Sterling Power BB1230, BB1260, BB122470, BB123670, BB124870 User guide

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Page 1

English Manual

Pro Batt Ultra

USERS MANUAL.

STERLI

POWER

BB1260 | BB122470 | BB123670 BB124870 | BB241235

Test Report Sheet

Each product gets uniquely tested and a report is generated. This unique test report is present inside this box. You must keep this test sheet in this box and keep this box safe. This sheet should be present when the charger is being warranted.

BB1230 | BB122430 BB244860

BBS1230 - New to 2020

Absorption

H Charge

Sterling Power Products

In / Unit

Audible alarm on/off

Volts Select

battery temp

sensor

TSAY

Optional Remote

Instructions inside

BBURC

Cond.

12.2

hold > 3 sec

On / Off

hold>3 sec

Fault

Float

Out / Rem

Batt.

Temp Menu Change

These instructions are for the & ( ) stripe BB modelsBLUE YELLOW solar

Ignition feed (4)

BMS 2 (5)

Upper

4 5 6

1 2 3

Lower

Battery temp. sensor (1,2)

ignition feed (4) recommended for Euro 6 vehicles (optional fit)

All BB models except solar

Engine

Remote

control

Batt. input +

BMS 1 (6)

FUSE

Starter

Engine Bat.

Aux

Com.

Bat out +

BB1230 layout shall be slightly Different

FUSE

Neg.

f u s e

House / Domestic / Aux / Bow thruster

MUST READ For the majority of users, reading this paragraph should be sufficient for installation. The unit can be installed by simply connecting it between an input and output battery, as depicted. The solar panel’s

positive and negative connectors go to the +ve and -ve connectors (BBS1230 model only) - voltage should

not exceed 31V (12V panel). The BB, by default, shall start charging when the starter input voltage exceeds

13.5V and switches off when the voltage drops below 13.3V (all models). The default charging profile is

14.4V abs. and 13.6V float - for sealed lead acid batteries (x2 for 24V | x3 for 36V | x4 for 48V). This means that the vast amount of installations can be fitted out of the box without any adjustments. In certain

circumstances, when installing in a Euro 6 vehicle, we recommend using an ignition feed to the unit. When the ignition is live, unit starts charging (may take up to 60 seconds). Please read the manual for additional information. If in doubt, and installing on a New Euro 6+, use ignition feed. For info on BMS, remote sense, temp sensors and remote control, please consult the manual. Solar charge shall operate when engine off and predominately go to the leisure battery. There shall be a small 0.5A-1A back feed to the starting battery to keep it topped up, too. Maximum wattage that can be harvested from the solar panels is 350W - 31V maximum and 16A maximum.

Sterling Power Products

C I

technology

ProDigital

RoHS

compliant

Solar Panel up to 31V (nominal 12V rated) - do not exceed. No limit to wattage, however, max harvest is ~350W

BBS1230 - New to 2020

Ignition feed (4)

BMS 2 (5)

BMS 1 (6)

4 5 6

Upper Lower

1 2 3

Remote

Battery temp.

Voltage

sensor (1,2)

sense (3)

ignition feed (4) recommended for Euro 6 vehicles (optional)

Engine Batt. input +

Starter

Engine Bat.

Negatives should all be common. Use cable, do NOT use chassis.

Solar Pos+

Solar Neg Max V

Com.

31V

Neg.

- -

+ + +

fuse 50A

House / Domestic / Aux / Bow thruster

Output To Aux Batt

Remote

control

Aux Bat out +

fuse 50A

Page 2

BB1230 BB1260 BB122470 BB123670 BB124870 BB241235 BB242435 BBS1230

Input Voltage (V DC) 11 - 20 11 - 20 11 - 20 11 - 20 11 - 20 22 - 40 22 - 40 11 - 20

Solar input voltage (V DC) N/A N/A N/A N/A N/A N/A N/A Up to 31V

Input Current (A) 30 60 70 70 70 35 35 30

Battery types (all models)

IP rating IP21 IP21 IP21 IP21 IP21 IP21 IP21 IP21

Ignition Protected Yes Yes Yes Yes Yes Yes Yes YES

Quiescent Current (mA) 1 1 1 1 1 1 1 1

Battery Connector WJ116VW WJ116VW WJ116VW W J116VW W J116VW

Weight (Kg) 1.2 1.4 1.4 1.4 1.4 1.4 1.4 1.4

Dimensions (LxWxD) mm 190 x 160 x 50 190 x 160 x 50

8mm input | W J116VW output

190 x 160 x 70

Legal and Safety Information Page 3 Automatic | Ignition Feed Modes Page 9

How to use the instructi ons Automatic activat ion (non ignition mode)

Safety a nd Precautions Changing battery prof ile type

Front Panel Display I Page 4 First and sec ond LED column meter rea dings

Front Label display annotated Guide to the 2 buttons Page 11

What the LEDs mean Simplified chart corresponding to button use

Front Panel Display II Page 5 FACTORY RESET

Under the red end cap Force Option feature explanation Page 12-13

Scaled dimensions of the BB Detailed descriptio n of button / force functions Cable and fuses guide Custom Settings Page 14-15

Installation Diagram (non Solar) Page 6 How to set a custom charge profile

wiring diagram for installation Adjusting bulk / absorption / float / times

temperature sensor insta ll Adjusting operation on / off v oltages BMS connectors operations Remote Control Operations Page 16

Remote voltage sense use Comprehensive breakdown of remote functions

Installation SOLAR BBS1230

Page 7 Troubleshoot | understanding panel LEDs Page 17

wiring diagram for installation Fault Finding Page 18

Fundamental fault + troubleshootings

Lithium Battery Installation Page 8 LED displays w/ meanings and solutions

Lithium Battery Charging Profiles Sterling's Warranty Statement Page 19

External and Internal BMS shutdowns Customer servic e and warranty declaration

0 Deg C temperature sensor trip

STERLI

Contents Page

POWER

Product Specifications

Sterling Power Products

Page 3

Legal and Safety

Using the Instruction Manual

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 the Sterling Power website. 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 a qualified and trained personnel only. The personnel must be familiar with the locally accepted guidelines and safety measures.

Sterling Power’s warranty statement

A comprehensive warranty statement is provide at the back of the instruction manual. A comprehensive warranty statement can also be found on sterlingpower.com.

Copyright © 2015 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.

Liability

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

Device modification

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.

Use the battery to battery charger only:

Ÿ For DC to DC conversion. Ÿ For DC current limiting. Ÿ With fuses protecting the DC cables. Ÿ In a well ventilated, dry, dust-free and condensation

free environment.

Ÿ When instruction manual has been read through.

Safety Symbols

CAUTION WARNING

Ÿ Example - WARNING. Never use the device in

situations where there is danger of gas / dust EXPLOSION or potentially flammable products.

General maintenance and repair

The device must be switched off during maintenance. 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.

General safety and installation precautions

Ÿ Install device in well ventilated space. Do not

expose device to: Rain, snow, spray, moisture, pollution, condensation. Do not cover or obstruct ventilation openings.

Ÿ Device connects to common negative. Common

negative must be earthed.

Ÿ In case of fire use a fire extinguisher. Ÿ Ensure reverse polarity and short circuiting is

avoided - to prevent damage to battery.

Ÿ Protect DC wires with the appropriate sized fuse. Ÿ Check cabling annually- fix where needed. Ÿ Avoid contact with device with damp hands. Ÿ Ensure the device is adequately and securely

mounted to prevent the unit from displacement.

Ÿ Use a professional to install device.

Battery safety

Excessive charge or discharge and high voltages can cause serious damage to batteries. Never exceed the recommended limits. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters the eye(s), immediately flood the eye(s) with running cold water for 20 minutes and seek medical

attention.

Give extra care to not drop metal tools or jewellery on to the battery terminals as short circuiting can take place. Refrain from charging battery up to 4 hours prior of installation to avoid the formation of explosive gases.

Never smoke / generate a spark around batteries.

EXPLOSION

Sterling Power Products

Page 4

Front Panel Display

12 13 14 15

D-Sulf

IUoUo

developed

in England

Bulk / Boost Absorption Conditioning Float (S) /Standby (fl)

Progressive DIGITAL software control Battery to Battery charger

Calcium

15.4 V

Open

15.1 V

AGM II

14.6 V

Lithium II

14.2 V

Lithium I

13.8 V

Sealed

13.4 V

AGM I

Output V

13.0 V

12.6 V

12.2 V

15.4V

15.0V

14.6V

14.2V

13.8V

13.4V

13.0V

12.6V

12.2V

GEL

Custom

High Volt in (fl) / out (S)

High temp trip (fl)

No Fault (S) / P.Pack (fl)

Regen timer off (S) / on (fl)

Batt. Sense on (S)

Volt drop sense (fl)

1/2 power (S) / night (fl)

Low Volt in (fl) / out (S)

High bat temp (fl)

23 24

Model:

Flashing on startup

Battery type selected

840 720 600 480 360 240

Alarms

120

BB1230 BB122430 Bb244830

Pro Batt Ultra - 4 Stage battery to battery charger DIGITAL control

IUoUo

12V-12V

60A input

Batt. to Batt.

Charger

Bulk / Boost Absorption Conditioning Float (S) /Standby (fl)

D-Sulf.

12 13 14 15

Calcium

Open

AGM II

Lithium II

Lithium I

Sealed

on start-up.

AGM I

GEL

Battery preset options.

