Samlex America BBM-1225 Owner's manual

Battery

Back-up

BBM-1225

Please read this

manual BEFORE

installing your

inverter

Owner's

Manual

2 | SAMLEX AMERICA INC.

OWNER'S MANUAL | Index

SECTION 1

Safety Instructions ................................................................ 3

SECTION 2

Layout and Dimensions ........................................................ 4

SECTION 3

Description and Principle of Operation ................................. 5

SECTION 4

Installation .......................................................................... 7

SECTION 5

Operation and Protections ................................................... 9

SECTION 6

Speci cations ..................................................................... 11

SECTION 7

Warranty ......................................................................... 12

Disclaimer of Liability

UNLESS SPECIFICALLY AGREED TO IN WRITING, SAMLEX AMERICA, INC.:

1. MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION

PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.

2. ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, DIRECT,

INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF

ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USERS RISK.

Samlex America reserves the right to revise this document and to periodically make changes to the content

hereof without obligation or organization of such revisions or changes.

document is prohibited without express written permission by Samlex America, Inc.

2 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 3

SECTION 1 | Safety Instructions

1.1 PRECAUTIONS WHEN WORKING WITH BATTERIES

• BatteriescontainverycorrosivedilutedSulphuricAcidaselectrolyte.Precautions

shouldbetakentopreventcontactwithskin,eyesorclothing.

• BatteriesgenerateHydrogenandOxygenduringchargingresultinginevolutionof

explosivegasmixture.Careshouldbetakentoventilatethebatteryareaandfollow

thebatterymanufacturer’srecommendations.

• Neversmokeorallowasparkoramenearthebatteries.

• Usecautiontoreducetheriskofdroppingametaltoolonthebattery.Itcouldspark

orshortcircuitthebatteryorotherelectricalpartsandcouldcauseanexplosion.

• Removemetalitemslikerings,braceletsandwatcheswhenworkingwithbatteries.

Thebatteriescanproduceashortcircuitcurrenthighenoughtoweldaringorthe

liketometalandthuscauseasevereburn.

• Ifyouneedtoremoveabattery,alwaysremovethegroundterminalfromthebattery

rst.Makesurethatalltheaccessoriesareoffsothatyoudonotcauseaspark.

4 | SAMLEX AMERICA INC.

2.1 LAYOUT

2 1

4 3 5

Fig. 2.1: Input Side

Fig. 2.2: Output Side

LEGEND:

1.PositiveInputTerminal

2.NegativeInputTerminal

3.CommonNegativeOutputTerminalforLoadandBattery

4.PositiveOutputTerminalforLoad

5.PositiveOutputTerminalforBattery

NOTE:Allinputandoutputterminals:Holesize:5mm/0.2";SetScrew:#10,24TPI,5/16"long

2.1 DIMENSIONS

114

4.3

22.15 35.7

Height: 47.5 mm

22.15

5.5

R2.5

2.92.9 93

98.8

NOTE:Alldimensionsareinmm.

Fig. 2.3: Dimensions

SECTION 2 | Layout and Dimensions

4 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 5

SECTION 3 | Description and Principle of Operation

3.1 DESCRIPTION

Thisunitisusedtoallowany12VDC/24VDCpowersupply(withratedCurrentLimit

valueofupto25A)tofunctionasaDCUninterruptedPowerSource(UPS).Thisunitis

apassivedeviceandfunctionsonlyasaninterfacebetweentheexternalpowersupply,

thebatteryandtheDCload.Aslongasthepowersupplyisoperatingnormally,itwill

supplytheloadaswellasoatchargethebattery.

Incasetheoutputofthepowersupplyfails,thebatterywillstartfeedingtheload

immediatelythus,ensuringuninterruptedDCpowertotheload.Duringthisperiod,

thebatterywillstartdischarging.Oncetheoutputofthepowersupplyisresumed,

thepowersupplywilltakeovertheloadandwillalsore-chargethebatteryatitsoat

voltage.

