Sterling Power BB12120 User guide

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Page 1

Part No:

BB12120

latest instructions

TEMP1

Temperature sensor

included

Sterling Power Products

Battery to battery charger

Handbook

BB12120

RoHS

compliant

www.sterling-power.com www.sterling-power-usa.com

Warranty (2 years return to factory)

Page 2

STERLING

POWER

INTRODUCTION

Introduction

02 03

Safety and Legal

04 05

Product Information

06 07 08 09 10

Troubleshooting

Dimensions drawing

(not to scale)

TABLE OF CONTENTS

Table of Contents | Dimension Drawing Welcome

Legal Guidelines / Warranty Statement Safety Guidelines

Basic Wiring Diagram / Installation Orientation Annotated diagram of unit face Annotated diagram of connector panel Front digital display functions 3 type of product activation

Troubleshooting and fault ﬁnding

Dimensions 270mm x 130mm x 73mm Weight 1.8Kg

CONTENTS PAGE

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STERLING

POWER

INTRODUCTION

Welcome

1.5KW BB

Product Code Understanding

WELCOME

Welcome to the Sterling Power Products Owners Handbook for the product BB12120, the 12V to 12V battery to battery charger (120A input rated).

Please take your time to read and fully understand the contents of this Handbook. These guidelines are developed with your safety and the products performance in mind and failure to follow or understand these guidelines may lead to voiding the product warranty or even leading to damage or injury for you or your setup.

If you are unsure of any step or guideline then please consider reaching out to Sterling via our web contact form or our phone service and we shall offer our support.

Thank you for joining the Sterling family and we hope to serve your travels well.

This battery to battery charger (Herein designated a BB) is a device typically installed between a starter battery (input) and a house / domestic / service battery (output). The BB is designed to utilise your alternator whilst your engine is running and transfer an optimised charge to your rear batteries. It is designed to work with vehicles (old / new) and (boats old / new). We recommend on all BB systems to have an alternator that is at least 20% more powerful than the BB input demand, so as to protect your alternator from being overworked.. This BB charges

both lead acid style batteries and lithium batteries.

Throughout this manual we will make reference to this product as the ‘BB’. The terms ‘12V’ or ‘24V’ are nominal voltage ranges, rather than specific voltages that you would see on the input or output.

To understand the Sterling product code system better and to therefore understand your new product better, the code for the BB naming system is simple. BB stands for Battery to Battery charger, the first two numbers are then the input voltage, and the remaining numbers are either the output voltage range and current input rating, or just the current input rating. Therefore, a Bb1224120 is a 12V to 24V 120A input charger.

Using this Handbook

Safety

12V to 24V Calculations

Specifications

This manual must be read throughout before installing this electronic device. Do not lose these instructions keep them safe. The most up to date instructions can be found on sterling-power.com. Please refer to the latest instruction manual before contacting Sterling. At Sterling, we endeavour to include all of the product information that we can think of into the manual.

Installation of the electronic device must be carried out by qualified and trained personnel only. The personnel must be familiar with the locally accepted guidelines and safety measures.

Your safety is Sterling’s top priority. Please follow all precautions to keep yourself safe. If you believe your unit requires repair then please contact Sterling or your distributor. Do not attempt to service the unit yourself.

This manual has been written predominantly with 12V nominal voltages in mind. If your input or output voltages on your BB model are 24V models or higher, simply multiply the numbers until they are in the correct threshold.

BB12120

Input voltage range 9V-16V Rated output power 110A at 13.8V Rated input current 120A Quiescent current 5mA Efficiency rating 92%-94%

Self recovering protections: under voltage protection input over voltage protection output over voltage protection over current protection charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan Dimensions 270mm x 130mm x 73mm Weight 1.8Kg

INTRODUCTION

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STERLING

POWER

SAFETY AND LEGAL

Warranty and Terms

LEGAL GUIDELINES

Your 100 % satisfaction is our goal. We realise that every customer and circumstance is unique. If you have a problem, question, or comment please do not hesitate to contact us. We welcome you to contact us even after the warranty and return time has passed.

