminal. If the RCM pin is
grounded and the SBAT terminal remains above the connect threshold for 2.5s, the solenoid will be closed. If the SBAT
terminal remains below the disconnect threshold for 10s (DMD pin open) or 5 minutes (DMD pin grounded) the solenoid will
be opened. When the SBAT voltage is between the connect and disconnect thresholds, the solenoid will maintain it’s state.
2. BMD pin grounded:
If the BMD pin is grounded, the state of the unit is dependent upon the voltage of both the SBAT terminal and the ABAT
terminal. If the RCM pin is grounded and either the SBAT or the ABAT terminal is above the connect threshold for 2.5s, the
solenoid will be closed. If the SBAT terminal is below the disconnect threshold for 10s (DMD pin open) or 5 minutes (DMD
pin grounded), the solenoid will be opened. (Once the solenoid is closed, the two batteries should be equal in voltage.) If
both inputs are between the connect and disconnect thresholds, the solenoid will maintain it’s current state.
MANUAL MODE:
Grounding the ISW input toggles the state of the solenoid and switches the unit into manual mode. The unit will remain in the
new state for 75 seconds. At the end of 75 seconds, the unit returns to automatic mode. The falling edge (i.e. switch closing
operation) of the ISW input places the unit in manual mode; holding the ISW input at ground does not keep the unit in manual
mode. (Note: If the voltage is between the connect and disconnect threshold the unit will maintain the state it is in. It does NOT
revert to the state is was in before manual mode was entered.) The 75 seconds is measured from the last falling edge of the ISW
input to the solenoid operation. In the remaining seconds of the MANUAL MODE delay, the inputs are scanned and solenoid will
either close, open, or remain in the same state according to the default program.
DISCONNECT LOCKOUT:
A grounded input from an engine run source such as the oil pressure switch can be
connected to the Lockout input to provide a lockout for disconnects. Whenever the
Lockout input is grounded, the solenoid will close if it is open and will not open for
either low voltage or a ground signal on the Switch input. If the unit was placed in
MANUAL MODE before grounding the lockout pin, the 75-second delay must
timeout before lockout mode takes precedence. After the Lockout input is opened,
the unit returns to automatic mode.

125
- SEE SHEET 1-
REV ECO REVISIONS
DESCRIPTION DATE BY
REV DRAWING NO. CAGE CODE NO.
55
1
56
SIZE
A
SCALE: NONE FILE:
TITLE
SHEET OF
F04-019-006
006
MODEL NO: 3104
INTERCONNECT CONTROLLER
12V,300A
SPECIFICATION OUTLINE
3104
3104-006
LED OUTPUT:
The state of the unit is indicated by the LED output. The LED is off for solenoid closed and on for solenoid open. When a switch
is pending (voltage above connect threshold or below disconnect threshold, but 2.5s / 10s / 75s / 300s has not elapsed), the LED
output flashes at a 7 Hz rate.
Flashing of the LED indicates errors. The error modes are the same regardless of the operational mode.
ERROR MODE 1: If there is a failure in solenoid closure and there is >2V difference between the START and AUX connections
(indicating a failed closure and relay is open), the LED will blink at a 2 Hz rate.
ERROR MODE 2: If the solenoid drive lines are shorted, the LED will blink at a 1 Hz rate.
ALARM OUTPUT:
If the voltage remains below the disconnect delay for more than 5s, the alarm output is driven low. The output resets if the
voltage rises above the disconnect threshold before opening the solenoid. If the solenoid opens, the alarm will remain low until
the relay is closed. The ALARM output is driven with a solid tone until the solenoid operates.
ADDITIONAL FEATURES:
ERROR MODE 1
If the solenoid is intended to be closed and there is >2V difference between the START and AUX connections
(indicating a failed closure and relay is open), the unit will immediately re-close the relay. If the relay is unable to be
closed, the LED will blink at a 2 Hz rate.
ERROR MODE 2
If the unit senses a short circuit on either drive line, it will automatically remove and resend power to the respective
drive line for two more cycles. If the short is still present after the 3 cycles are exhausted, the LED will blink at a 1 HZ
rate. Once the short is removed, the ISW input can be utilized to put the relay in its intended state.
MECHANICAL SPECIFICATIONS:
Weight: 1.6 LBS (0.74Kg)
M10 Lug Installation Torque: 112.5 In-lbs, 12.71N-m

