VOTRONIC Battery Protector 100 User guide

Installation and Operating Manual

Battery Protector 100 Switching Capacity 12 V - 24 V / 100 Amperes No. 3078

Please read this operating and installation manual thoroughly prior to connection and
start-up.

All-automatic battery protection for special purpose vehicles, campers, boats and industrial application.

The battery protector 100 is connected between supply battery and consumers. It protects the battery from dangerous total
discharge and the consumers from low voltage as well as from overvoltage.

Note: The values being indicated in parentheses ( ) apply to 24 V operation.

Functions:

 The unit protects the battery from dangerous total discharge.
 Maximum admissible current 100A; thus, it is also suitable for high-capacity consumers.
 Disconnection of the consumers for protection against dangerous overvoltage.
 The disconnection can be cancelled manually by means of the "EMERGENCY-ON" function.
 Applicable as battery main switch.
 Simple remote control with single-pole external switch is possible.
 Preliminary alarm as soon as the preliminary alarm level is reached.
 Recognition and disconnection of hidden current consumers (with switching threshold automatism).
 Immediate emergency shut-down in case of defective battery or extremely discharged battery 7.8 V (12.0 V).
 Visual indication of the operating state.
 Audible indication in case of preliminary alarm and disconnection (can be deactivated).
 Output for external alarm indication (max. 0.2 A short circuit-proof).
 Compensation of voltage loss in the feed line by separate sensor cable is possible.
 Suitable for any type and brand of lead batteries (Acid, Gel, Dryfit, Heavy Duty, Solar, fleece, AGM etc.)
 Least own electricity consumption during operation (acc. to EN13976).
 No own electricity consumption in case of disconnection by external remote control switch.

Installation:

1. Chose an installation place being clean and being protected from humidity and dust.

2. The installation place of the unit should be chosen in such a way, that the cables of battery and consumers

3. The battery protector is fastened solidly with screws in the casing flanges. The unit can be installed in any

4. In case of great distance to the battery, we recommend to connect a separate sensor cable.

5. The cable lugs of the connection cables for battery and load should be connected solidly to the terminals

6. Observe to fasten the connection cables in such a way, that neither high tensible force, nor high force of

Connection:

It is recommendable to use connection cables of different colours to avoid malfunctions due to mixed up connections.

Observe: Only use red cables for plus "+" connection and black cables for minus "-" connection.
The unit will not be damaged by eventual wrong polarization, but it will not be operating.

Imperatively observe the cable cross sections and cable length, as well as the polarity. Insert the fuses near the battery.

Please observe the connection plan, page 2!

can be as short as possible (losses) and that the pushbutton "EMERGENCY" is easily accessible. The unit
should never be covered by any objects.

position.

"Battery" and "Load" by means of the delivered screws M6. The provided rubber caps must imperatively be
used as short-circuit protection for those terminals.

pressure is acting on the terminals.

ALWAYS DISCONNECT THE POWER SUPPLY TO THE BATTERY PRIOR TO
WORKING ON THE ELECTRIC SYSTEM TO AVOID SHORT-CIRCUITS!

--2--

Start-up:

Option: Operation with sensor cable

Selector switch 6 "Sens. Batt." in position "-" (ON)

Particularly in case of powerful consumers being equipped with long charging cables, it is recommendable to measure the
battery voltage via a "sensor cable" directly at the battery. This allows precise observation of the charging voltage rates for
connection and disconnection. Use a fuse 3 A for the connection of the sensor cable being located as near as possible to the
positive pole (+) of the battery.

Option: Remote Control with Switch

Remote control of the battery protector 100 is possible by insertion of a simple switch into the sensor cable. If the relay is
switched-on by the remote control switch, the relay will be closing for at least 30 s, also if U bat.<disconnection voltage.
Activation of the (EMERGENCY-ON function) is effected by switching-off the switch for 1 second and switching it on
again.

Option: External Alarm Indication

It is possible to connect an external alarm indication at the terminal alarm.
(+switching, max. 200 mA, overload-proof and short-circuit-proof).
The output will be active in case of: preliminary alarm, disconnection of the relay by low voltage, overvoltage recognition.

In case of disconnection by the remote control switch, also the alarm output will be switched-off.

Connection Plan:

--3--

S3 S2 S1

Disconnection Voltage 24 V Connection Voltage

- - -

21.2 V / 40 s

24.8 V / 1 s

-

-

x

23.0 V / 40 s

25.0 V / 1 s

- x -

23.6 V / 40 s

25.6 V / 1 s

-

x

x

Automatic

25.0 V / 2 s

S3 S2 S1

Disconnection Voltage 12 V Connection Voltage

x

-

-

10.6 V / 40 s

12.4 V / 1 s

x - x

11.5 V / 40 s

12.5 V / 1 s

x

x

-

11.8 V / 40 s

12.8 / 1 s

x x x

Automatic

12.8 V / 2 s

Push-button EMERGENCY:

The following functions can be controlled by means of the integrated push-button "EMERGENCY ON/OFF":

If the unit had been switched-off due to drop below the disconnection voltage, it can be switched-on by means of the
push-button ON/OFF. If the disconnection voltage will be reached again, the Battery Protector 100 will automatically be
switched-off again with the corresponding preliminary alarm.

