CASE STUDY | Low Voltage | On-board | Sungwoo Motors, South Korea

About SUNGWOO MOTORS

SUNGWOO MOTORS is a Korea-based original equipment manufacturer (OEM) of HYUNDAI MOTOR Company for service vehicles, such as ambulances, camping cars and limousines. SUNGWOO MOTORS is also engaged in the provision of vehicle components, distributing its products to Hyundai Motor Company the and recreational vehicle (RV) market.

This dynamic, solutions focused company has around 70 employees and produces around 1300 ambulances, 300 Camping cars and 1500 service vehicles for HYUNDAI every year.

The challenge

SUNGWOO MOTORS was appointed to provide 8 fully equipped ambulances for use at the South Korea Winter Olympics. And just like the athletes competing in the Olympics, medics supporting Olympians from around the world needed to deliver a great performance should medical assistance be required.

The Hyundai vehicles are packed with vital and potentially life-saving equipment, all of which are powered by a secondary service battery. SUNGWOO MOTORS needed to ensure that this critical service battery was always sufficiently charged and regularly maintained, they also wanted to supply the ambulances with a guaranteed 5-year battery life. To meet these requirements SUNGWOO MOTORS needed an on-board charging solution that delivered power when the vehicle was parked up in the depot and also whilst it was on the move, drawing power from the alternator.

“Any charging solution we specified needed to ensure that equipment worked whenever the crew needed it.”
- Mr. CY Hwang, R&D Director, SUNGWOO MOTORS

The ambulances were fitted with a Euro 6 smart ECU (Engine Control Unit) controlled alternator to increase fuel efficiency and lower emissions. Smart alternators deliver a variable out- put and are shut off when they’re not needed. Any solution needed to ensure power was delivered to the service battery at all times whilst the vehicle was on the move. CTEK was asked by SUNGWOO MOTORS to specify a complete charging solution.

THE SOLUTION

To deliver power whilst on the move, CTEK specified the D250SA DC-DC battery charger and the SmartPass 120, an on-board power management system. Combined together these two market leading products deliver a whopping 140A of power to the service battery so the battery could be charged even on short journeys. These standalone units are easy to install and there is no need for additional diodes or VSR relays, so it’s a cost-effective solution too.

An XS25000 25A mains powered charger, was also specified to deliver power to the vehicle if it was parked in the depot or anywhere else where there was access to mains power.

The combination of these chargers, would result in 100% charge and maintenance of the service battery, increasing battery efficiency and guaranteeing performance.

CTEK worked with SUNGWOO MOTORS on the project from initial concept, field testing and through to implementation, delivering technical training to installers too.

ABOUT THE D250SA

Compatible with Smart Alternators, the D250SA is a 20A DC/DC on board charging system that will maximise the performance and increase the life of the service battery. 

Drawing its energy from the vehicle alternator, this small yet powerful charger continuously determines the needs of the service battery, delivering a safe, powerful charge whilst making sure that it doesn’t damage the alternator or overcharge the battery. 

ABOUT THE SMARTPASS 120

The SmartPass 120 is a fully automatic 120A power management system that distributes power between the starter battery, the service battery and on-board equipment, without the need for traditional diodes or VSR relays. It features Current Source priority to prioritize power to critical equipment directly from the alternator, as well as a built in under voltage protection for the service battery and a useful Start Assistance, that uses power from the service battery to start the engine if the starter battery is flat.

ABOUT THE XS 25000

The XS 25000 is a 12V, 25A smart mains battery charger. This battery charger and maintainer has an extended five pulse per second de-sulphation stage providing maximum opportunity to fully restore battery capacity. The CTEK XS 25000 will revive, charge, condition and maintain the service battery and can be connected indefinitely if required, without risk of over or under-charging the battery. 

All three specified units use patented CTEK technology to exactly meet the needs of the service battery. They deliver a really ‘clean’ charge so it’s safe for the vehicle too - there isn’t any risk of disruption to the vehicles ECU settings. 

The unique and advanced charging cycle in both the D250SA and the XS 25000 means they are fast, effective and will charge the leisure battery in the shortest possible time.

BENEFITS

Initial comparative field tests (against an existing Sungwoo onboard charging system) and feedback following the roll-out of the new system demonstrated the benefits and effectiveness of the system

- Complete battery separation between starter battery and service battery so that critical equipment is guaranteed.
- Service battery is charged to 100% - reducing the risk and hassle of a flat battery and loss of power for important vehicle devices.
- Improved SoC of the service battery during daily activities:

- Additional maintenance of the vehicle starter battery - once the service battery has been fully charged, the D250SA will also deliver an additional maintenance charge of both the leisure battery and starter battery.
- Automatic Emergency Start function to get the vehicle moving if the starter battery is flat.

It will also reduce the risk of battery related warranty returns for SUNGWOO MOTORS, support their commitment to customer service and maintain the strong relationships that they have with their customers.

Sungwoo Motors factory