Batt Type LED displayed

Custom

Specifications: 12V-12V 60A input

- Current limiting

- Thermostatic control fan

- Auto or ignition feed

- Suitable for use with

- Smart alternators

- Regen. braking

www.sterling-power.com

www.sterling-power-usa.com

4 3

2 1

15.4V

15.0V

14.6V

14.2V

13.8V

13.4V

13.0V

12.6V

12.2V

SETUP ENTER

1312 14 15

840

720

-2

600

-4

480

-6

360 240

-8

Input voltage

120

-10

-12

-30

LT Trip

1 26

SELECT

2434

1 sec =

1x blue flash

Battery charge progress

15.4V

15.0V

14.6V

14.2V

13.8V

13.4V

13.0V

12.6V

12.2V

960 18

High Volt in (fl) / out (S)

High temp trip (fl)

No Fault (S) / P.Pack (fl)

Regen timer off (S) / on (fl)

Batt. Sense on (S)

Volt drop sense (fl)

1/2 power (S) / night (fl)

Low Volt in (fl) / out (S)

High bat temp (fl)

Sterling Power

Alitech

BB1260

10R-0513962

12V - 12V

Designed and Developed in England

Made in Taiwan

21 22

Output

Alarms

23 24

25 26

MODELS: BB1260 / BB122470 / BB123670 BB124870 / BB241235 BB123670 / BB124870

Designed and

made in Taiwan

Input voltage

Voltage

Front label display

1 & 26) ENTER / SETUP and SELECT buttons, used to

adjust settings.

2 & 25) Background light for button, used also to show

unit is operational.

3)-11) The first column of LEDs have 3 different

functions. Firstly, on unit start up the battery type is displayed. Secondly, after startup it becomes an input voltmeter. Thirdly, during custom setting the voltage scale is used to set the voltage - refer to later.

12) This LED has 2 meanings. Firstly, when on battery

type selection mode this is the Desulphation setting indicator. Secondly, on default mode (most times) this shows the charger is on fast charge mode.

13 -1 5) These LE Ds show the batt er y c harge

progression through its cycle.

15) Flash when in asleep. 16-24) Has 3 functions: Firstly, during operation they

show the output voltage. Secondly, if an alarm is present the alarm shows up. Thirdly, this row is used in the custom setup procedure to set timing functions, voltages and time factors. Its general function is as an output voltmeter, in the event 2 LEDs are on the voltages is between the 2 settings, if the top or bottom red LED is on then the vo ltag e is outside the parameters off the voltmeter.

16) High voltage, if on solid it is high output voltage, if

flashing it is high input voltage.

17) High temp trip, if flashing then high unit temperature

trip.

18) No faults (solid on). Power Pack mode / live voltage

output (flashing).

19) No regen. mode or regen. timer at 0 = solid LED.

Regen on / timer on = flashing LED.

20) Remote Battery sense cable connected (solid).

Sterling Power Products

Auxiliary Information

Ignition feed live

Solar power live

Solar High V Trip live

on start-up.

Input voltage &

Battery preset options.

Batt Type LED displayed

Ignition

feed (4)

BMS 2 (5)

BMS 1 (6)

4 5 6

1 2 3

Battery temp.

sensor (1,2)

D-Sulf.

Calcium

AGM II

Lithium II

Lithium I

Sealed AGM I

Custom set voltages

Custom

Remote Voltage sense (3)

Battery to Batter charger and Solar MPPT

with starter battery maintainer

IUoUo

Bulk / Boost Abs / Solar (fl) Conditioning Float (S) /Standby

12 13 14 15

Open

10 9 8 7 6 5 4

GEL

Model: BB solar

Battery charge progress

1312 14 15

Active

30.0V

15.4V

840

28.0V

15.0V

720

26.0V

14.6V

600

24.0V

14.2V

480

22.0V

13.8V

360

20.0V

13.4V

240

18.0V

13.0V

120

16.0V

12.6V

14.0V

12.2V

1x blue flash = 1 second

1 26

SETUP

SELECT

2435

ENTER

Solar

25 25

Pos+

Engine

Solar Neg

Batt.

Max V

input +

31V

- -

+ + +

16 17 18 19 20 21 22 23 24

Com. Neg.

Designed and

made in Taiwan

12V-12V 30A continuous

- 350W solar processing

-1A engine batt. maintain

- Unlimited solar size

- Current limiting

Sterling Power

10R-0513963

(fl)

960 18

High Volt in (fl) / out (S)

High temp trip (fl) /BMST(S) No Fault (S) / P.Pack (fl) Regen timer off (S) / on (fl)

Batt. Sense on (S) Volt drop sense (fl)

1/2 power (S) / night (fl)

Low Volt in (fl) / out (S)

High bat temp (fl) / TCO (S)

Due to poor conductivity through chassis. Please use appropriately rated DC cable direct from engine to

auxiliary battery. Do NOT use chassis.

Output To

Aux Batt

Aux Bat

out +

developed

in England

Alitech

BBS1230

12V - 12V

LT Trip

Output

Voltage

+2 0

-2

-4

-6

-8

-10

www.sterling-power.com

-12

www.sterling-power-usa.com

-30

2434

Remote control

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

12V-12V 30A

- Current limiting

- Thermostatic control fan

- Automatic or ignition feed

- Thermal compensation

- Lithium thermal adjust

LT Trip

-2

-4

-6

-8

-10

-12

-30

2434

960 18

Battery charge progress

Under lid

ProDigital

A N

Technology

Batt. to Batt. Charger | MPPT solar reg. | Starter batt. maintainer

27 28

Upper

Lower

BBS1230

Battery sense voltage drop in cable outside the 21) prescribed 1.5V drop maximum, thicker cable required - LED flashing. PIM = Pure Ignition feed mode - if this LED is on solid during status, then the unit is set to operate only if ignition feed is live.

22) Device’s power ability reduced due to high

ambient temperature or voltage drop in output cable too large. Alarm will be in conjunction with other information alarm. If flashing, unit is in night mode with reduced power and lower fan speed.

23) Low voltage alarm, low voltage on input = flashing

LED. Input alternator not supplying enough power or failed. Low voltage output = solid LED. Something consuming a lot of power or unit not working. No voltage output then LED on solid.

24) If flashing then battery temperature too high. TCO

Temperature Compensation Off LED means that when illuminated the temp comp is off.

31) Numbers relating to battery custom setup (if

used) this is the charge factor number.

32) Numbers relating to custom setup mode these

numbers relate to timing, i.e. maximum and minimum time settings.

33) Solar voltage reading - this column becomes a

solar input voltmeter when solar power is on.

34) Low temperature thermometer readings.

Auxiliary Information

Ignition feed live

Solar power live

Solar High V Trip live

35) Solar input voltage. When

solar power live LED (27) is on, the left panel displays solar panel input voltage. BBS solar model

only.

27) Solar power live LED comes on when the solar is

active. this also means that the voltmeter LEDs voltage legend changes to the yellow / solar voltage input. BBS Solar only.

28) If solar voltage exceeds 32V the red LED comes on

+ unit stops. BBS solar only.

29) Ignition feed LED - if ignition feed is connected

AND live, this LED shall come on. BBS solar only.

Page 5

Front Panel II (under red end cap)

input cable output cable Model (mm2) / AWG (mm2) / AWG input fuse output fuse BB1230 10mm2 / 8 10mm2 / 8 40A 40A BBS1230 10mm2 / 8 10mm2 / 8 40A 40A BB122430 10mm2 / 8 6mm2 / 10 40A 30A BB242435 10mm2 / 8 10mm2 / 8 40A 40A BB244830 10mm2 / 8 4mm2 / 12 40A 20A BB1260 16mm2 / 6 16mm2 / 6 80A 80A BB122470 16mm2 / 6 10mm2 / 8 80A 40A BB123670 16mm2 / 6 6mm2 / 10 80A 30A BB124870 16mm2 / 6 4mm2 / 12 80A 20A BB241235 10mm2 / 8 16mm2 / 6 40A 80A

10 89

BMS 1 (6)

111213

Remote Voltage sense (3)

Remote

control

Ignition feed (4)

Upper

Lower

BMS 2 (5)

4 5 6

1 2 3

Battery temp. sensor (1,2)

MODELS: BB1260 / BB122470 / BB123670 BB124870 / BB241235

Engine Batt. input +

Com. Neg.

f u s e

Aux Batt out +

Under the lid

1) N/A

2) Negative fuse (position, model dependent).

3) DC output to auxiliary battery.

4) Common negative.

5) DC input from start battery (green connector or brass nut / bolt - model dependent).

6) N/A

7) Remote control socket.

8) BMS 1 - 0V signal from BMS shall trip BB.

9) BMS 2 - positive signal (+ve) from BMS shall trip BB.

10) Ignition feed connector (on) Euro 6 engines.

11) Remote battery sense wire to compensate for voltage drop in cable (optional, does not need to be used).

12) Battery temperature sensor, optional fit, if not used product will work on default at 20 deg C setting. Polarity does not matter when connecting.

13) Other wire associated with the temp sensor, as per 12.

Cables and fuses (guideline only)

10 8 9

Ignition feed (4)

Upper

Lower

Battery temp. sensor (1,2)

BMS 2 (5)

4 5 6

1 2 3

BMS 1 (6)

111213

SETUP

SELECT

f u s e

Engine

Com.

Batt.

Neg.

input +

+ +

Aux Batt out +

control

Remote

345

Models: BB1230 | BB122430 | BB242435 | BB244860

10 8 9

Ignition feed (4)

Upper

Lower

Battery temp. sensor (1,2)

BMS 2 (5)

4 5 6

1 2 3

BMS 1 (6)

111213

Remote Voltage sense (3)

Models:

BBS1230

f u s e

Solar Pos+

Engine Batt. input +

Solar Neg Max V 31V

- -

+ + +

Com. Neg.

