48540 - FlexMod Battery Isolator Controller Info Sheet

hot feed
Environmental Specifications
Characteristic
Parameter
Notes
-40° to +85°C
Operating temperature range
10A at 85°C
-40° to +185°F
Ingress protection
IP67
Humidity
0 to 90 %RH
Vibration
10-500Hz
Information on New Products from Cole Hersee Company
Per IEC 529
NEW
per SAE J1455
Shock
per SAE J1455
Thermal shock
per SAE J1455
Inductive transient
+/- 600V
per SAE J1455
Load dump
+ 150V
Per SAE J1455
Preserves starting battery voltage by isolating the
auxiliary battery when system voltage drops.
Electrical Characteristics
For vehicles with two batteries (or banks of batteries).
Unit is auto-ranging – it senses 12V or 24V systems.
Characteristic
Min
Typical
Max
Notes
Operating voltage (12V)
9V
12V
32V
Operating voltage is the system voltage.
Disconnect voltage
(12V 24V )
12.7
25.4
When voltage drops below 12.7V (25.4V), for 1 minute,
the isolator disconnects the solenoid/relay.
Connect voltage
(12V 24V )
13.2
26.4
When either of the battery banks rises above 13.2V
(26.4V) for 2 minutes, the isolator connects the
solenoid/relay.
Quiescent current
1mA
Load current
2mA
FlexMod Smart Battery
Isolator Controller
TM
Compact design (4"x3"x1") unit is waterproof, dustproof
and vibration-proof. Mounts anywhere on a vehicle, even
places where road-splash is a problem. Sealed to IP67
standard.
Turns any electromechanical solenoid or relay into
a Smart Isolator.
Cole Hersee part number
Circuit operating current.
48540
48540-01 includes harness
10A at 85°C
Overcurrent protection
Status light load
Features & Benefits
System will disconnect load after 1 sec. of excessive
current. Auto-recover after 10 sec.
15A
200mA
• Isolates main and auxiliary batteries when system voltage drops below 12.7V, and automatically reconnects
battery banks at 13.2V. Preserves starting power; eliminates downtime and jump starts due to dead batteries.
High side LED circuit
• Start assist feature provides boost to starting battery, when needed.
• Compatible with modern electronically controlled alternators (some diode Battery Isolators are not).
Smart Battery Isolator Controller eliminates false battery warnings created by diode isolators.
Accessories
• Status light output drives remote light, informing operator when banks are connected.
Momentary Switches
(for boost)
Cole Hersee Relays
58311-02
12805 Harness Kit
Installation Configuration
Order part number 48540-01 for
FlexMod Controller and harness
Optional
Status Light
Optional
Boost Switch
24117
Start
Battery
55020-04
Battery
Isolator
Controller
Aux
Battery
24143
Solenoid
20 Old Colony Avenue, Boston, MA USA 02127-2467 • 617-268-2100 • Fax 617-268-9490
See our interactive product catalog at www.colehersee.com
All specifications and information is subject to change without notice.
Copyright
Cole Hersee Co.
Copyright
Cole Hersee Co.
Rev 00
Rev 00
D-632
D-632
The FlexMod Family of Products
Common FlexMod Applications
TM
The FlexModTM family is a series of small,
robust electronic modules. They have two
inputs (one analog and one digital) and two
solid state outputs (one 10A, one 200mA)
that can be programmed to do almost
any job.
TM
Easy snap-in wiring with
standard sealed connector
Two outputs,
two inputs
Compact unit
3" x 4" x 1"
In-Cab
Radio
48540 Smart Battery Isolator Controller
The FlexMod unit monitors two battery banks and controls
one or more relays or contactors to make sure starting
power is protected by isolating the starting and auxiliary
battery banks. See Cole Hersee Hot Feed D-632.
48541 Electronic Voltage Sensing Relay & Timer
The FlexMod unit monitors both battery voltage and ignition
status, shutting down non-critical loads when the cutoff
voltage is reached, or at the set time after the ignition is
turned off. It is a timer and voltage sensor in one easy-toconnect unit. See Cole Hersee Hot Feed D-633.
Engineering
Panel Lights
Battery
• Rated for more than 1,000,000 on-off cycles – unit operates for the
lifetime of the vehicle. Solid state technology gives long life and low
maintenance.