3.2 PRINCIPLE OF OPERATION

INFO

Explanationgivenbelowisbasedonuseofexternalpowersupplywith

"ConstantCurrentLimit"valueof25A.InaConstantCurrentLimitPower

Supply,whentheCurrentLimitvalueisreached,theoutputvoltagewillnot

beregulatedandwilldrop.

D2D1

INPUT

BATTERY

LOAD

D1,D2

R1,R2

SCHOTTKY DIODE, 30V/30A

POWER RESISTOR 1R2 (1.2 OHM), 25 WATTS

EXTERNAL

POWER SUPPLY

BATTERY

FUSE F1

32V, 25A (FAST BLOW)

FUSE F2

32V, 25A (FAST BLOW)

LOAD

Fig. 3.1: Schematic and Installation Diagram

PleaserefertotheschematicandinstallationdiagramatFig.3.1.

6 | SAMLEX AMERICA INC.

SECTION 3 | Description and Principle of Operation

ExternalpowersupplyisconnectedtothePositiveandNegativeinputterminals.Thebattery

isconnectedtothebatteryterminalsthroughFuse1andtheloadisconnectedtotheload

terminalsthroughFuse2.

ThevoltagefromthepowersupplyisfedthroughtheisolatingSchottkyDiodeD1to

theloadandtothebatterythroughthechargingcurrentlimitingresistorsR1andR2.

DiodeD1providesisolationbetweenthepowersupplyandthebatterytoprevent

thebatteryfromfeedingbackintothepowersupplycircuit.D1hasaforwardvoltage

dropofupto0.5V.Hence,thevoltageavailabletotheloadandtothebatteryfor

oatchargingwillbeupto0.5Vlowerthantheoutputvoltageofthepowersupply.

In a battery backup application, the battery will normally remain in a fully charged,

standby condition most of the time. It will discharge to the load only when the power

supply fails. Under this standby application, the battery should be charged at the

recommended  oat voltage. Assumingthestandbyoatchargingvoltagesof12V/24V

SealedLeadAcid(SLA)Batteriestobe13.5Vto13.8Vand27Vto27.6V(at60ºFto77ºF)

respectively,the output voltage of the power supply should be adjusted as follows:

• Power Supply Voltage for 12V SLA Battery Backup: Adjust to 14V

Theoutputvoltageofthisunitfortheloadandforoatchargingofthebattery

willbe14Vminusdropofupto0.5VacrossdiodeD1i.e.around13.5V.

• Power Supply Voltage for 24V SLA Battery Backup: Adjust to 27.6V

Theoutputvoltagefortheloadandforoatchargingofthebatterywillbe27.6V

minusdropofupto0.5VacrossdiodeD1i.e.around27.1V.

Aslongastheexternalpowersupplyisoperatingnormally,itwillsupplytheloadas

wellaschargethebatterythroughresistorsR1andR2,each1.2Ohm,25W(R1andR2

areconnectedinparallelandwillprovideanetseriesresistanceof0.6Ohm).

NOTE: As the external power supply is required to feed the load as well as charge the

battery, the current rating of the power supply should be at least 20% more than the

sum of the maximum load current and the maximum charging current (4A for 12V and

8A for 24V).

Ifthepowersupplyfails,theloadwillbesuppliedbythebatterythroughtheSchottky

DiodeD2.AsinthecaseofSchottkyDiodeD1,therewillbeaforwardvoltagedropof

upto0.5VacrossD2.Thus,whenthebatteryissupplyingtheload,thevoltageseenby

theloadwillbeupto0.5Vlessthanthebatteryvoltage.NotethatSchottkyDiodeD2

isconnectedinparallelwithresistorsR1anR2andisusedtobypassresistorsR1andR2

whenthebatteryisdischargingthroughtheload.