Output To

Aux Batt

Remote

control

Aux Bat out +

3415 165

15) Solar positive input from 12V solar panel (up to 31V)

16) Solar negative input from 12V solar panel (up to 31V)

Dimensions

158.00

199mm(H) 158mm(W)

70mm(D)

50mm(D)

4.60

0 6

. 0 1

4.60

units in millimetres (mm)

158.00

.50

3 1

. 2 1 1

3 1

. 3 4

1 5

. 8 9 1

0 0

. 3 7

0 0

. 4

This chart is a guideline based on the typical lengths of cable that shall run to and from the BB. Please only use this chart as a guide. If you wish to make the cable longer than typical, then you would generally use thicker cable. We recommend rating the fuse based on cable thickness. Rate the cable based on the current going down the cable and the length of the run.

Page 6

Installation Diagram / all non Solar Models

Ignition feed (4)

Upper Lower

BMS 2 (5)

4 5 6

1 2 3

Battery temp. sensor (1,2)

(recommended if vehicle is Euro 6)

line to ignition

Important

NEGA

TIVES

should all be common.

DON'T USE CHASSIS

e recommend joining the BB’

s neg. to the starter battery negative. For improved efficiency

Engine Starter

(connected to alternator)

BMS and remote features appear later

BMS 1 (6)

Remote

control

fuse

remote voltage sense compensates for potentially long cable

Battery

runs to domestic battery.

Engine Batt. input +

Com. Neg.

f u s e

Aux Batt out +

Temperature (T Polarity of wires into

(1) matter

fuse

House / Domestic /

Battery Bank

(arranged here as a 12V bank)

Y) o

and (2) does NOT

Fuse ratings on Page 5

Aux

Temperature sensor (part no. TSAY)

Temperature sensor cables are not polarity sensitive, install either way. If you wish to install, connect the temp sensor to the negative of the domestic / aux. batteries.

When temperature sensor senses the temperature lower than 20Deg C the voltage shall go up on the charger’s output and when the temperature is higher than 20Deg C the charge voltage shall drop. The rate is 18mV (0.018V) per Deg C or 0.018V / Deg C. If sensor temperature is at 10 Deg C the voltage elevation shall be 0.018 x 10 = 0.18V. This shall explain why, in cooler climates / seasons you may see slightly elevated charge voltage / voltage at your batteries. This is no concern. In warmer climates / seasons you shall see slightly lower charge voltages. This voltage fluctuation is only with ‘lead acid style’ batteries. For lithium profiles, there is no voltage fluctuation.

ptio

Sensor

nal

fuse

The temperature sensor shall trip the charger if the temperature at the battery >55DegC.

If the BB is in either lithium profiles the unit shall trip at 0DegC, if temp sensor is connected. This temperature can be adjusted. If you do not want the 0DegC trip or any trip, please uninstall the temperature sensor.

BMS connectors

BMS 2 status: operational: 0V trip voltage: 2V-17V

Use BMS 2

use voltage is received. Once the BMS removes this trip status, i.e. the +ve signal goes back to 0V signal, the BB shall start charging

These please from

- if your BMS trips

BMS

2. This shall

again.

BMS connectors can also

use

BMS

you

a BMS, they can come from any

a +ve voltage (2V

result in the

wish

for

the BB to turn

BB turning of

used

simple

source.

-17V), then f

when this

on/off signal

f based on

BMS (2)

BMS (1)

5 6

connectors. If you wish

a ground (0V)

Use BMS 1 - if your BMS trips and provides a 0V (ground signal), then use BMS 1. This shall result in the BB turning off. Once the BMS removes this trip status, i.e. the 0V signal goes back to a +ve signal, the BB shall start charging again.

signal,

for

the BB to turn

use BMS 1. These signals do

BMS 1 status: operational: 2-17V trip voltage: 0V

f with a live

not

have to

(+ve) signal

come

Remote voltage sense

The remote voltage sense is designed to achieve the correct charge voltage at the charging battery (house) itself. There is often voltage drop across DC cabling, this sense feeds back to the BB what the charge voltage at the BB should be in order to get the correct charge voltage at the battery. The sense cable, itself, carries no current, it can be as thin as you can find. Please connect between (3) and the positive terminal of output battery.

Page 7

Installation Diagram Solar BBS1230

Sterling Power Products

Please be advised that the solar charger and the BB charger do not work at the same time. When your engine is running, the BB aspect of the BBS charges. When the engine / ignition is off, the solar charger works. They do not work simultaneously.

Ignition feed

Upper

Lower

Battery temperature sensor

BMS (2)

4 5 6

1 2 3

BMS (1)

Controller

see previous page about BMS

Optional fit

Remote Voltage sense

lithium

BMS

(if used)

Solar

Pos +

Solar Negative

Engine Batt. in+

- -

+ + +

Common Negative

fuse

50A

Optional fit

emp

T Sensor on negative

House / Domestic / Aux

Battery Bank

(arranged here as a 12V bank)

line to ignition

(recommended if vehicle is Euro 6)

Optional fit

Must fit

Engine Starter

Battery

(connected to alternator)

Solar input. There is no limit to the solar panel array combined wattage, however, the BBS unit can only process up to 350W. However, i n milder climate s larger cells can be used as the mean average - because in non sunny climates panels shall not produce full power.

Max 31V DC. Max harvest 350W

Absorption

Cond.

H Charge

Float

Sterling Power Products

12.2

In / Unit

Audible alarm on/off

hold > 3 sec

On / Off

Volts

hold>3 sec

Select

Fault

Remote

control

Aux Batt. out +

in compliance with good electrical practice all wires di rectly conn ected to a battery should be correctly fused. The applicable fuse must be fitted close to the battery side of the cable.

50A

fuse

Must fit

optional remote BBURC

Important

TIVES

NEGA

should all be common.

DON'T USE CHASSIS

e recommend joining

the BB’s neg. using cable

direct to the starter battery negative. For improved efficiency.

Negatives: The reason to not use CHASSIS ground is that the conductivity is poor. This shall result in worsened performance. Output voltage shall climb at a slower rate. Charging rate shall be slower. Please use direct cable for best performance.

Out / Rem

Batt.

Temp Menu

Change

main current flow during solar charging

Engine Starter Battery

(connected to alternator)

House / Domestic / Aux

Battery Bank

(arranged here as a 12V bank)

Page 8

Lithium Battery Installation

This page is unique to those installing lithium batteries as a domestic battery bank. This page assumes that you have a lead acid style starter battery and a domestic lithium battery bank that is within the C rating of the battery to battery charger that you have chosen. Typically, an individual 100Ah lithium battery has a 0.5C maximum charge current (~50A) and a 1C discharge current (100A) - these current figures double, triple by parallelling 2x, 3x etc.. lithium batteries together. Please consult your lithium battery documentation to ensure that the BB selection is suitable for your lithium battery and within about 70-80% of the rating of your alternator (or lower) - to increase lifespan of your alternator. The BB shall operate with an internal or external BMS. A BMS is a must have when charging lithium batteries. If this paragraph means little to nothing to you we would consult advise before proceeding.

Changing battery type

We provide 2 lithium profile presets. Lithium I is 14.2V charge and 13.8V float. Lithium II is 14.4V charge and 13.8V float. These can be selected in the normal battery type selection process. By putting the BB into either of these modes immediately removes the reverse polarity protection and put the BB into ‘power supply mode’. If you wish to customise your charge profile proceed through the custom route, however, please change the power supply mode to on in the settings.

External BMS shutdown

Certain lithium batteries shall have an external battery management system. Particularly if the bank is large or contains multiple batteries and/or in sophisticate setups. External BMS generally do a better job of managing multiple lithium batteries within a large bank. These external BMSs give out either a positive signal or ground signal when they wish to tell the charger to stop charging (trip signal). The BMS 1 and BMS 2 connectors on the BB are the connectors that the external BMS’s signal shall feed into. Make sure you select the correct port.

Use

BMS

if BMS received. signal

your

This shall result in the BBC

Once

goes back

BMS

the BMS

signal,

trips

to a +ve

removes

the

voltage

turning off when

this

BBC

shall

BMS 2

status: operational: 0V trip voltage: 2V-17V

(2V

-17V), then use

status,

trip

start

charging

this

i.e.

voltage is

+ve

the

again.

BMS 1

BMS (2)

BMS (1)

5 6

Use BMS 1 - if your BMS trips and provides a 0V (ground signal), then use BMS 1. This shall result in the BBC turning off. Once the BMS removes this trip status, i.e. the 0V signal goes back to a +ve signal, the BBC shall start charging again.

status: operational: 2-17V trip voltage: 0V

Remote trip - the BMS connector can also be used as a basic remote trip. Simply apply the correct trip signal voltage to the relevant BMS connector for the desired effect.

Internal BMS shutdown

Drop in style, off the shelf, lithium batteries tend to have an internal BMS that looks after that specific battery. The parameters of that BMS shall trip and engage when the BMS deems the environment either hostile or acceptable to accept charge. There is no back-feed mechanism to the BB required here as the BMS itself trips the battery internally. Some specifications of these BMS require the BB to not provide any charge at low temperature 0 DegC or below. Please read below.

0 Deg C trip

If you want the BB to

Firstly, connect the temperature and then connect the other end (two wires) to the appropriate connector on the BB - normal temp sensor installation.