Each product manufactured by Sterling Power comes with at least a 2 year limited factory warranty. Certain Products have a warranty period of time greater than 2 years. Each product is guaranteed against defects in material or workmanship from the date of purchase. At our discretion, we will repair or replace free of charge any defects in material or workmanship that fall within the warranty period of the Sterling Power product. The following conditions do apply:

- The original receipt or proof of purchase must be submitted to claim warranty. If proof cannot be located a warranty is calculated from the date of manufacture.

- Our warranty covers manufacture and material defects. Damages caused by abuse, neglect, accident, alterations and improper use are not covered under our warranty.

- Warranty is null and void if damage occurs due to negligent repairs.

- Customer is responsible for inbound shipping costs of the product to Sterling Power either in the USA or England.

- Sterling Power will ship the repaired or warranty replacement product back to the purchaser at their cost.

If your order was damaged in transit or arrives with an error, please contact us ASAP so we may take care of the matter promptly and at no expense to you. This only applies for shipping which was undertaken by our company and does not apply for shipping organised by yourself. Please do not throw out any shipping or packaging materials. All returns for any reason will require a proof of purchase with the purchase date. The proof of purchase must be sent with the returned shipment. If you have no proof of purchase call the vendor who supplied you and acquire the appropriate documentation.

Liability

Device Modification

To make a claim under warranty, call our customer care check telephone numbers on www.sterling-power.com or www.sterling-power-usa.com. We will make the best effort to repair or replace the product, if found to be defective within the terms of the warranty. Sterling Power will ship the repaired or warranty replacement product back to the purchaser, if purchased from us.

Please review the documentation included with your purchase. Our warranty only covers orders purchased from Sterling Power. We cannot accept warranty claims from any other Sterling Power distributor. Purchase or other acceptance of the product shall be on the condition and agreement that Sterling Power USA LLC and Sterling Power LTD shall not be liable for incidental or consequential damages of any kind. Some states may not allow the exclusion or limitation of consequential damages, so, the above limitations may not apply to you. Additionally, Sterling Power USA and Sterling Power LTD neither assumes nor authorizes any person for any obligation or liability in connection with the sale of this product. This warranty is made in lieu of all other obligations or liabilities. This warranty provides you specific legal rights and you may also have other rights, which vary from state to state. This warranty is in lieu of all other, expressed or implied.

Copyright © 2022 Sterling Power. All rights reserved. Reproduction, transfer, distribution or storage of part or all of the contents of this document is strictly prohibited. If you wish to use all of this document, or excerpts from it, Sterling Power must be contacted.

Sterling Power can not accept liability for:

Ÿ consequential damage due to use of this device Ÿ possible errors in the manuals and the results thereof

Please do not modify the device unless you have been instructed to do so by Sterling Power directly. Product modification shall be done at Sterling when needed. Warranty shall be voided if personal attempts are made to modify the device without Sterling’s approval.

SAFETY AND LEGAL

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STERLING

POWER

SAFETY AND LEGAL

Product Guidelines

Transport and Storage

General Maintenance

Safety Precautions

SAFETY GUIDELINES

Your Sterling Power product should only be utilised for it’s designated purpose. Use the Battery to Battery Charger ONLY : For DC to DC power conversion With fuses protecting both the input and output DC cables In a well ventilated, dry, dust-free and condensation free environment When the Owners Handbook has been read and wholly understood

Ensure that the mains supply and battery leads are disconnected before transporting or moving the unit. No liability can be accepted for damage in transit once equipment has been unpackaged. Store the product in a dry environment, between –20°C to 60°C.

Refer to the battery manufacturer's manual for information on transportation, stowage, charge rates, recharging and battery disposal for your battery care.

The device must be switched off during maintenance and all cables removed from the direct feed to or from the unit. It must also be protected against unexpected switching off. Remove battery connections and ensure unit is off. If repair is required, only use original parts. Unauthorised attempts to repair Sterling units will lead to the warranty being voided. Only someone with adequate understanding of electronics and the unit itself should attempt a repair.

Ensure your connections are good and clean and aim to protect your unit from humidity and water ingress.

Electrical appliances can be heavy. Please do not lift heavy units unassisted.

