This interactive publication describes Scotty AI 1500
Travel the World, Live in a World, Without Consuming the Earth
SCOTTY AI 1500
INSTALLATION & OPERATION MANUAL FWD 5 m to SCOTTY 1500 12-48 V
This is completely different to Scotty Ver. 1 Wiring
Travel the World, Live in a World, Without Consuming the Earth
• This manual contains important instructions that shall be followed during installation and maintenance. • Danger of explosion from sparking and danger of electric shock.
SAFETY
GENERAL SAFETY REGULATYIONS • Please read the safety instructions below before installing and using the Scotty AI 1500 to avoid risks of fire, electric shocks, personal injuries or equipment damage. • This product is designed and tested in accordance with international standards.The equipment should be used for its designated application only and in accordance with the specified operating parameters. REGULATIONS FOR SAFE INSTALLATION • For electrical work, follow the local national wiring standards, regulations and these installation instructions. • Install the product in a heatproof environment. Ensure therefore that there are no chemicals, plastic parts, curtains or other textiles, etc. in the immediate vicinity of the equipment. • It is normal for the Scotty AI 1500 to get hot during operation. Keep any objects that are heat-sensitive away.
• Never install or use the product at sites where gas or dust explosions could occur. • Use flexible multi-stranded copper cables for the connections (UL: Class I; IEC: Class 5).
• The installation must include a fuse in accordance with the recommendations in the table Cable type recommendations. • Always remove all dirt and paint from chassis connection points. Apply the correct torque when fastening the connection bolts.
The alternator temperature sensor is essential for the operation of the Scotty Al. Attach the alternator housing as close as possible to the regulator, but not on it.
GND
AT FIRST CONNECT THE SCOTTY GND CONNECTION POINT TO THE CHASSIS ! NEVER DISCONNECT
Connect Harness Wiring in this order: 1. Connect Alternator Temp (black) to Scotty AI ground. 2. Connect the alternator Temp. (red) to the Alt Temp positive wire in the wiring harness. 3. Connect the alternator voltage sensor wire (fuse at 3 A) to the Alt + wire in the wiring harness.
Fuse: 150 A for 70 mm² - 12V Fuse: 80 A for 25 mm² - 48V
24-48 V+
Alternator Temperature SenseWire to harnass is a MUST AlternatorVoltage SenseWire to harnass is a MUST
12 V+
48 V Side: Single 25 mm² to 48V Battery
Additional Single 35 mm²
4.
The feature ‘Start or Stop charging’ is used when a high or low voltage signal is needed to stop charging. Otherwise coil and reserve. CAN Hi (if connected to CAN BMS; if there is no CAN BMS do not connect). CAN Lo (if connected to CAN BMS; if there is no CAN BMS do not connect). The Enable Wire feeds the microprocessor and can be 12 V or 24 V, but NOT 48 V.
Single 35 mm² to chassis
Single 70 mm²
5.
Additional Single 70 mm²
CAN Bus connection is preferred
6.
STARTER BATTERY
7.
Canopy 12V Power and/or Anderson Plug rear (fuse to match the cable size)
INSTALLATION 1. Have your High Side 24 V or 48 V (HS) batterie connected and the isolator applied so there is no power connection. Connect the 12 V Low Side and the ‘Enable Wire to 12 V Side’. A green flashing LED starts flashing. No Power will flow as no 24 V or 48 V battery is connected to HS. 2. Open phone/tablet/laptop to WiFi > scan> connect to ‘Scotty XXXX’ SSID. The initial password is either 12345678 or on newer versions Scottyai@0 (capital S) . You can change the password later. 3. Once connected, the ‘wheel connection indicator may still be turning’ as there is no internet. Go to the browser (we use Chrome) and type in: 172.24.24.1. Save this page to your home screen for future easy use. Check the values on the status page. 4. You are ready to go. Just turn on the 24 V or 48 V battery on the HS to operate. Apply a voltage greater than 13 V and up to 125 A of current to the Low Side (LS), which will then charge a 24 V or 48 V battery on the High Side as a maximum of 60 A for a 24 V battery at 28 V, or 30 A for 48 V battery at 52 V. OPERATION • ‘Soft’ puts the lowest load on the 12V Power Supply. • Turn Scotty AI ‘Off’ and select ‘Soft’ for the lowest load setting. • Go to ‘Medium’ for first-time users who are unsure. • Go to ‘Hard’ to drive the maximum power from Low Side. THINGS TO KNOW/CHECK Low Side Low Side Current to High Side High Side HS Current to Low Side Temperature of Power Board Minimum 12.0 V-DC 10 A 25 V-DC 5 A Minimum 10°C Maximum 1 5.0 V-DC 125 A Set Point Used for Power Conversion LS to HS 12.8 V-DC (set to Maximum) None Set Point Used for Power Conversion HS to LS 12.6 V-DC
54 V-DC 30 A Max at 54 V 60 A Max at 28.8 V 90°C Operating 100°C Turns off. 15.0 Voltage DC
Enable Power to Microprocessor External Temp Sensor on Alternator CAN
12.0 Voltage DC
None
The Status section shows actual time performance. It also shows the power loss in Watt for the Low Side and battery side of CAN BMS. Most importantly, the dynamic text shows why Scotty AI is not running.