Secondly, set the BB battery Preset I 14.2V on the temperature sensor

If you want a different temperature trip then you must go through the custom charge profiles as appears

If you do not want this engage the BB to charge.

stop charging when your lithium battery is at 0Deg C then please read here.

sensor (TSAY) that is supplied with the device to the negative terminal of the lithium battery bank

to lithium battery type (I or II) - using the normal ‘battery type setup’. Once you

(x2 for 24V etc) or lithium battery Preset II (x2 for 24V etc). By selecting either

the BB now defaults to 0 Deg C trip.

feature at all, please remove the temperature sensor from the connector on

-2

-4

-6

-8

-10

-12

-30

As there is no temp sensor now connected there shall be no tripping based on battery temperature.

After custom charging profiles have been set, the last option in the custom procedure is to set temperature trip. The default, as it assumes lead acid, is -30 Deg C, so the RED LED at the bottom shall illuminate. For lithium, bring this LED up to your desired trip temperature. E.g 0,

-2, -4 Deg C etc.

have selected either lithium

of these presets and by putting

on page .15

the BB. This shall immediately

1 2 3

temp sensor connection

Page 9

Automatic mode & Ignition feed modes

Please refer to the installation diagrams on pages 6 and 7 for installation instructions.

Automatic Activation

Automatic activation (default setting) - no ignition feed required. This means that the battery to battery

charger operates based on sensing voltages at the input battery connector. No ignition feed. When the

input voltage exceeds 13.5V-19.0V (x2 for 24V) then the unit will simply start charging. If the voltage drops below 13.3V the unit shall turn off. With a caveat, read on.

However, if the input voltage has exceeded 13.5V (2x for 24V) for 5 seconds the regen. braking timer is prepped and shall become active if the input voltage drops down to 12.0V-13.3V. This timer is 240s (default can be changed) and allows the charger to continue charging at these lower input voltages. If the voltage drops below 11.9V the charger goes to sleep irrespective of the timer. If the input voltage remains between 11.9V-

13.0V for over 240s the charger also goes to sleep. To wake the charger, the input voltage needs to rise above

13.2V - this shall also reset the regen. braking timer. These parameters can be modified.

2x Ignition feed modes

Ignition mode 1 (default when ignition feed is applied) allows the user to operate the BB based on the

automatic activation voltage parameters, as above, whilst also having control of the BB using the ignition signal. If your vehicle’s alternator is putting out a voltage below that of 13V (26V for 24V) the live ignition feed signal shall still operate the BB (10V+). Whereas, in the mode above the BB shall turn off when the voltage drops below

13.0V or may never even turn on if this voltage is never met. This is why we recommend installing an ignition feed for Euro 6 vehicles. The BB shall turn off only when the input voltage drops below 13.0V AND the ignition feed switches off. The possible downside of this mode is that the BB shall work even when the ignition feed is not applied - provided the input voltage is above 13V (x2 for 24V). This may be sub optimal if you wish for your BB to remain off when the vehicle is parked up and you have alternative charging sources onto your DC system. However, this mode may be what you wish for precisely that reason. If you want a more classic binary on/off ignition mode - please see ignition feed mode 2 below. Mode 1 is default, once live ignition is applied.

Ignition feed mode 2 (Pure ignition). This mode is slightly different to mode 1. If, you want the BB to simply be

on/off based purely on ignition then you shall want to use this mode. For example, if the only time you ever want the BB to work is when you’re driving (ignition live) then this is ideal. It shall not operate based on the DC voltage at the input terminal. If you have a live ignition the BB shall turn on, when the ignition is off the BB shall stop charging. Simple on/off. There are no voltage parameters at the DC input terminal that need to be met here, simply 10V+ (2x for 24V). To put it in this mode, apply an ignition feed cable to the ‘Ignition’ terminal on the connector block, as above. ALSO, you shall need to turn on ‘pure ignition feed’ mode by holding down SETUP button for 20 flashes and letting go. The unit shall now ONLY operate when there is a live ignition feed - if the BB is wired up without an ignition the unit shall simply not function. This shall limit the unit’s flexibility. However, this mode shall be ideal for those that have solar chargers or auxiliary chargers who wish for the BB to be OFF when vehicle is parked up. Apply a factory reset if you wish to restore default settings.

when BB receives ignition feed signal the regen. braking timer = 0 seconds

+ve

Ignition feed (4)

Upper

Lower

4 5 6

1 2 3

for both ignition feed modes wire like this

WARNING: If ignition on the vehicle is left ON and the engine is OFF, you shall deplete your starter battery down to 10V. Also, if your alternator is less than 60A or can not produce 60A at idle revs you may discharge your starter battery.

With any of these modes selected, the BB may take up to 60 seconds to turn on. This is due to the BB being asleep, when not in use. This preserves battery life. It brings the quiescent current down to 1mA.

Sterling Power Products

Page 10

First Time Use (when wiring up)

On first start up all LEDs will light up. A beep should sound. The fan shall then start running for around 5 seconds. If, after this, 2 red LEDs flash for 8 seconds you may have a calibration issue and the unit should be returned to Sterling. If 2 solid red LEDs are on at the top or bottom then you either have high or low input voltage (respectively) - check your voltages.

Changing charging profile during startup

After the initial start up an LED on the first column shall light up for 5 seconds, this shall indicate the battery type selected - default is ‘Sealed’ lead acid. This is your window of opportunity to change the charging profile. If you have missed the opportunity, you can wait for the unit to go in to normal operation and follow the instructions immediately below.

voltage. (x2 for 24V | x3 for 36V | x4 for 48V)

prop ortion al inc rease o r decr ease in the

further from 20DegC in either direction leads to

senses less than 20DegC = increased voltage.

Higher than 20DegC = decrease voltage. The

Preset Battery Options

Bulk / Abs. Cond. Float Min | Abs. | Max

Options

1) Gel

2) AGM I

3) Sealed

4) Lithium I

5) Lithium II

6) AGM II

7) Open

8) Calcium

9) Desulphation

10) Custom

Volts

13.80

14.00

13.75

14.10

14.15

14.40

13.60

14.20

13.80

14.40

14.10

14.60

14.00

14.80

14.30

15.10

-------

15.50 Custom Charging Profile

Volts

13.70

13.40

13.60

13.80

13.70

13.30

13.60

-------

Mins

600

120

30 30 60 60 60

240

Mins 1440

480 480

30 480 480 360 240

all voltages are based on 20 Deg C. If sensor

*Lithium profiles have reverse polarity protection disabled. **All voltages shall be 0.1V higher for the first 3 minutes of the chargers operation.

If eithe r l ithiu m sett ings a re selec ted AND the temperature sensor is connected to the negative terminal of the lithium battery, the BB shall trip at <0Deg at the sensor. This can be adjusted in custom profile, or simply remove temp sensor.

Remember it is the voltages that are more important than our battery types. After installation, test the voltage from the BB is the desired voltage. Ensure you remove at

least 1 wire from the battery temperature sensor as the product voltage may be higher (if in cold climate) or lower (if in warm climate) than the preconceived voltage. The voltage requirements of the battery

company will override our recommendations as it is them who are supporting the battery warranty.

Left and right meter readings (BB larger model).

During normal operation

IUoUo

Bulk / Boost Absorption Conditioning Float (S) /Standby (fl)

input

D-Sulf.

Open

AGM II

Sealed

AGM I

GEL

voltage

15.4V

15.0V

14.6V

14.2V

13.8V

13.4V

13.0V

12.6V

12.2V

Calcium

Lithium II

Lithium I

Custom

Input voltage (x2 for 24V)

If battery temperature sensor is connected then

Out of range voltage values

Battery charge progress

output

840

720

-2

600

-4

480

-6

360 240

-8

Input voltage

120

-10

-12

-30

LT Trip

Output voltage

(x2 for 24V, x3 for 36V, x4 for 48V)

voltage

15.4V

15.0V

14.6V

14.2V

13.8V

13.4V

13.0V

12.6V

12.2V

960 18

High Volt in (fl) / out (S) High temp trip(fl) BMST(S) No Fault (S) / P.Pack (fl) Regen timer off (S) / on (fl) Batt. Sense on (S) Volt drop sense (fl) PIM (S) 1/2 power (S) / night (fl)

Low Volt in (fl) / out (S)

High bat temp (fl) / TCO (S)

Alarms

If voltage exceeds the meter’s range the upper right LED shall flash. If the voltage falls short of the meter’s range the lower LED shall flash. If two neighbouring LEDs, on the voltmeter, are on simultaneously then the real voltage is between these two pa rameters. Example, if LEDs at 14.6V and 14.2V were on then the approximate voltage shall be ~14.4V.

Low or high output voltages

If the output voltage is below 1V (2V at 24V) or reverse polarity then the low output voltage LED will flash (number 23). Similarly, if the output voltage is above

15.5V (31.0V at 24V) the high voltage LED shall flash (number 16). To resurrect these problems, bring the voltage above 1V on the output and below 15.5V, correct the polarity and then restart the device.

Return to factory default: This shall irreversibly

erase all previously entered settings. Press and hold

both buttons for 8+ flashes and let go. 3 green LEDs on both columns shall flash. The unit should then reboot with the default settings.

To view charger ’s status:

Simply hold the SELECT button for 1 second and the right LED should flash indicating the status of the charger. This shall flash for 8 seconds. To return quickly, press the SETUP/ENTER button once.

Changing charging profile during operation.

While the unit is running, hold down SETUP button for 10 flashes. All LEDs on the first column shall now flash. By using both buttons toggle through the various profiles (see below). The right button is up the column and the left button takes you down the column. The LED shall light up demonstrating which profile you have selected. When the LED has illuminated at your desired profile simply hold both buttons for a couple of seconds or simply just leave the charger alone for 30 seconds and it will set the desired profile. The corresponding LED shall flash to confirm. The unit shall then restart and go through the starting cycle again in this new charging profile.