Maximum Battery Charging Current

LeadAcidBatteriesshouldnotbechargedatveryhighchargingcurrent.Themaximum

recommendedchargingcurrentofabatteryisnormallyrelatedtoit’sAh(AmpereHour)

capacity,designatedas“C”(basedon20ADischargeRate).Themaximumcharging

currentforanSLAbatteryisnormallyspeciedwithinarangeofC/5(0.2C)toC/10(0.1C).

6 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 7

Battery Backup Application Using 12V, 40-100 Ah Battery

ThisBatteryBackupUnithasbeenpresetforbatterybackupapplicationfora12V

batteryofapproximately40to100Ahcapacitywiththemaximumchargingcurrent

limitedtoapproximately4A(Atpowersupplyvoltagesetat14.0Vandbattery

dischargedto11.1V).

Battery Backup Application Using 24V, 40-100 Ah Battery

Whenusingthisunitinthepresetconditionfor24V,40-100Ahbatterybackup

application,thechargingcurrentwillincreaseapprox.twotimesto8A(Atpowersupply

voltagesetat27.6Vandbatterydischargedto22.3V).

Calculating Maximum Battery Charging Current

MaximumbatterychargingcurrentIb={(Vp – Vd)–Vb} divided by Rs……….Equation 1

Vp=Outputvoltageofthepowersupply(14Vfor12Vbatteryand27.6Vfor24Vbattery)

Vd=ForwardvoltagedropacrossSchottkyDiodeD1(upto0.5V)

Vb = Battery voltage

Rs=Equivalentseriesresistance.Inthiscase,R1(1.2Ohm)andR2(1.2Ohm)in

parallel=0.6Ohm(SeeFig3.1).

Assumingthevoltagesoffullydischarged12Vand24Vbatteriestobe11.1Vand22.3V

respectively(atDischargeRateofaroundC/10(0.1C)Amps),themaximumcharging

currentswillbeasfollowsasper Equation 1:

For 12 V battery backup=(14V–0.5V–11.1V)dividedby0.6Ohm= 4A

For 24 V battery backup=(27.6V–0.5V–22.3V)dividedby0.6Ohm=8A

SECTION 4 | Installation

4.1 INSTALLATION DIAGRAM AND DIMENSIONS

Fig3.1showstheinstallationdiagram.DimensionaldetailsaregivenatFig2.3.

4.2 CABLE SIZING, TERMINATION AND FUSING

Thesizeofthecablesusedtoconnectthepowersupply,thebatteryandtheloadto

thisunitwilldependuponthemaximumvalueofthecurrentowandthelengthof

thecablerun.Currentowingthroughacablewillproduceanundesirablevoltage

dropalongthelengthofthecable.Thevoltagedropisproportionaltotheresistanceof

thecable.Higherresistanceproduceshighervoltagedrop.Theresistanceofthecable

increasesasthecablebecomesthinner.Similarly,theresistanceincreaseswiththelength

ofthecable.Itisdesirabletolimitthevoltagedropto2%whichwillbe0.24Vfor12V

batteryand0.48Vfor24Vbattery.

SECTION 3 | Description and Principle of Operation

8 | SAMLEX AMERICA INC.

SECTION 4 | Installation

Abatterycansupplyveryheavycurrentincaseofshortcircuitinthepathacrossits

terminals.Thiscancauseoverheatingofthecables/connecteddevice(s)andconsequent

riskofmeltedinsulationandpossibilityofre.Hence,forsafety,afastactingfuseof

appropriatecurrentcapacityshouldbeconnectedinserieswiththePositivecableand

shouldbeplacedwithin7"ofthePositiveterminalofthebattery.AutomotiveBlade

TypeofFuses,TypeATO/ATCmaybeused.

ThefollowingTablegivestherecommendedsizesofcableandfusesforexternalpower

supplyratedat25A.