140°C
10°C
Set to 100°C
250 baud SMA/Lux. Protocol Stand J1939
Sa ery Pty Ltd. • ABN: 87 624 588 807 • 45/8 Distribution Court - Arundel - QLD 4214 - Australia (07) 210 22 55 3 • www.sa ery.com • sales@sa ery.com
Travel the World, Live in a World, Without Consuming the Earth
SCOTTY AI TROUBLE SHOOTING INSTRUCTIONS & DIAGNOSIC PROCEDURE
When Scotty AI is not charging or performing as expected, scroll to the bottom of the main page and read the reported fault. The figure shows a list of failures on the main page. • After reading, goto: Potential Solutions Guidance to understand what the fault means. • The following text shows an Enumeration list of Fault Problems and possible Solutions. ‘Feature In’ Activated: The designed feature allows the receipt of stop charge requests from the house battery when the CanBus connection from the battery management system (BMS) is not in use. • It is recommended to verify the condition of the house battery; • If this feature is not required, you can disable it from the system settings. ‘Inverted Feature In’ Activated: This functionality is similar to the 'Feature In' feature but with an inverted operation. • It activates when it detects a 0 V signal in the 'Feature In' wire. • It is recommended to verify the condition of the house battery; if this feature is not required, you can disable it from the system settings. If this is selected and nothing is connected to the feature-in, Scotty will naturally stop! HS (High Side) battery preventing charge: A high-side battery preventing charge means that the house battery BMS is not accepting a charge, which may suggest that the Battery is already fully charged. • However, it is also possible that there may be underlying issues with the Battery's health. • Therefore, we recommend thoroughly checking the house battery's condition to ensure optimal functionality. Alternator current limit is configured to 0: The alternator current limit pertains to the maximum current drawn from the alternator. • The limit is currently set to zero, indicating that no charging is taking place. • To modify this setting, please navigate to the 'Tuning page' where you can adjust the alternator current limit to the desired level. Alternator temperature protection is active: The current indication is that the alternator is overheated, so you cannot use it now. • If the alternator's temperature is not high, there is a possibility that the temperature probe may have become disconnected. Therefore, we recommend checking the wiring to ensure it is properly connected. • Most Engines run around 90ºC under the engine bay, but some vehicles go as high as 105ºC. • We recommend increasing it to 120ºC in this case. HS Charge Voltage is reached: Based on current readings, the high-side battery voltage has reached the maximum allowable charge voltage. • To modify this setting, please access the designated 'Tuning page.' • However, we strongly advise referring to the battery manufac- turer's specifications before making any changes.
HS Charge Voltage is reached: Based on current readings, the high-side battery voltage has reached the maximum allowable charge voltage. • To modify this setting, please access the designated 'Tuning page.' • However, we strongly advise referring to the battery manufactur- er's specifications before making any changes. An Error Occurred: We suggest checking for error messages, which may indicate that the HS or LS terminal is not adequately connected to the Battery. • To begin troubleshooting, we recommend inspecting the fuses and isolators and ensuring they function correctly. Voltage Sense Wire disconnected: The current indication suggests that the sense wire is not detecting sufficient voltage. • It may be due to a disconnected wire or a depleted starter battery. • If the cause of insufficient voltage is a depleted starter battery, it may not be possible to charge it via the current system. In this case, we recommend connecting an external charger to increase the starter battery voltage to an acceptable level.