Ensure that your product is correct for your intent. 12V battery. Incorrect use can lead to damage. Orientation is not critical to unit function, however may affect water ingress rating. Install device in a well ventilated space for cooling purposes. Do not expose the unit to snow, rain, water, spray, condensation, pollution etc, unless it is a waterproof unit. If it is a waterproof unit, only expose it to situations it is correctly rated for. Do not cover or obstruct the ventilation. Device connects to common negative. Common negatives must be earthed. In case of fire, use fire extinguisher equipment suitable for electrical fires. Avoid all possibilities of reverse polarity or short circuiting. Check cabling and connections frequently and ensure the connections are sufficient. Always protect DC cabling with the appropriate fusing. Ensure the unit is adequately and safely mounted to prevent displacement and damage. Always use a professional to install electrical products. Ensure the product is correctly set up for your battery. Keep out of reach of children

Cross Voltage Chargers

READ THIS

WARNING :

CROSS VOLTAGE THRESHOLD BATTERY TO BATTERY CHARGERS MUST BE INSTALLED WITH CARE

A COMMON NEGATIVE IS PARAMOUNT TO OPERATION, HOWEVER, BE INCREDIBLY CAREFUL NOT TO SHORT CIRCUIT OR REVERSE POLARITY ANY EQUIPMENT OR CABLE.

All electrical appliances carry the risk of electrical shock. This equipment is designed to be used in combination with a permanent energy source (the battery). Always isolate the DC before performing any maintenance or inspection.

Do NOT remove the panelling to inspect the internals unless expressly told to by Sterling. This is not a product designed to be user-serviced.

Do NOT use the device in situations where there is danger of gas / dust / vapour explosions, or around potentially flammable produce.

SAFETY AND LEGAL

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STERLING

POWER

PRODUCT INFORMATION

Basic installation diagram

Here, we hope to provide a very

basic installation diagram for the

vast majority of installers to

follow.

If a process is not mentioned

here, the chances are that it is

not a pre-requesite to get the

BB12120 to function.

The default charging profile is a

standard sealed lead acid

charging profile of 14.4V and

13.3V float.

If you wish to charge a lithium

battery, please refer to page 9 to

change the charging profile.

SIMPLE WIRING DIAGRAM

*Label rendered for clarity, .

Air Flow Air Flow

nothing to change in the setup. Simply plug cables in and start engine.

12V ignition signal, required for

Euro 6 / Smart alternator use.

Ignition gives a binary on / off

style signal to control the

BB12120.

If ignition signal is not used, the

BB needs to see 13.5V on the

input terminal to begin charging

the output battery. When the

input then drops below 12.8V

the BB will stop charging.

Recommended installation

orientation

The BB12120 can be mounted in

any orientation. However, if the

area is prone to getting wet or

damp, we recommend the first or

second install.

12V ignition signal (optional)

Alternator

Input / starter

battery

35mm2 / 2AWG cable

150A

fuse

12V

ign

alarm

GND

35mm2 / 2AWG cable common negative

Ensure you have the

correct battery to

battery charger for

your install. The

voltage ratings for the

chargers are specific.

35mm2 / 2AWG cable

150A

fuse

Domestic / House

Output Battery

If prone to getting damp, this mounting option may result in pooling of water at the bottom

BASIC WIRING DIAGRAM

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STERLING

POWER

PRODUCT INFORMATION

BB12120 Diagram

UNDERSTANDING YOUR UNIT, PT.1

*Label rendered for clarity, .

Air Flow Air Flow

12V

ign

alarm

The top mounting plate. Composed of 2x 5mm wide mounting feet. There are 2x 5mm wide mounting feet at the

GND

bottom, too.

Location of 2x heat extracting fans. The air is sucked through the BB and the direction of air flow is demonstrated

above.

Display panel. More information on page 9.

Connection blocks. This region is described in more detail overleaf. This is the area where all the physical

installation connections to the BB12120 are made. Also, this region contains additional 2x 5mm mounting feet.

PRODUCT INFORMATION

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STERLING

POWER

PRODUCT INFORMATION

BB12120 Diagram

UNDERSTANDING YOUR UNIT, PT.2

*Label rendered for clarity, .

1314

The left large green connector is for direct connection to the input / starter battery. 12V input connection. Ensure the cable thickness is 35mm2 / 2AWG. Ensure this cable is fused at ~150A fuse.

5 6 7

These 2 central connectors are for common negative cable. For convenience, use the left GND to connect to the

input battery’s negative and use the right GND connector to connect to the output battery’s negative. Use similar sized cable as positive.