During normal operation, this push-button can be used to disconnect the consumers, which have been connected to the
Battery Protector 100 (main switch function). In this case, reconnection of the consumers must also be effected by means
of this push-button.

How to set the switching voltages and how to select the operating modes:

The different operating modes and switching voltages can be adjusted by means of the 6 selector switches at the unit rear.
Adjustment is made by vertically moving the white levers to the desired position.

Switches S1 and S2: Switching thresholds for 12 V and 24 V batteries and manual mode or automatic mode
Switch S3: Battery voltage 12 V ( x ) or 24 V ( - )
Switch S4: Audible alarm (beep) ON ( x ) or OFF ( - )
Switch S5: Not assigned, always in position ( - )
Switch S6: Sensor cable active ( - ) (see page 2: Option: Operation with sensor cable)

1. EMERGENCY ON Function

If the emergency-on function is activated over the mechanic switch of the relay (relay manually), automatic
disconnection will not be effected after 30 s. This allows full exploitation of the residual charge of the
battery in an absolute emergency situation. It must, however, be observed that the battery might be in
harmful low voltage range (<10.5 V), which requires soonest recharging.

2. Main Switch Function

Selector switches at the unit rear
Figure shows the factory-adjustment:

(Figure corresponds to the disposition on the unit)

Operating Voltage: 12 V
Disconnection Voltage: (OFF) Switching Threshold Automatism
Connection Voltage: (ON) 12.5 V
Audible Alarm: ON
Operation without sensor cable

Table for operation with fixed adjustment of switching-on and switching-off levels:

--4--

Operating State

LED ON

(green):

LED OFF

(red)

Beep

Switching

Position of the

Relay

Alarm Output

Normal Operation

Main Output ON

-

ON

not active

Preliminary alarm
voltage is reached

-

-

ON

Output

activated

Switched-off by

U Bat. < disconnection

voltage

-

every 40 s -

OFF

Output

activated

Disconnection by

Overvoltage

U Bat > U Max

-

-

every 40 s -

OFF

Output

activated

No operating voltage

OFF

not active

Manual disconnection by

ON/OFF key

OFF

not active

Supply of operating

voltage

------

OFF

not active

Function Switching Threshold Automatism:

The switching threshold automatism allows maximum use of the battery capacity and ensures optimum battery protection
in case of

 very large consumers in the range of minutes, hours.
 average consumers in the range of hours, days.
 small consumers in the range of days, weeks.
 latent smallest consumers in the range of several weeks.

The switching threshold automatism continuously determines the parameters for disconnection voltage and time. If a
battery is permanently charged with only small current rates, disconnection must be effected in case of higher voltage
levels. By this method, the cells are protected from degenerative changes and long-lasting damages at the electrodes.
Example: Disconnection will be effected at 12.1 V in 4 weeks.

Consumers with large current consumption will cause a quick drop of the battery voltage. In this case, full exploitation of
the battery capacity requires a comparatively low disconnection voltage. The Battery Protector continuously determines
the optimum parameters for the disconnection by means of an integrated lead accumulator pattern. A preliminary alarm of
40 s (LED "OFF", beep and alarm output) will be given prior to disconnection. This allows the user to switch-off
redundant consumers to avoid release of the low voltage disconnection. If the battery had been relieved appreciably after
that, the preliminary alarm will be reset.

The switching threshold automatism effects automatic reconnection, in case of the following voltage levels:

12 V Operation: 12.5 V
24 V Operation: 25.0 V

Or manually by means of the push-button EMERGENCY ON / OFF.

Indicator Lamps:

The LEDs of the display are indicating the operating state by different flashing cycles. A window "Relay manually" in the
unit front can be used for control of the switching position "On / Off" of the relay.

Explanation of the signs: - = LED is flashing

--5--

Operating Instructions:

 Overvoltage Limitation:

Sensitive consumers are protected by disconnection of the supply voltage at 15.5 V (31.5 V). Reconnection is

effected 30 seconds after a drop below this voltage level. If such high voltage levels will be reached repeatedly, the
charging controller, the battery, the charger and the battery terminals should be checked.

 Lifetime of the battery:

The Battery Protector 100 can extend the lifetime of the battery considerably. The following general rules must be

observed:

In contrast to other battery types, batteries on lead basis do not have any harmful memory effect. Consequently: In

case of doubt, partially discharged batteries are to be charged fully as soon as possible.

Store only fully charged batteries and recharge them periodically, particularly in case of used (older) batteries and

higher temperatures. Sulphation of the battery plates due to total discharge is to be prevented by immediate
charging, particularly in case of low and high ambient temperatures.

Keep batteries as cool as possible; choose an appropriate location for installation and observe the instructions of the

manufacturers.