Sa ery Pty Ltd. • ABN: 87 624 588 807 • 45/8 Distribution Court - Arundel - QLD 4214 - Australia (07) 210 22 55 3 • www.sa ery.com • sales@sa ery.com
Travel the World, Live in a World, Without Consuming the Earth
TROUBLE SHOOTING CONTINUED... AND DIAGNOSTIC PROCEDURE
CAN Bus Signal Lost: The current indication suggests that the system may have lost its connection, as it requires a functioning CanBus system to operate even when not connected to a CAN Bus battery. • We recommend checking the CAN-H and CAN-L cables and performing a power cycle to resolve this issue. HS Battery is in Float Mode: • Based on current readings, it appears that the high-side battery float charge mode. To modify this setting, please access the designated 'setting page.' • However, we strongly advise referring to the battery manufac- turer's specifications before making any changes. Idle Setting Off: The current configuration appears to be in the Prevent charging mode because Scotty AI is turned off. • To modify this parameter, please access the main page and adjust the 'Idle' settings accordingly. The Car Engine is Off: The system thinks the car engine is off, so there is no charge. • Please note that the system has a less-than-minute delay in changing states. HS Battery Preventing Discharge: High Battery-preventing discharge means that the house battery BMS is not accepting a discharge, which may suggest that the Battery is already fully discharged. • However, it is also possible that there may be underlying issues with the Battery's health. • Therefore, we recommend thoroughly checking the house battery's condition to ensure optimal functionality. The Car Engine is On: The system thinks the car engine is on, which means no discharge. • Please note that the system has a less-than-minute delay in changing states. HS Min Discharge Voltage is reached: Based on current readings, the high-side battery voltage appears to have reached the minimum allowable discharge voltage. • To modify this setting, please access the designated 'setting page.' • However, we strongly advise referring to the battery manufac- turer's specifications before making any changes. LS (Low Side) Load is Low: Based on the current readings, there is an insufficient load connected. • We recommend checking the camping voltage and LS voltage to ensure the system's proper functioning. SCOTTY DIAGNOSTIC PROCEDURE IN CASE OF
If all the above is correct, do the following: • Run the engine at cruising speed. • Watch the data on the Status Page. • Note the LS alternator Voltage sense. If it is above 12.8 V, then the alternator is producing power to match the load. Take a screenshot of this status page to keep a record of the LS alternator Voltage sense. • Go to the Starter battery. • Measure the voltage on the starter battery accurately. • Compare this to the Voltage on the screenshot. The voltage difference x the current in A is the cable loss. So 13.2 V at the battery, and 12.8 V on the Scotty AI Status Page, means 0.4 V at, so say 100 A = 40 W. It is far too high, and you check the Negative path at first for a good connection. A good loss is 10-15 W. • Look at the Scotty Status page screenshot. If the number it shows is less than the above calculation, then the problem is the negative connection. • The negative wire from the Starter battery to the chassis in the engine bay must be bolted to an paint-free and clean metal surface. • The negative wire from the Target Auxiliary battery to the chassis must be bolted to an paint-free and clean metal surface on the chassis. • We do not recommend laying a separate negative wire, unless there is no chassis for example on a boat. The negative wire is generally the problem in 95% of all circumstances. If the negative connection is resolved and you still have insufficient power, it is one of these things: 1. The starter battery MUST be AGM or Lead/Acid. If it is Lithium, remove it and return it to the factory standard. 2. The alternator can not deliver enough power. 3. Engine or vehicle loads on a 12 V alternator are high. (Nissan Patrol has electric power steering and takes a lot of power, leaving little powerfor Scotty AI. Scotty AI takes power AFTER the vehicle loads, so they are not compromised. 4. Cable sizes are too small (both positive and or negative). 5. Target Battery(s) can not accept charging at a higher rate, either because they are high SOC or, the temperature has limited BMS, or the Lithium battery just has a lower charging rate (less expensive Lithium batteries.) 6. If charging a caravan from a vehicle with Scotty AI in it and a 7-10 m run at 48 V from Scotty AI to Lithium in the Van, then especially when solar is running, the voltage differential will not be as high and an expected charge rate is 1000 W at caravan 49-50 V and 2000 W when the expected caravan charge rate is 47-48 V. 7. Note that Scotty AI does not use the State of Charge in any calculation.We only use voltage for control. 8. State of Charge is a ‘Calculated concept’ and does not exist in any measured form. It is a calculation that may be reasonable after the batteries are 100% for 2 hours or so. If batteries operate in the 20-85% band repeatedly over a 1-2 week period, they will likely be around 50% max of their capacity, because the cells have not balanced. Safiery’s 48 V batteries actively balance between 90-95% SOC calc value.They are only fully charged when the calculation shows 100% SOC.
INSUFFICIENT POWER At first do the Auto-Tune: • Check the Tuning Page.
- Ensure that the Alternator Size is Correct? - Ensure that max Alternator Current is Correct? • Check the Status Page. • Ensure that Scotty AI is set to ’Hard’?
NEVER DISCONNECT THE NEGATIVE - NEVER
Sa ery Pty Ltd. • ABN: 87 624 588 807 • 45/8 Distribution Court - Arundel - QLD 4214 - Australia (07) 210 22 55 3 • www.sa ery.com • sales@sa ery.com
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