Table 4.1 Sizing of Cable and Fuses

Current

Cable Length

up to 3 ft

Cable Length

up to 6 ft Fuses F1, F2

25A #12AWG #8AWG 32V,25A

Theterminalshaveatubularholeofdiameter5mmwithsetscrewforconnectingthe

inputandoutputcables.Ifthebareendofamulti-strandedcableisuseddirectly,the

setscrewmaynotpinchallthestrandsrmlyandwillresultinalooseconnectionwhich

willcausevoltagedropandexcessiveheating.For a  rm connection, the cable ends

should be terminated with suitable pin type of terminal.

4.3 ADJUSTING OUTPUT VOLTAGE OF EXTERNAL POWER SUPPLY

Beforetheexternalpowersupplyisconnectedtothisunit,itistobeensuredthatthe

outputvoltageofthepowersupplyisadjustedtotherequiredvoltageasexplained

underSection3.2.

4.3 CONNECTIONS

Switchoffthepowersupply.ConnectthePositiveandNegativeoutputofthepower

supplytotheinputterminalsoftheunitmarked“INPUT+”and“INPUT–”respectively

(1,2inFig2.1).

ConnecttheDCloadtotheterminalsmarked“LOAD+”and“LOAD–”(4,3inFig2.2)

Connectthebatterytotheterminalsmarked“BATTERY+”and“BATTERY–”(5,3inFig2.2)

CAUTION!

Ensurecorrectpolarityofallconnections.

8 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 9

SECTION 5 | Operation and Protections

5.1 OPERATION

CAUTION!

 Pleaseensurethattheratedoutputcurrentofthe12VDCor24VDCpower

supplyisonlyupto25A.

AsalreadystatedatinSection3.1,thisunitisapassivedeviceandfunctionsonlyasan

interfacebetweentheexternalpowersupply,thebatteryandtheDCload.

SwitchONtheexternalpowersupplytopowerontheloadandalsotostartcharging

thebattery.IfthepowersupplyfailsorisswitchedOFF,theloadwillbeimmediatelyfed

bythebattery.Whentheloadissuppliedbythebattery,thebatterywillstartdraining

anditsvoltagewillcontinuetodrop.Duringthistime,thevoltageattheLoadTerminals

(4&3,Fig2.2)willbeupto0.5VlowerthanthevoltageattheBatteryTerminals(5&3,

Fig2.2)duetotheForwardVoltageDropacrosstheinternalSchottkyDiodeD2.

5.2 PROTECTING THE BATTERY AGAINST DEEP DISCHARGE

Forlongerlife,LeadAcidBatteriesshouldnotbeallowedtodischargemorethan

80%.Forexample,a12V/24VloadedbatteryatloadcurrentofC/10Amps(CistheAh

capacity)willbe100%dischargedataround11V/22Vand80%dischargedat11.5V/23V.

Itisrecommendedthatasuitable“LowVoltageDisconnectDevice”,alsocalled“Battery

Guard”,maybeusedinserieswithPositivelineoftheloadforprotectionagainstdeep

dischargeofthebattery.Battery Guard, Model No. BG-40, made by Samlex America, Inc.

may be considered.

5.3 OVERLOAD AND SHORT CIRCUIT PROTECTION

INFO

 Explanationgivenbelowisbasedonuseofexternalpowersupplywith

“ConstantCurrentLimit”valueof25A.InaConstantCurrentLimitedPower

Supply,whentheCurrentLimitvalueisreached,theoutputvoltagewillnotbe

regulatedandwilldrop.

Iftheloadtriestodrawcurrenthigherthanthecurrentlimitvalueoftheexternal

powersupply(25A),theoutputvoltageoftheexternalpowersupplywillnotbe

regulatedandthevoltageattheLoadTerminals(4&3,Fig2.2)willdrop.Portionof

overloadcurrentbeyondthecurrentlimitvalueoftheexternalpowersupply(25A)

willnowbefedfromthebatteryandthebatterywillstartdrainingatthisdifferential

current.ThevoltageattheBatteryTerminals(5&3,Fig2.2)willstartdroppingandwill

beequaltothevoltagecorrespondingtostateofdischargeofthebattery.Thevoltage

attheLoadTerminals(4&3,Fig2.2)willbeupto0.5VbelowthevoltageattheBattery

Terminals(5&3,Fig2.2).External25AFuse(F2)ontheloadsidewillblow.