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Page 11

# flashes

Both buttons

8 - 35

Factory Reset

# flashes

only buttonSetup

0-1

Silence Buzzer / Status display / Change to voltage display

Software version

Select battery type

Power supply mode / live output voltage

Pure ignition feed mode

Change operational on/off voltage

Set auto regen. braking timer

Temperature voltage compensation

Buzzer off (long term)

Maintenance Mode

# flashes

Select only button

0-1

Silence Buzzer / Status display Change to voltage display

Display temperature

Force to float

Night Mode

1/2 Power Mode

Standby

Turn unit off / on again

OEM Lock

Solar Charger on*/off

BB Charger on*/off

NN Ą ŒŎÕMǾ

mode

on/off*

ĘĘ ŃOMǾŊÑ

on*/off

(solar)

ĞŎǾŃÑ PŎ ĞÕŎMP

Î ĜÌ ÕŎŃÔ

ĘMPPÑǾŘ PŘŐÑ

ĞMŃPŎǾŘ Ī ÑŒÑP ǼǼǼË

Í ÒŊOP ÖŎŇÑ

ĈCČ ŐŎR ÑǾ Ö ŎŇÑ

Ĭ PMŌŇNŘ

İ ÞǾŌ ŎŅŅ ÞŌÒP

ĘMPPÑǾŘ Ö MÒŌPMÒŌÑǾ

on*/off (solar)

ŃOMŌŊÑ

operational

on-off voltage

Ĩ ŎR ÑǾ ŒÞŐŐÕŘ

mode

ŐÞǾÑ ÒŊŌÒPÒŎŌ

mode

Ĭ ÑP ĞMŌ Ĭ ŐÑÑŇ ĂŌŎP ŇŎŃÞÖ ÑŌPÑŇÅ

ÖMÒŌPÑŌMŌŃÑ

mode

ŒŎÕMǾ ŃOMǾŊÑ

on*/off

(solar)

Ĭ ÑP ĖÞPŎ

Regen timer

İ ÑÖŐ QŎÕPMŊÑ

comp

NÞŖŖÑǾ ŎŅŅ

(long term)

Guide to the buttons

If BB is in sleep mode, either buttons can be pressed to wake the BB up. The BB needs to be on (lit up) for any of these buttons to operate

SETUP ENTER

SELECT

SETUP

SELECT

BBS solar only

1x blue LED flash = 1 second

For a more detailed description of these options please look at the next 2 pages

Factory Reset

To restore the BB to default settings simply press and hold both buttons together for between 8-35 flashes and let go. This shall restore the BB to factory default settings. To confirm a successful reset, 6x Green LEDs shall flash.

A factory reset may be worth doing if your BB is behaving incorrectly after having made adjustments to it, as it allows your start again.

Page 12

Force Options

Silence Buzzer

If the buzzer is sounding and you wish to silence it, simply press SETUP button with a quick but firm press. This should silence the buzzer. It is a short term feature. If you wish to turn the buzzer off forever, please press the SETUP button down for 40 flashes.

to view the status of the charger - do a quick press. to view the BB as a voltmeter - do a quick press.

Software version

If you are interested in the software version of your BB, press and hold the SETUP button down for 5 flashes. The display is in binary format.

Battery type select

Please consult page 10 regarding changing battery type. Also, for custom battery type please consult page 14.

Force unit to output live charge voltage without output battery connected (i.e. as a power pack / live output ) - (default off).

This mode shall allow the unit to operate without needing a voltage on the output terminal. Hold down the SETUP button for 15 flashes and let go. A charge voltage shall now be applied to the output terminal - irrespective of whether there is a battery there. Press SETUP for 15 flashes then let go.

Pure ignition feed mode (default off)

Pure ignition feed mode, if this mode is enabled the BB shall ONLY operate if there is an ignition feed. It shall NOT activate based on voltage DC input at the Batt input terminal. Press SETUP for 20 flashes.

Change operational on/off voltages (13.2V on / 13.0V off default x2 for 24V)

If you wish to change the BB’s activation voltages then you can do it here. The default is 13.2V on (x2 for 24V etc) and off is 13.0V (x2 for 24V etc). Press the SETUP button down for 25 flashes. Then the second column of LEDs shall flash. The voltages on this column then become the reference to activation voltages. The first option to select is ‘on’ activation voltage. Default is 13.2V (hence that LED flashes) - use the SETUP / SELECT buttons to toggle up and down to column to the desired activation voltage. Press and hold both buttons together to confirm voltage selection. Only the on voltage needs to be selected, the off voltage is always 0.2V below. These settings shall last until a factory reset has happened.

Set auto regenerative braking timer (default 240 seconds).

If no ignition feed is being used on the BB then this timer is relevant with EURO 6+ installations. With Euro 6 engines the alternator is often turned off during driving. This timer enables the BB to continue working even when the alternator is off. Within this timer window the ECU on board should prompt the alternator to turn on again as the ECU is monitoring the starter battery’s depletion. When the alternator turns on again the voltage should climb up and the regen. braking timer restarts. The timer engages when the input voltage drops below the operational off voltage (default 13.0V, as above) and reactivates above the on voltage (13.2V, as above). IF ignition feed is applied to the unit this deactivates this braking timer. When ignition feed is no longer in use this timer reactivates. Press SETUP for 25 flashes. The second column of LEDs shall flash. Use the orange numbers as a reference with regards time in seconds. Use the SETUP / SELECT buttons to toggle the LEDs up and down that column to select the time you wish to set as the regen. braking timer. For EURO 6+ simply use ignition feed and do not worry about this feature.

Temperature voltage compensation (default on)

If you do not wish the BB to fluctuate output voltage based on temperature at the temperature sensor then this mode needs to be set to off. Default mode means that the BB shall elevate the voltage by the rate of 18mV per Deg C below 20Deg C and reduce the voltage by 18mV per Deg C above 20Deg C. You may need to set this to off if: You have a lithium battery and have set custom charge profile feature and you want to monitor the temperature at the battery because you want a 0Deg C trip, for example. If you are in a lithium profile (I or II) this mode is off anyway.

Turn off buzzer (buzzer on as default)

If the buzzer alarm is coming on and it annoys you, you can turn it off!. Please press the SELECT button down for 40+ flashes. This shall disable the buzzer altogether, indefinitely. You can reapply the buzzer function by repeating this procedure.

Maintenance Mode (default off)

This mode locks the unit in voltmeter mode so you can fault find. The columns of LEDs stay on as voltmeters. This is ideal if you do not have a voltmeter and you wish to provide information above what the input and output voltages are at the BB itself. The unit shall remain in Maintenance Mode until you repeat the 45 flashes or do a factory reset. Maintenance mode maintains charging function but the BB does not go into sleep and remains constantly live. The charger shall not go to sleep and shall remain on (not necessarily charging). The BB shall charge if the input voltage / ignition feed is as per normal operation. As the unit does not go to sleep the BB shall consume about 200mA at 12V (2.5W). This is compared with 1mA at 12V (0.12W) when in sleep mode.

Sterling Power Products

quick press

5 flashes

10 flashes

15 flashes

20 flashes

40 flashes

45 flashes

25 flashes

30 flashes

35 flashes

Page 13

Force Options

Silence Buzzer

to view the status of the charger - do a quick press. to view the BB as a voltmeter - do a quick press.

Display temperature

If you wish to view the temperature at the battery temperature sensor (if installed) - you can view it here. The temperatures that can view are between -30DegC and +2DegC on the front panel. If you wish to view a full range of temperature then you shall need the remote control BBURC.

Force unit to float

We recommend that you understand what float means before committing to float mode. It is basically a lower maintenance voltage - fairly harmless. Once you have forced the unit into float mode it shall remain there, forever - until you either do a factory reset or repeat this procedure.

Force unit to 1/2 power mode

This mode shall put the charger into half power mode. As the name suggests, if you have a 60A charger it shall put the maximum current to 30A. A 30A BB charger shall reduce to 15A (approximately) etc... The BB shall remain at half power forever, until either a factory reset is done or this method is repeated. You may need this mode if you want to reduce the current for the sake of keeping within the maximum charge rate of your batteries or due to pre-existing cabling being insufficient for the full power of the charger.

Force unit to night mode

This mode shall put the charger into half power mode (as above) but only for 8 hours at a time. The BB shall be on half power mode for these 8 hours only. It shall then resume as normal full power after these 8 hours. You have to repeat this procedure every time you need it.

Turn the charger to standby

If you wish to put your BB into standby then apply this mode. Standby is a one off setting. It shall stop the boost of the BB but shall remain on - pending a button press to get out of standby. The BB shall come out of standby during the next charge cycle, so is not a permanent setting. To indicate that standby is on LEDs 12 and 15 shall flash. Press any button to take out of standby.

Turn charger off

If you wish to turn your BB off then apply this mode. Off means the BB shall stop charging awaiting you to press either button. To turn off is a one off indefinite setting. It shall stop the boost of the BB - pending a button press to get out of standby. The BB shall turn on again only when a button is pressed. If the charger is disconnected and reconnected the BB shall remain off, also, during power cycles it shall remain off. To display the charger being off the top row of LEDs 12, 13,14,15 shall flash.

OEM lock

If you are an installer and wish to make settings to the BB and then lock the charger in these settings, to prevent tampering by the end user, then apply OEM lock. Once this mode has been applied NO options can be adjusted. Factory reset is the only method to remove this feature and restores the BB to defaults. The BB demonstrates OEM lock by flashing 4 Red corner LEDs.