The right large green connector is for direct connection to the output / leisure battery. 12V output connection.

Ensure the cable thickness is 35mm2 / 2AWG. Ensure this cable is fused at ~150A fuse.

This 12V output provides a 12V signal at 50mA. This can be used to trigger an operation / provide a 12V signal.

This 12V signal shall only become live if the Ground connector (11) is connected to the common negative rail.

Ignition feed connector. The BB12120 can be operated based on an ignition signal - this is recommended if you

have a smart alternator (Euro 6 engine). Wire a feed from your ignition into this terminal. Ensure that this feed is ~12V when the ignition is live and goes to 0V when ignition is turned off. Once the BB12120 receives its first successful ignition signal it shall render the unit dependent on an ignition signal going forward. Therefore, the BB shall not operate based purely on input voltage coming from the input battery but based on whether your ignition

is live or not. You can reset this feature by removing the ignition feed and pressing / holding the front button down for 15 seconds and letting go.

Alarm. If the BB faults - this alarm connector shall put out a live 12V | 100mA. Therefore, you can wire in an

10.

audible 12V alarm or a 12V light / LED to convey a fault. These are optional fits. You can also use this connector to relay a 12V signal to another device to prompt an action if the BB were to fault. Ground connector (11) must be connected to the common negative rail for this alarm output to operate. More information on page 11.

Ground. To utilise connectors 8 or 10, a ground / negative (0V) feed needs to be connected here. For the ignition

feed connector to operate, a negative feed is NOT required.

Vibration sensor on / off switch. Default off. If turned on, the BB12120 shall begin charging when the vibration

12.

sensor detects 2x vibration events. This shall override the ignition signal and allow you to install the BB without the need to install an ignition signal. This is also an operational method if you have a smart alternator / Euro 6 engine (or younger). This mode comes with cautions, please read page 10. Switching between on / off can be done at anytime. There may be a 10 second delay in unit operation between switches - no need to reset / reconnect the BB.

Temperature sensor connector. Here is where to install the temperature sensor - TEMP1. Connect the terminal

13.

end of the temperature sensor to the negative terminal of the output battery. If in a Lead or AGM setting the temperature sensor compensates the voltage being delivered by the charger based on sensor temperature. If in a lithium setting, there is no voltage compensation. In lithium, the charger stop charging if sensor detects 0DegC or lower.

For remote control connection - BBR

14.

CONNECTORS

Page 9

STERLING

LED sequence

Battery Type

Absorptions (V)

Float (V)

Lead I

14.4V

13.3V

Lead II

14.6V

13.5V

AGM I

14.2V

13.1V

AGM II

14.7V

13.6V

Lithium I*

14.4V

13.8V

Lithium II*

14.2V

13.6V

POWER

PRODUCT INFORMATION

LED panel

To turn off reverse charging. Press and hold the Select button for 20 seconds - after you see the LEAD, AGM and Lithium LEDs stop flashing then release. You can now use the Select button to toggle the Reverse Charging LED on / off. On = reverse charge. Off = no reverse. Then let go when this LED is lit / not lit.

PANEL Controls | Battery Type Select

Lead Acid Charging Profiles

Orange LED status:

Fast flashing = Bulk / Fast Charge Slow flashing = Absorption Solid = Float

This LED shall be on when the BB is allowing charge flow back to the input battery.

The reverse charging feature shall only come on when there is plenty of available power (surplus) in the output battery and shall charge and maintain the starter battery at 13.4V. When your engine is off and you have either solar / charger on your output battery, the voltage shall rise on your output battery activating the reverse charging feature. When you either start your engine or apply a live ignition signal to the BB does it revert back to the normal charging direction. This feature does NOT deplete your output battery. If you have a lithium battery the on/off activation voltage is 13.5V at the output battery. If you have any lead acid style battery the on/off voltage is 13.2V.

Jump Start Assistance Mode.

Simply press the Select button 4 times in a row. The Reverse charging LED should come on. The BB required at least 11V on output battery and at least 5.5V on input battery in order to provide back feed.

Lithium Charging Profiles

Orange LED status:

Fast flashing = Bulk / Fast Charge Slow flashing = Absorption

Lithium

Absorption time lengths:

As the BB can measure both current and voltage it shall make an intelligent decision as to when to transfer from absorption to float mode. This algorithm detects both the rate of rise of voltage and the rate of decline of current. If the target absorption voltage has been met and the current has dropped to a few amps the charger shall transfer to float mode.