126
- SEE SHEET 1-
REV ECO REVISIONS
DESCRIPTION DATE BY
REV DRAWING NO. CAGE CODE NO.
55
1
56
SIZE
A
SCALE: NONE FILE:
TITLE
SHEET OF
F04-019-006
006
MODEL NO: 3104
INTERCONNECT CONTROLLER
12V,300A
SPECIFICATION OUTLINE
3104
3104-006
ENVIRONMENTAL SPECIFICATIONS:
Control module is encapsulated in epoxy, solenoid is hermetically sealed.
Characteristic Parameter Units
Operational Temperature Range -40 TO +74 °C
Storage Temperature Range -55 TO +74 °C
Humidity SAE J1455
Altitude SAE J1455 Note 1
Vibration SAE J1455 Note 1
Shock SAE J1455 Note 1
Note 1: Not validated at this revision, SAE J1455 represents design intent. Vibration and Shock have been validated on
similar product.
ELECTRICAL:
MAXIMUM RATINGS:
Maximum ratings establish the maximum electrical rating to which the unit may be subjected.
Characteristic Symbol Parameter Unit Notes:
Input Voltage VINMAX 16 V
Damage to solenoid MAY occur if repeatedly operated above 16V
Standoff Voltage VSO 50 V
Applies to START, AUX, SBAT, & ABAT terminals only.
Time at Standoff tSO Continuous V
Control is protected from continuous operation at 50V
Solenoid current IS,MAXC 300 A
Continuous
Solenoid current IS,MAXO 2400 A
Overload
Rupture current IS,RUPT 3000 A
Current above which solenoid may explode.
Electrical Isolation VISO 500 V AC
All terminals together with respect to ground.

127
- SEE SHEET 1-
REV ECO REVISIONS
DESCRIPTION DATE BY
REV DRAWING NO. CAGE CODE NO.
55
1
56
SIZE
A
SCALE: NONE FILE:
TITLE
SHEET OF
F04-019-006
006
MODEL NO: 3104
INTERCONNECT CONTROLLER
12V,300A
SPECIFICATION OUTLINE
3104
3104-006
ELECTRICAL CHARACTERISTICS:
Unless otherwise stated, conditions apply to full operational temperature range (-40°C TO +74°C) and full voltage range
(9V to 16V)
Characteristic Symbol MIN TYP MAX Unit Notes:
Normal Input Voltage VIN 9 16 V
Voltage range unit is guaranteed to function
within specification.
Minimum Input Voltage VINMIN 8.5 9 V
Proper solenoid operation not guaranteed
below 9V, but typically operates to 8.5V
Undervoltage Shutdown VUSD 8.3 9 V
Voltage at which unit will reset.
Input Low Voltage VINLO 0.7 V
Maximum voltage on input for processor to
recognize a ground condition.
Contact voltage drop VIOD 0.15 V
300A resistive load.
Contact life 50,000 Cycles 300A resistive load.
Connect Voltage: VCON 13.0 13.2 13.5 V
Disconnect Voltage: VDCON 12.5 12.7 13.0 V On models with suffix numbers, the suffix
specifies the disconnect voltage, e.g.
3104-125 has a 12.5V disconnect voltage.
Connect Voltage
Adjust Range VCONR 12 to 14 9 to 16 V Factory and Customer set range
Disconnect Voltage
Adjust Range VDCONR VCON-0.3
to
VCON-5 VCON
to
VCON-8 V Factory and Customer set range
Note: disconnect voltage tracks connect
voltage adjustment.
Quiescent Current IQUES 9 15 mA
Solenoid not switching, LED off, ALRM off,
ISW not grounded.
Solenoid drive current ISOLD 6.6 A
Solenoid drive time tDR 400 500 600 ms
LED drive current ILED 15 20 25 mA
LED output
compliance voltage VLEDC GND VIN-5 V Range of voltages that LED output current is
specified for.
ALRM current limit IALRM 45 50 55 mA

128
- SEE SHEET 1-
REV ECO REVISIONS
DESCRIPTION DATE BY
REV DRAWING NO. CAGE CODE NO.
55
1
56
SIZE
A
SCALE: NONE FILE:
TITLE
SHEET OF
F04-019-006
006
MODEL NO: 3104
INTERCONNECT CONTROLLER
12V,300A
SPECIFICATION OUTLINE
3104
3104-006
ELECTRICAL CHARACTERISTICS Continued…
Connect Delay tCD 2 2.5 3 s
Disconnect Delay
(short) tDDS 9 10 11 s
Delay mode jumper input open.
Disconnect Delay (long) tDDL 270 300 330 s
Delay mode jumper input grounded.
Manual Mode Delay tMD 65 75 85 s
Measured from last falling edge of ISW input
to solenoid operation.
Switch pending LED
flash rate fDFLSH 6 7 8 Hz
Delay to alarm output tALD 4 5 6 s
Delay from voltage drop below threshold until
alarm output signals.
Error Mode 1 voltage VERR2 ±1 ±2 ±3 V Voltage across solenoid to enter error mode 2.
Error Mode 1 flash rate fEFLSH1 1.8 2 2.2 Hz
Error Mode 2 flash rate fEFLSH2 0.9 1 1.1 Hz