40 flashes

quick press

5 flashes

10 flashes

15 flashes

20 flashes

25 flashes

30 flashes

Solar charger on* / off

the solar charge feature of the BBS1230 can be turned off, if not required. Default is on. Press the SELECT button for 45 flashes and let go, to turn off.

45 flashes

BBS1230 only

BB charger on* / off

If you wish for the BBS1230 to be pure a solar charger and for the BB aspect to be switched off - use this mode. Press the SELECT button for 50 flashes and let go to turn the BB charging off. Solar charging ONLY! May be ideal for a bright sunny day and you wish to save a very small amount of fuel.

BBS1230 only

50 flashes

Sterling Power Products

Page 14

Custom Settings

CUSTOM BATTERY TYPE SETTING (for expert use

only - not required for general operation)

Before proceed ing with this, p lease read a nd understand all instructions as it is quite complex and could take more than one attempt. There are timed intervals of 30 seconds per setting so it is very important to know exactly what you require before starting. If any errors are made simply wait a few minutes and you can start the cycle again. The settings offered for adjustment in sequence:

Important information: If during these operations you get yourself in a mess and find yourself pushing buttons aimlessly, then please resort to the factory reset. To delete all and return the product to its default factory settings.

A) Boost / absorption voltage (high voltage charge). B) Condi tioni ng volta ge (medi um charg e r ate

normally between boost and float voltage).

C)Float voltage (no longer charging, this will provide

voltage at a reduced level to maintain the batteries and provide power for any loads applied).

D) Absorption time factor adjust. The length of time

spent in absorption can be adjusted by a factor 0-18. Th is may be benefi ci al fo r d if fe rent ba ttery chemistries. Gel, for example, tends to absorb current at a low rate, thus, increasing the length of time spent in absorption may be beneficial (set nearer 18). AGM, the reverse (set nearer 0). If in any doubt, ask your battery retailer or simply use one of our preset values. To calculate the absorption time from the time factor simply multiply the factor number (0-18) by the length of time it takes for the charging voltage to hit the absorption voltage (typically 14.4V). If it takes 40 minutes to reach absorption and you set your ATF to 4 then 4x40mins = 160 minutes. The maximum time the unit can stay in absorption is 24 hours 1440 minutes.

E) Minimum and maximum absorption times.

Here you can set the maximum and minimum time the unit stays in absorption. For example, you may have AGM that may need a maximum of one hour, or GEL which could require a minimum of 720 minutes (12 hours). We recommend that you write down your required voltages and times in the space below. This is so you know what to programme during setup.

Desired custom values - make a note.

Boost / bulk / absorption (V) ________ Conditioning (V) ________ Float (V) ________ Absorption Time Factor (0-18) ________ Absorption Minimum (0-960 minutes) ________ Absorption Maximum (0-960 minutes) ________

Operation

Press and hold SETUP button for 10 flashes, let go.

All of the first column of LEDs shall flash

Press the setup/select button to move LED down to custom. Hold both buttons for 2 seconds to confirm.

Sterling Power Products

Opportunity to adjust Fast Charge / Bulk / Absorption voltage.

Red Custom LED will flash for 3 seconds to confirm. Red Custom LED will come on constant, Green Fast

Charge LED will flash (section 1 on graph). Adjust

Fast Charge voltage by using the Select and Setup buttons to go up and down the right LED column to select the correct Fast Charge voltage. Once content, wait 30 seconds, or press both buttons to confirm. The unit shall then proceed to Conditioning charge voltage (next below).

Opport unity t o adjus t Condi tioning charge voltage

Red Custom LED will come on constant and Green

Conditioning LED will flash (section 3 on graph).

Likewise, adjust the conditioning voltage by using the Select and Setup buttons to go up and down the right LED column to select the correct Conditioning voltage. Once content, wait 30 seconds, or press both buttons to confirm. The unit shall then proceed to float voltage set (next below).

Opportunity to adjust float charge voltage

Red Custom LED will come on constant and Blue

Float LED will flash (section 3 on graph). Likewise,

adjust the float voltage by using the Select and Setup buttons to go up and down the right LED column to select the correct Float voltage. Once content, wait 30 seconds, or press both buttons to confirm. The unit shall then proceed to float voltage set (next below).

Opportunity to adjust absorption time factor

Red High Temp LED will come on constant. Green

Fast Charge LED will flash and will Blue Float LED

flash (section 1 and 4 on graph). This time, adjust the time by using the Select and Setup buttons to go up and down the right LED column (refer to the blue scale

scale 0-18) to select the correct time. Once content,

wait 30 seconds, or press both buttons to confirm. The unit shall then proceed to minimum absorption time factor (next below).

Why use Absorption Time Factor (ATF)?

ATF is simply a number (0-18) that can be used to multiply by the length of time the charger takes to reach the absorption voltage from start. For example,

if the absorption voltage is reached in 10 minutes with the ATF at 4, then 10mins x (ATF 4) = 40 mins of absorption.

Opportunity to adjust minimum absorption time factor

Red High Temp LED will come on constant. Yellow

Absorption LED will flash and will flash blue Float

(section 2 and 4 on graph). This time, adjust the time by using the Select and Setup buttons to go up and down the right LED column (refer to the brown scale 0-

960) to select the correct time. Once content, wait 30

seconds, or press both buttons to confirm. The unit shall then proceed to maximum absorption time factor (next below).

Page 15

Custom Settings continuation

Opportunity to adjust maximum absorption time factor

Red High Temp LED will come on constant.

Green Conditioning LED will flash and blue

Float will flash (section 3 and 4 on graph). This

time, adjust the time by using the Select and Setup buttons to go up and down the right LED column ( ) to refer to the brown scale 0-960 select the correct time. Once content, wait 30 seconds, or press both buttons to confirm.

A from the middle of each row will green LED flash for around 8 seconds to confirm the setup is completed. The unit will then restart.

Opportunity to adjust temperature sensor trip. FINAL custom setting.

The fi na l s etting t o adjust i n t he c us to m

configuration is to set temperature trip. This turns off

the BB’s charging if this temperature is reached at

the temp sensor (if temp sensor not fitted, then

-2

this mode is irrelevant). The default, as it assumes

-4

lead acid, is -30 Deg C, so the RED LED at the

-6

bottom shall illuminate (24). For lithium, bring this

-8

LED up to your desired trip temperature. E.g 0, -2, -4

-10

Deg C etc. Use the SETUP and SELECT button to

-12

-30

bring the LEDs up and down the second column to

the desired temperature. Press both buttons to confirm the selection. If y ou have lead acid batteries. We recommend leaving it at -30DegC (default) - if charging lead acids. Lithium batteries may vary around the 0DegC mark.

Adjustment of operational voltages.

The 4 main control voltages below are inextricably linked. The voltages can only be adjusted as a block (not individually). For example, if you wish to reduce the Cutoff

voltage by 0.2V then all other voltages in the block shall

reduce by 0.2V.

Input voltage

Charging voltage 13.5V

13.2VCutoff voltage

regen braking timer

Lower voltage trip 12.0V Volt. trip w/ ignition 10.0V

Charging voltage (default 13.5V) (always 0.3V above

Cutoff voltage): At this voltage the charger starts

charging. After 5 seconds above 13.2V the regen braking timer is set. If the input voltage drops to 11.9V - 13.0V this timer begins. Timer reset when input voltage is 13.2V+.

Cutoff voltage (default 13.2V): This voltage is only

relevant after the charging voltage has been met and the charger is charging. When the input voltage drops below this cutoff voltage the charger stops charging and shall eventually go to sleep. If the input voltage remains between 13.2V-13.5V the charger shall continue charging. The Cutoff voltage is the parameter that the user

changes. Cutoff voltageAs noted, by adjusting the you

change the other three voltages mentioned by the same amount.

Lower voltage trip (default 12.0V) (always 1.2V below

Cutoff voltage): When the input voltage drops below the

Lower voltage trip the charger turns off. The 11.9V

threshold is only relevant if the is regen braking timer activated. If not, then the low voltage trip is 13.0V. If in ignition feed mode, the low voltage trip is 10.0V.

Low voltage trip (default 10.0V) always 3.0V below

Cutoff voltage):

All 4 vol tages ar e always link ed. This block can be adjusted b y chan ging t he

Cutoff voltage value up and

do wn. T his su bseq uently ch ang es t he o the r th ree voltages by the same value.

Sterling Power Products

During this particular setup procedure we have made the voltage setup LED bar more sensitive so that the adjustment can be made in 0.1V increments. For example, for 13.1V the 13V LED is on and the 13.4V LED is flashing. The same idea for 12.9V. The 13V LED is on and the 12.6V LED is flashing. Remember

that you are adjusting the whilst Cutoff voltage simultaneous adjusting the voltage, Charging Lower voltage trip and the Low voltage trip.

13.4V 13.4V LED ON

13.3V 13.4V LED ON + 13.0V LED FLASHING

13.2V 13.4V LED ON + 13.0V LED ON

13.1V 13.4V LED FLASHING + 13.0V LED ON

13.0V 13.0V LED ON

12.1V 12.2V LED FLASHING

12.0V 12.2V LED FAST FLASHING

To enter the menu press (SETUP/ENTER) & SELECT for more than 20 seconds.

BOOST CONDITIONIN G, , and ABSO RPTION

FLOAT LEDs will flash to indicate Cutoff voltage

Setting Menu. At the same time the actual Cutoff

voltage will be displayed in the left LED voltage bar

according to the description above. To decrease voltage press SETUP/ENTER and to increase voltage press SELECT button. The range you can choose is Cutoff voltage

between 12.0V-14.6V.

Charging voltage is always 0.2V higher. Lower voltage trip is always 1.1V lower. Low voltage trip (ignition mode) is always 3.0V lower.