• Provides overvoltage and overcurrent protection to every direct load
in that circuit– gives extra levels of protection.
LVD
Light Bar
Radios
Computers
LVD
LVD
• Small lightweight sealed design – Uses less space; mounts outside
or inside. Saves money by eliminating other hardware, and provides
better wire routing.
VSRT
FlexModTM Dimensions
Typical Application 3
Combined timer/voltage shutoff for police vehicles
Cordless
Light
Charger
Battery
48541 FlexMod VSRT combines two functions in one small unit
that opens up options for mounting in a small space, and simplifies
wiring and other components. The FlexMod VSRT protects starting
power with simultaneous sensing of time and voltage.
Optional
Relay
4.00 [101.6]
3.30 [83.8]
Internal
Lighting
1.01 [25.8]
0.27 [6.9]
Stereo
2.70 [68.6]
Smart Isolator
Typical Application 4
Smart charging system for boats
Ignition
Switch
LVD
Timer
0.62 [15.7]
Solenoid
Battery 1
8-Pin sealed
Deutsch connector
Typical Application 2
NFPA 1901 Load Manager compliance for fire
vehicles
Program the 48610 FlexMod LVD to combine low voltage warning
and/or single circuit load management in one unit. A second 48610
FlexMod LVD can manage other loads, and if mounted close to the
loads, will minimize wiring runs.
LVD
LVD
• Factory programmable unit is highly versatile: with a broad range of
presets available to match any special application.
Custom Electronic Modules
Do you have a specific electronic need that cannot be
easily met with one of our off-the-shelf modules listed
above? Do you need custom modules reliably built on
a tested hardware platform that is rugged enough for
commercial vehicles? Contact your Cole Hersee distributor
or representative and we will design a FlexMod to solve your
problem. Or contact Cole Hersee at [email protected]
Compartment
Lights
• Ultra low 1mA standby current means minimal battery drain –
especially valuable when vehicle is in storage or not in use.
Use the 48610 FlexMod LVD to protect starting power, and
save fuel (and fines!) by eliminating idling. By connecting safety
signboard (or other loads) to the LVD, the signboard can be safely
be allowed to run with the engine off, without the risk of a dead
battery. By connecting the horn or external alarm to the alarm circuit,
the vehicle operator will be warned of impending shutdown.
Flashlight
Charger
Horn
Radios &
Computer
Typical Application 1
Idle reduction for work vehicles
Battery
• Simple wiring, accepts snap-in standard sealed connector – unit is
easy to install. Part number with -01 suffix includes wiring harness.
• FlexMod is auto-ranging – automatically senses the voltage of the
system (12 or 24V) and selects the presets appropriate to that
voltage. Single unit means less stock and fewer SKUs. (Timer 48636
is dual voltage, 12 or 24V).
LVD
Microrelay
Sealed to IP67. Can be
mounted anywhere
48610 Electronic Low Voltage Disconnect
The FlexMod unit prevents the internal lights inside a
trailer from being left on and draining the battery. Vehicle
operator operates a momentary switch which turns lights
on, allowing safe operation inside the cargo compartment.
After 20 minutes the FlexMod flashes the lights and gives
the operator increasingly urgent warnings to either exit the
cargo compartment or reactivate the timer before the lights
go out. See Cole Hersee Hot Feed D-631.
LVD
External
Alarm
Ultra-low
standby current
48636 Electronic Timer for Interior Lighting
Traffic Arrow Board
Optional Relay
We have created some standard units (see
below) to meet specific application needs.
If one of these fits your needs, but you need
custom parameters, Cole Hersee can program
them into your FlexModTM at our factory.
The FlexMod unit preserves battery charge and protects
battery banks by automatically disconnecting loads when
battery voltage drops to a critical level. See Cole Hersee
Hot Feed D-630.
Cole Hersee designed these units to solve problems in many industries. Here are a few of the thousands of potential
applications. Contact us with your specific application requirements.
1.31 [33.3]
Battery 2
Bilge Blower
The 48540 FlexMod Smart Isolator Controller turns an existing
solenoid charging system into a smart system. The FlexMod
protects the alternator with priority charging, and allows shore power
connected to the house battery to charge the starting battery as well!
The 48610 protects batteries from damage.