Notes:

--6--

Safety Regulations:

Appropriate Application:

The Battery Protector 100 had been designed according to the valid safety regulations.

Appropriate application is restricted to:

1. Installation of the indicated fuses near the battery to protect the cabling of the unit.

2. Technically faultless condition.

3. Installation in a well-ventilated room, protected from rain, humidity, dust, aggressive battery gas, as

well as in an environment being free from condensation water.

Never use the unit at locations where the risk of gas or dust explosion exists!

 Open-air operation of the unit is not allowed.
 Cables are always to be laid in such a way that damage is excluded. Observe to fasten them tightly.
 Never lay 12 V (24 V) cables and 230 V mains supply cables into the same cable conduit (empty conduit).
 Check live cables or leads periodically for insulation faults, points of break or loosened connections.

Occurring defects must be remedied immediately.

 The unit is to be disconnected from any connection prior to execution of electrically welding or work on the

electric system.

 If the non-commercial end-user is not able to recognize the characteristic values being valid for a unit or the

regulations to be observed, a specialist is always to be consulted.

 The user/buyer is obliged to observe any construction and safety regulations.
 The unit is not equipped with parts, which can be replaced by the user.
 Keep children away from batteries and connections.
 Observe the safety regulations of the battery manufacturer.
 Ventilate the battery room.
 Non-observance may result in injury or material damage.
 The warranty period is 24 months from the purchase date (against presentation of the sales slip or invoice).
 The warranty will be void in case of any inappropriate utilisation of the unit, if it is used beyond the

technical specification, in case of improper operation or external intervention. We do not assume any
liability for any damage resulting hereof. The liability exclusion is extended to any service being executed by
third, which has not been ordered by us in writing. Service is to be effected exclusively by VOTRONIC
Lauterbach.

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Technical Data:

Nominal Operating Voltage (DC): 12 V or 24 V (switchable)
Operating Voltage Range (DC): 8.5 V – 40 V
Current Consumption ON 3 mA
Current Consumption OFF 3 mA
Current Consumption ON by remote control switch 3 mA
Current Consumption OFF by remote control switch 0 mA

Load Output:

maximum switching current 100 A / 150 A max. 10 sec.
Short-circuit-proof and overload-proof according to IEC and DIN EN 61036 / 61037

Adjustable Switching Level: 12 V

Voltage Level OFF (at choice): 10.6 V / 11.5 V / 11.8 V 30 sec.
Voltage Level ON (at choice): 12.4 V / 12.5 V / 12.8 V 10 sec.
Overvoltage Disconnection (U max) 15.5 V 2 sec.
Adjustable Switching Level: 24 V
Voltage Level OFF (at choice): 21.2 V / 23.0 V / 23.6 V 30 sec.
Voltage Level ON (at choice): 24.8 V / 25.0 V / 25.6 V 10 sec.
Overvoltage Disconnection (U max) 31.5 V 2 sec.

Switching level fixed for switching
threshold automatism: 12 V

Voltage Level OFF < 12.2 V 4 Weeks
Voltage Level ON > 12.5 V 2 sec.

Switching level fixed for switching
threshold automatism: 24 V

Voltage Level OFF < 24.4 V 4 Weeks
Voltage Level ON > 25.0 V 2 sec.

Alarm Output:

Execution Open Collector Hi-Side (+ switching), maximum 200 mA
Internal fuse 1 A self-resetting
Output Voltage during Alarm (active) Voltage at Terminal Battery -0.3 V
Output Voltage without Alarm (not active) 0 V

Battery Types: any lead battery with nominal voltage 12 V (24 V)
(Acid, Gel, Dryfit, Heavy Duty, Solar, fleece, AGM etc.)
Fitting Position of Unit: any
Working Temperature Range: -20/+45 °C
Protection Class: IP21
Dimensions (mm): 105 x 77 x 38 mm
Weight: 180 g
Ambient conditions, humidity of air: max. 95% RH, no condensation

--8--

Disposal of the
product in the
normal household
waste is not
allowed.

The product
conforms to RoHS.

Thus, it complies
with the directives for Reduction of
Hazardous Substances in Electrical and
Electronic Equipment.

Delivery Scope:

 Battery Protector 100
 2 Rubber Caps for Capacity Connection Terminals
 2 Screws M6 for Capacity Connection Terminals
 Operating Manual

Declaration of Conformity:

According to the stipulations of the regulations 2006/95/EG, 2004/108/EG, 95/54/EG this product corresponds to the
following standards or standardized documents:
EN55014; EN55022 B; DIN14685; EN61000-4-2; EN61000-4-3; EN61000-4-4

Subject to misprints, errors and technical modification without notice.

All rights reserved, particularly the right of reproduction. Copyright  VOTRONIC 10/12.

Made in Germany by VOTRONIC Electronic-Systeme GmbH & Co. KG, Johann-Friedrich-Diehm-Str. 10, D-36341 Lauterbach

Phone: [phone] Fax: [phone] E-mail: [e-mail] Internet: www.votronic.de