If you do not touch any buttons for 30 seconds the default voltage of 13.0V shall be restored and saved.

To confirm your custom voltage you must press both buttons (SETUP/ENTER) and (SELECT) simultanously for 2 flashes.

The chosen voltage will be saved and the unit will restart. If you feel unsure, do not touch any buttons. The default value will be restored automatically.

Page 16

Remote Control

1) Volts select button.

2) Voltage displayed is voltage into product.

3) LCD screen with backlight.

4) Fast charge led indicator.

5) Condition battery stage.

Volts Select Button (left)

Volts

Select

Quick push = back light on. Short press ~1 second = input voltage, press again for output voltage, press again for remote sense voltage.

Hold for 4 seconds to toggle between buzzer on/off, bu2 should appear.

Setup - Menu:

to escape menu hold both buttons down until ‘END’ appears. Or, just leave the remote for 10 seconds.

Both Left and Right buttons

Hold both buttons for 2 seconds to force to float FtF, toggle on / off.

Press and hold both buttons for 4

seconds to enter standby mode, Stb should appear. Repeat to turn unit on.

Press and hold both buttons for 6 seconds to turn unit off. oFF shall appear. Repeat to turn unit on.

Toggling is unidirectional

“rt” displays remaining absorption or conditioning time

Press “select” button to see value.

“btY” displays battery profile type (0-9). This number

denotes which charging profile the charger is set to. Press “select” to see value. (Ref: table labelled ‘Battery Chemistry Selection’ on).

“coU” displays input cut off voltage (the voltage at which the

unit stops charging) (13.4V). Press “select” to see value.

“IoU” display input / output base voltage (12/24V). Press

“select”. First input voltage will be displayed with “in” LED on for 3 sec. then output voltage with “out” LED on for 3 sec.

change from celcius to fahrenheit or back (default = “C/F” *

celcius). Press “select” button to enter setting. Then press right button to change between Fahrenheit (FAH) and Celsius (CEL). Confirm setting by pressing “select” button.

“CL” set current limit to 1/2 or 1/1 (full). Press “select” button

to see actual setting. Press “change” (right) button to change setting. Press “select” to confirm setting.

“buC” turn Buzzer on / off (default = on). Press “select” to *

see actual setting. Press “change” button to change between settings. Press „select“ again to confirm setting

Autoscroll on / off (default = off). Press “select” to see “Asc”

actual setting. Press “change” button to change between settings. Press “select” again to confirm setting.

“Von” Voltage / temp display during standby and sleep.

Toggle between on and off, press “select” (left) button to select.

“con” change contrast value from 0 to 7 (default = 3). *

Press “select”. First the lowest and the hightest value will be displayed. Then the actual value. Press “change” button to change settings. Press “select” again to confirm setting.

change backlight colour . off <- auto -> green -> red -“bLc” *

> blue (default = auto). Press “select” to see actual setting. Press “change” button to change between settings. Press “select” again to confirm setting.

“bLt” change backlight time . 1 - 600 seconds, 0 = always *

on, (default = 60). Press “select”. First the lowest and the hightest value will be displayed. Then the actual value.

“br9” change remote display colour red to green voltage

threshold.* 8.0V-13.3V (default 12.4V). When below 12.4V

display is red and when 12.4V or above the remote goes green. When Press “select”. First the lowest and the highest value will be displayed.

6) Charge complete on float.

7) Voltage displayed is volts out of product.

8) Scroll menu button.

9) Screen display showing a unit fault.

Volts

Select

Change

Temp

Temp Menu

Cond.

12.2

hold > 3 sec

On / Off

hold>3 sec

Fault

Float

Out / Rem

Batt.

Temp

Change

Temp Menu Change (right button)

Quick press = back light on. Short hold ~1 second = switch between unit’s temperature and temperature sensor. If nc appear it m eans that the temperature sensor is not connected.

Hold for 2 seconds to toggle night mode on / off, nn should appear. 1/2 power for 8 hours.

Hold button for 4 seconds to enter the Setup Menu “rt” shall appear.

Then the actual value. Press “change” button to increase value. Hold “change” button to accelerate. When max. value reached it will start with lowest value. Press “select” again to confirm setting. Press “change” button to increase value. Hold “change” button to accelerate. When max. value reached it will start with lowest value. Press “select” again to confirm setting.

“b9b” change voltage from green to blue backlight 12.4 - *

16.0V (default 13.4V). Press “select” .First the lowest and the hightest value will be displayed. Then the actual value. Press “change” button to increase value. Hold “change” button to accelerate. When max. value reached it will start with lowest value. Press “select” again to confirm setting.

“Led” change LED on time 1 - 600 seconds, 0 = always on,

(default = 60). Press “select” .First the lowest and the hightest value will be displayed. Then the actual value. Press “change” button to increase value. Hold “change” button to accelerate. When max. value reached it will start with lowest value. Press “select” again to confirm setting.

“uId” display Unit ID. Press “select”. Value will be displayed for

5 sec.

“uSW” display unit software version. Press “select”. Value will

be displayed for 5 sec.

“rSW” display remote software version. Press “select”. Value

will be displayed for 5 sec.

“Loc” Unit lock code = 1 to 999 (default = 00 = unlocked).

WARNING This mode shall lock menu setting options of the

unit by virtue of a pass code, be careful. Press “select” to enter “Loc” setting. Press “change” button to increase value, hold to accelerate. Stop when on the number you require and press “select” button to confirm. The software shall store this number, then the display shall read: loc -> on -> #. # = number you have stored. To remove loc, return to loc and re-enter the number, Press “select” button and the display should read: loc -> off (green back light). Please make a note of this loc code

here:_______.

“rSt” Resets remote to default values*. Press “select”. “NO”

will be displayed. Press “change” to toggle between “YES” and “NO”. Confirm by pressing “select”. rSt will display if resetting.

“rSu” Resets the battery charger to default settings. Press

“ ” “NO” “ ”select . will be displayed. Press change to toggle between YES and . “ ” “NO” Confirm by pressing “select”. rSt will display if resetting.

Remote control:

cut hole diameter 54mm

(unidirection)

Temp Menu

Change

Absorption

H Charge

Sterling Power Products

In / Unit

Audible alarm on/off

Volts Select

Remote Error Codes E00 = high input voltage E01 = high output voltage E02 = high unit temp E03 = high batt. temp E04 = no output voltage

menu scroll

Page 17

Understanding the front LED

information control panel

Pro Batt Ultra - 4 Stage battery to battery charger DIGITAL control

IUoUo

12V-12V

60A input

Batt. to Batt.

Charger

Bulk / Boost Absorption Conditioning Float (S) /Standby (fl)

D-Sulf.

Calcium

Open

AGM II

Lithium II

zone

Lithium I

Sealed

on start-up.

AGM I

GEL

Battery preset options.

Batt Type LED displayed

Custom

Specifications: 12V-12V 60A input

- Current limiting

- Thermostatic control fan

- Auto or ignition feed

- Suitable for use with

- Smart alternators

- Regen. braking

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

Battery charge

zone

progress

12 13 14 15

15.4V

840

15.4V

15.0V

720

15.0V

-2

600

14.6V

-4

480

14.2V

-6

360

13.8V

13.4V

Input voltage

-10

13.0V

-12

12.6V

-30

12.2V

LT Trip

1 26

SETUP ENTER

1 sec =

1x blue flash

13.8V

240

-8

13.4V

120

13.0V

12.6V

12.2V

SELECT

7 6 5 4 3

960 18

High Volt in (fl) / out (S)

High temp trip (fl)

No Fault (S) / P.Pack (fl)

Regen timer off (S) / on (fl)

zone

Batt. Sense on (S)

Volt drop sense (fl)

1/2 power (S) / night (fl)

Low Volt in (fl) / out (S)

High bat temp (fl)

Sterling Power

Alitech BB1260

10R-0513962

12V - 12V

Designed and Developed in England

Made in Taiwan

Output

Alarms

Voltage

BB1260 range

zone

BB1230 range

Batt. to Batt. Charger | MPPT solar reg. | Starter batt. maintainer

Upper

Lower

Battery to Batter charger and Solar MPPT

with starter battery maintainer

Battery charge progress

15.4V

15.0V

14.6V

14.2V

13.8V

13.4V

13.0V

12.6V

12.2V

SELECT

Solar Neg Max V

Com.

31V

Neg.

- -

12V-12V 30A continuous

- 350W solar processing

-1A engine batt. maintain

- Unlimited solar size

- Current limiting

(fl)

960 18

High Volt in (fl) / out (S) High temp trip (fl) No Fault (S) / P.Pack (fl) Regen timer off (S) / on (fl)

zone

Batt. Sense on (S) Volt drop sense (fl)

1/2 power (S) / night (fl)

Low Volt in (fl) / out (S)

High bat temp (fl) SVEM (S)

Due to poor conductivity through chassis. Please use appropriately rated DC cable direct from engine to auxiliary battery. Do NOT use chassis.

Output To

Aux Batt

Auxiliary Information

zone

Ignition feed live

Solar power live

Solar High V Trip live

zone

on start-up.

Input voltage &

Battery preset options.

Batt Type LED displayed

Ignition feed (4)

BMS 2 (5)

BMS 1 (6)

4 5 6

1 2 3

Battery temp. sensor (1,2)

Calcium

Lithium II

Lithium I

Custom set voltages

Custom

Remote Voltage sense (3)

IUoUo

zone

Bulk / Boost Abs / Solar (fl) Conditioning Float (S) /Standby

Active

12 13 14 15

D-Sulf.