Float to absorption trigger voltages. If the charger is in float

and the output batteries voltage is dragged below the following voltages the charger shall go back to absorption. Lead I = 12.6V Lead II = 12.7V AGM I = 12.4V AGM II = 12.8V Lithium I = 13.4V Lithium II = 13.2V

Battery Type Select

When charger is on, press and hold the Select button for 5 seconds until the LEDs flash. Then, press the Select button to toggle through the 6 different battery types - the flashing orange LED shall depict the battery type. Type 2 LED shall light up to display the second profiles of the battery types. Once you have the LED on the battery type you, want wait until the LED stops flashing - after a few seconds the flashing stops and the LED stays on solid - this confirms setting.

Lithium* = live output voltage, ideal for waking up BMSs on batteries. Please ensure your lithium battery has an internal or external BMS. If you want a float voltage please use Lead or AGM profiles. If temperature sensor connected, no voltage compensation on lithium profiles. If temperature sensor detects 0 Deg C - BB stops charging.

Description of faults on page 11

FRONT PANEL AND BATTERY TYPE

Page 10

STERLING

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PRODUCT INFORMATION

Automatic Mode (Default)

This mode is the simplest way to install the BB12120, however, not the most effective if you are using this BB on a modern vehicle that has regenerative braking (Euro 6 engine or newer).

To activate the BB, you require 13.5V+ on the input terminal. You shall achieve this voltage by charging up your input battery (starter battery) with an alternator (for example).

When the input voltage drops below

12.8V (when you turn your engine off), the BB shall turn off and go to sleep.

Ignition feed Mode (requires 12V signal feed)

In this mode you control the BB based on an ignition signal. Essentially when you are running your engine the signal is ~12V and BB works. When you turn your engine off - signal turns to 0V - the BB turns off.

The BB also requires 11.0V+ on the input battery. If starter battery is lower than this w/ live ignition, BB will not work.

WARNING, if ignition is live, but engine not running, flat starter

battery!

Charge control modes - how to get the BB12120 to turn on and begin charging

Input voltage

Charger on - 13.5 -> 16V Charger off - <12.8V

12V

ign

alarm

Alternator

Input / starter

battery 12V

150A

fuse

13.5V+ on <12.8V off

GND

Output

battery 12V

35mm2 / 2AWG cable

35mm2 / 2AWG cable common negative

Input voltage + ign feed.

Charger on - 11V -> 16V Charger off - <10V

12V

ign

alarm

GND

35mm2 / 2AWG cable

35mm2 / 2AWG cable common negative

11V+

~12V ignition signal

Alternator

Input / starter

battery 12V

150A

fuse

Output

battery 12V

By applying a live signal to the ignition connector you put the BB into ignition dependent mode. The BB shall NOT work unless it has a live ignition signal - even if you remove the ignition feed cable and provide 13.5V+ onto the input terminal.

150A

fuse

150A

fuse

Vibration sense Switch position ON.

This mode requires the BB to detect 2 vibration events in order for it to turn on and charge. For example, turning an engine on shall provide sufficient vibration to get the BB to begin charging.

This mode essentially acts like an ignition signal and is designed for installers to do away with having to run an ignition feed.

WARNING, if vibration signal activates BB, shall drag starter battery voltage to below 11V. Possible flat starter battery! The BB does monitor the input battery and shall turn off after 2 minutes if the voltage does not climb up.

To reset the BB back to Automatic Mode, ensure BB is on - I) Remove ignition cable from ign connector. II) Press and hold SETUP button for around 15 seconds until the 3 LED battery types flash at the same time. III) Release button and charger reverts to Automatic Mode.

Input voltage + vib. sense.

Charger on - 11V -> 16V Charger off - <10V

on off

select switch position ‘on’ at anytime to engage vibration mode.

Alternator

Input / starter

battery 12V

150A

fuse

35mm2 / 2AWG cable

on off

12V

ign

alarm

GND

11V+

Output

battery 12V

35mm2 / 2AWG cable common negative

150A

fuse

CHARGING MODES

Page 11

STERLING

Problem

Possible Cause