129
- SEE SHEET 1-
REV ECO REVISIONS
DESCRIPTION DATE BY
REV DRAWING NO. CAGE CODE NO.
55
1
56
SIZE
A
SCALE: NONE FILE:
TITLE
SHEET OF
F04-019-006
006
MODEL NO: 3104
INTERCONNECT CONTROLLER
12V,300A
SPECIFICATION OUTLINE
3104
3104-006
ELECTROMAGNETIC COMPATIBILITY:
Radiated Immunity Test Level Notes:
Absorber Lined Chamber
150MHz to 14GHz 80V/m Ref. SAE J1113/21 Rev 10/94.
Stripline Test Method
10kHz to 150MHz 100V/m Ref. SAE J1113/23 Rev 9/95.
Transient Immunity Test Level Notes:
Inductive Load Switching ±600V Ref. SAE J1455, Section 4.11.2.2.2 Rev 8/94
Mutual Coupling ±300V Ref. SAE J1455, Section 4.11.2.2.3 Rev 8/94
Load Dump 100V Ref. SAE J1455, Section 4.11.2.2.1 Rev 8/94
Electrostatic Discharge
Immunity Level Notes:
ESD ±8kV direct
±15kV air Ref. SAE J1113/13 Rev 2/95. Meets class C to ±8kV contact
and air. Meets class B to ±15kV air.
Emissions Limit Test Level Notes:
Conducted Emissions Per Spec Ref. SAE J1113/41 Rev 7/95
Radiated Emissions Per Spec Ref. SAE J1113/41 Rev 7/95
All terminals protected against all combinations of reverse polarity conditions excepting reversal of one of the battery bank
polarities. (Solenoid is not current limited. Connecting battery banks of opposite polarity will damage solenoid).
Solenoid drive lines, LED output and ALRM outputs are protected from continuous shorts to ground.
Jumper inputs, ISW, and LOCK inputs are protected from connection to battery inputs.

1210
- SEE SHEET 1-
REV ECO REVISIONS
DESCRIPTION DATE BY
REV DRAWING NO. CAGE CODE NO.
55
1
56
SIZE
A
SCALE: NONE FILE:
TITLE
SHEET OF
F04-019-006
006
MODEL NO: 3104
INTERCONNECT CONTROLLER
12V,300A
SPECIFICATION OUTLINE
3104
3104-006
-+
(+)
+ -
(+)
(+)
-+ -+

1211
- SEE SHEET 1-
REV ECO REVISIONS
DESCRIPTION DATE BY
REV DRAWING NO. CAGE CODE NO.
55
1
56
SIZE
A
SCALE: NONE FILE:
TITLE
SHEET OF
F04-019-006
006
MODEL NO: 3104
INTERCONNECT CONTROLLER
12V,300A
SPECIFICATION OUTLINE
3104
3104-006
LED
INDICATOR
GND
LED
AUX
3104
RCM
SWITCHED LOADS
300A MAX
LED
INDICATOR
LED
SBAT
ABAT GND
ISW
3104
AUX
STRT
RCM
SPST N.O. MOMENTARY
CLOSE TO TOGGLE
ISW
DMD
LOCK
ENGINE RUN
SIGNAL
STRT
OPTIONAL
+
LOADS
UNSWITCHED
12V ALARM
ALRM
(+)
-
12V ALTERNATOR
CLOSE TO TOGGLE
SPST N.O. MOMENTARY
START
300 AMP MAX
(+)
AUX -
+
START
LOADS LOADS
AUX
ISOLATOR
3002
+
-START
REMOTE SENSE
TYPICAL APPLICATION
LOW VOLTAGE DISCONNECT
ISOLATOR PLUS INTERCONNECT APPLICATION
SOLENOID/CONTROLLER
12V ALTERNATOR
SBAT
SOLENOID/
CONTROLLER

1212
- SEE SHEET 1-
REV ECO REVISIONS
DESCRIPTION DATE BY
REV DRAWING NO. CAGE CODE NO.
55
1
56
SIZE
A
SCALE: NONE FILE:
TITLE
SHEET OF
F04-019-006
006
MODEL NO: 3104
INTERCONNECT CONTROLLER
12V,300A
SPECIFICATION OUTLINE
3104
3104-006
UNIT DIMENSIONS
NOTE: Connection diagram is oriented as facing relay side on unit.
1.180 [29.97]
3.25 [82.6]
MAX
(.28 [7.1])
3.63 [92.2]
MAX
3.56 [90.4] 3.63 [92.2]
MAX
(3.08 [78.2])
(2.53 [64.3])
2X M10 x 1.5 HARDWARE
(Ø.39 INCH THREAD)
2X Ø.28 [7.1]