30.0V

15.4V

840

28.0V

Open

15.0V

720

AGM II

26.0V

14.6V

600

24.0V

14.2V

480

22.0V

13.8V

20.0V

13.4V

18.0V

13.0V

GEL

16.0V

12.6V

14.0V

12.2V

1 26

SETUP ENTER

25 25

Engine Batt. input +

+ + +

1x blue flash = 1 second

Solar Pos+

360 240 120

Sealed AGM I

BBS1230 Solar

Designed and

developed

in England

made in Taiwan

Sterling Power

Alitech

BBS1230

10R-0513963

12V - 12V

LT Trip

Output

Voltage

Aux Bat out +

-2

-4

-6

-8

-10

-12

www.sterling-power-usa.com

-30

Remote control

www.sterling-power.com

Battery to battery chargers are complex systems that have a lot of external sources impacting upon them. The response of the product, as the product designer and engineer I simply cannot see how its possible for some companies to make this product with no back feed information to the new owner. The BB panel will display normal every day input and output voltages (most of the time). When in alarm mode or in setup / select feature mode then the display shall denote something different. It is important to distinguish this. In basic terms, if at least, one LED on each section is on then all operation is okay and you are reading the voltmeter. If only 1 LED is on in box 2 then it's a fault.

if all the 4 LEDs are flashing in zone 3 then the product has been manually switched off in the control panel, see instructions.

this panel may at first be very daunting but its broken down into 3 simple modes or operation (4 for the solar version), they are: A) Normal every day operation: at least 1 LED on in Zone 1- 2 and 3. B) Alarm mode / warning / fault finding: 1 LED only on in Zone 2. C) System adjust / battery type / special operation setup 1 LED Zone 1. D) Solar BB only. Zone 4.

Using the solar unit as a example (as it has the 4 areas).

Zone 1 - Primarily concerned with displaying the input voltage to the unit. Either from the starter battery / alternator or from solar.

Zone 2 - is primarily concerned with displaying the output voltage from the unit (plus alarms and setup information, see more details in the instructions).

Zone 3 - is primarily concerned in showing the progression of the charge (however, can show other information).

Auxiliary Information

Ignition feed live

Solar power live

Solar High V Trip live

on start-up.

Input voltage &

Battery preset options.

Batt Type LED displayed

Zone

Breakdown

IUoUo

Bulk / Boost Abs / Solar (fl) Conditioning Float (S) /Standby

D-Sulf.

15.4V

Calcium

Open

15.0V

AGM II

14.6V

Lithium II

14.2V

Lithium I

13.8V

Sealed

13.4V

AGM I

13.0V

GEL

12.6V

Custom set voltages

Custom

12.2V

SETUP ENTER

Active

30.0V

840

28.0V

720

26.0V

600

24.0V

480

22.0V

360

20.0V

240

18.0V

120

16.0V

14.0V

1x blue flash

1 26

= 1 second

SELECT

Battery charge progress

15.4V

15.0V

14.6V

14.2V

13.8V

13.4V

13.0V

12.6V

12.2V

(fl)

960 18

High Volt in (fl) / out (S)

High temp trip (fl)

No Fault (S) / P.Pack (fl)

Regen timer off (S) / on (fl)

Batt. Sense on (S)

Volt drop sense (fl)

1/2 power (S) / night (fl)

22 23

Low Volt in (fl) / out (S)

High bat temp (fl)

LT Trip

-2

-4

-6

-8

-10

Output

Voltage

-12

-30

Zone 4 - is only concerned with the solar operation mode.

On initial startup all the LEDs and fan will come on in sequence to simply show all the lights etc are okay. Then one LED only will operate in Zone 1 for seconds to show which battery chemistry is in operation in the product. After that the unit will go into normal operation mode. It is vital to notice that there must be at least 1x LED on each of the areas 1/2/3. Of this there is at least 1x LED on in each of the 3x Zones when the product is working in normal mode and the LEDs are showing voltages in areas 1 and 2 and battery charge progression in Zone 3.

Reading the voltage: Take, for example, the input voltage. If only one LED is on say ‘13.8V’ then the input voltage is

13.8V. However, if the 13.8V LED is on and also the 14.2V LED is flashing then the voltage is between 13.8V and

14.2V, but closer to the solid LED (so 13.9V). If the 13.8V is on and the 13.4V is also on then the voltage is between

13.8V and 13.4V, so about 13.6V. This is true for both input and output voltmeters.

If only 1 LED is on area 2 and no LEDs on in area 1 and 3 then this is a fault condition, as such the text faults are what the LED is indicating (and no longer the voltage).

Solar Panel Zone 4, when the solar unit is in operation (I.e. engine stopped) then, when the yellow LED in Zone 4 marked solar power live, then the input voltage scale will change, it will move from the gray voltage scale (normal operation) to the yellow voltage scale (but only when the yellow solar LED is on, the voltage measurement concept is the same).

Page 18

Fault Finding | Troubleshooting

Firstly, ensure the Pro Batt Ultra (BB) is wired up as per page 6 / 7. Ensure negatives are common and the BB charger’s negative is connected to the starter battery’s negative - avoid connecting to chassis negative. Voltages between common negatives should be ~0V.

Secondly, to test the BB, remove (or turn off) any secondary charging source like AC to DC battery chargers or solar chargers going to the battery banks. Leave the primary charger connected (alternator) ensure alternator is working. We also recommend turning off any loads (inverters etc.).

How to test if the Pro Batt Ultra (BB) is charging:

With engine running (alternator charging), what is the voltage on the input terminal of the BB? What is the voltage on the output terminal of the BB? Measure these voltages at the BB’s terminals, not at the batteries terminals.

Is your output voltage slightly higher or lower than expected - even with no loads / chargers on?

Check if you have the temperature sensor connected. If so, no problems leaving it there, it is simply voltage compensating for when the temperature at the sensor is lower or higher than the benchmark 20DegC (69F). If lower, then the voltage shall rise and vice versa. The further from 20DegC in either direction leads to proportional increase or decrease in the voltage.

Possible, voltage drop across long cabling / fuse holder / diode. Use our remote sense connection on the unit - refer to page 6, yellow wire.

LED 16 flashing red - over voltage on input. This LED comes on if there is 19V for more than 3 seconds on the input terminal. Check the voltage at the input. Possible regulator fault, or alternative charger’s voltage is too high.

Even though, by default, the BB can work down at 12.0V on the input; it still requires over 13.5V+ to turn on and get going. If you are getting alternator voltage at the input terminal (~14V) and 14V+ on the output terminal the chances are your BB is working fine. If little to no current is passing through the charger at these voltages then the batteries are either full or they are deceased. If the output voltage is between 13V-14V (but rising) then you could have a situation where the output batteries were very low in charge (or large in capacity) and the charger shall be charging at maximum current. Provided the voltage continues rising the BB is charging.

If your output voltage is less than 13V and your input voltage is healthy, it could be three things:

1) You have a large load on your output bank - turn load off.

2) The BB has been turned off - hold SELECT button for 10 flashes and let go, to turn on again.

3) The BB is not working.

If your input voltage is less than 13V, it could be several things:

Automotive: Your alternator’s voltage is at less than 13V (the alt. is regenerative braking mode sometimes expected on modern Euro 5/6+ engines) take vehicle for drive and measure alternator ’s voltage and set up the BB to suit these needs. All vehicle manufactures have their own software / characteristics for regen. braking. Automotive or Marine: If your alternator’s voltage is ~14V then check continuity between the alternator’s B+ terminal and the starter battery. If you are getting ~14V on starter battery then check continuity between starter battery and BB input terminal. Automotive or Marine: If your alternator’s voltage is 0-13V (starter battery voltage) then alternator may have failed. Or, requires increase rpm of engine, possible belt slip. Or, your alternator current rating is lower than the rating of the BB. Possibly set BB to half power mode. You need a larger alternator.

LED 16 solid red - Over voltage output. There is 16V+ for more than 3 seconds on output terminal. Check the voltage at the output. Turn charger off, if voltage drops when off and rises again when turned on the possible charger fault. If 16V+ irrespective of charger being on then check alternative charging source.

LED 17 flashing red - over temperature. Unit has become too hot and switches off. Possible defective fan. Or, high ambient temperature, ensure good ventilation or the charger’s vents may be blocked

LED 21 flashes yellow - high voltage drop across output cable. When the battery voltage sensor is connected the device has detected too high a voltage drop between the output and the positive terminal of the battery (>1.5V). Verify that the cable thickness is sufficient. Possibly the terminals are corroded or bad connection. Also check if the cable is actually connected to the battery.

LED 22 solid yellow or flashing - the charger is in 1/2 power. It has either been manually forced into 1/2 power mode or night mode (refer to page 11-13 ). Or,

the charger has engaged1/2 power mode itself due to the device’s temperature (> 85°C). In this case, check the fan and the ambient temperature. Possibly the installation is not properly ventilated. Make the adequate ventilation.

LED 23 solid yellow or flashing - undervoltage. If the LED flashes, the input voltage is too low. Check the alternator or the charging source of the starter battery. If the LED is solid, the output voltage is very low output batteries are likely to be defective.

LED 24 flashing red - high battery temperature. The unit h as s hut dow n due t o exces siv e batte ry temperature (> 55°C). Either the battery is defective or the ambient temperature is too high. Provide adequate ventilation.

Page 19

Customer Service & Warranty

STERLI

POWER

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.

Product Warranty:

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.

To make a claim under warranty, call our customer care line at ( USA 1-(207)-226-3500, England 01905

771771). 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.

Sterling Power Products Ltd

England

www.sterling-power.com

Sterling Power USA

Warranty Service Center

www.sterling-power-usa.com

Sterling Power Products