10 | SAMLEX AMERICA INC.

Incaseofshortcircuitontheloadside,theexternal25AFuse(F2)ontheloadsidewill

blowbecauseofveryhighadditionalcurrentsuppliedbythebattery(Additionalbattery

currentsuppliedintotheshortcircuitontheloadside=Shortcircuitcurrentminus25A

fromtheexternalpowersupply).

INFO

 OvercurrentprotectionprovidedbyafuseisdeterminedbyitsTimeversus

CurrentCharacteristic.Forexample,basedontheTimeCurrentCharacteristics

of32V,25ABladeFuseTypeATC-25fromCooperBussmann,thefusecanpass

extremelyhighcurrentsforshorterdurationsasfollowsandwillblowat25A

continuousfor>100sec:

 • 550Afor10ms

 • 170Afor100ms

 • 40Afor1sec

 • 25Acontinuous(for>100sec)

5.4 PROTECTION AGAINST REVERSE POLARITY OF BATTERY CONNECTION

CAUTION!

Pleaseensurethatthepolarityofbattery/loadconnectionisnotreversed.This

unitdoesnotprovideprotectiontotheexternalpowersupply/loadagainst

reversepolarityconnection.Thisprotectionhastoprovidedbytheuserincase

thepowersupply/loaddonothaveintegralprotectionagainstreversepolarity.

Damagetotheexternalpowersupply/loadduetoreversepolarityofbattery/

loadconnectionisnotcoveredbywarranty.

SECTION 5 | Operation and Protections

10 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 11

SECTION 6 | Specications

NOTE: Specicationsaresubjecttochangewithoutnotice.

MODEL NO. BBM-1225

INPUT

INPUTVOLTAGEFROM

EXTERNALPOWERSUPPLY

14VDCfor12VBattery/27.6VDCfor24VBattery

INPUTCURRENTFROM

EXTERNALPOWERSUPPLY

Uptomaximumof25A

OUTPUT

OUTPUT VOLTAGE

ExternalPowerSupplyisONand

issupplyingpowertotheLoad

andchargingtheBackUpBattery.

Load Terminals:

Upto0.5Vlessthan

InputVoltage

Battery Terminals

(Battery fully charged):

Upto0.5Vlessthan

InputVoltage

Battery Terminals

(Battery not

fully charged):

Voltage equivalent

toStateofCharge

ofthebattery

OUTPUT VOLTAGE

ExternalPowerSupplyisOFF.

BackupBatteryissupplyingthe

Loadandisgettingdischarged.

Load Terminals:

Upto0.5Vless

than voltage on

Battery Terminals

Battery Terminals:

Voltage equivalent

toStateofCharge

ofthebattery

OUTPUT CURRENT

ExternalPowersupplyisON

andissupplyingpowertothe

LoadandchargingtheBattery.

Load Terminals:

•=RatedAmpsof

ExternalPowerSupply

minus Battery

ChargingCurrent

•Maxlimit=25A

Battery

Terminals

(Battery Fully

Charged):

Upto0.1%ofAh

capacityofBattery

Battery Terminals

(Discharged Battery):

•12VBattery:

Upto4A(at11.1V)

•24VBattery:

Upto8A(at22.3V)

OUTPUT CURRENT

ExternalPowerSupplyis

OFFandExternalBatteryis

supplyingpowertotheLoad.

Load Terminals:

Maximumlimit=25A

OTHER

EXTERNALBACKUPBATTERY

LeadAcid:12V/24V,40Ahto100Ah

ENVIRONMENT

OPERATINGTEMPERATURERANGE

0°Cto40°C/32°Fto104°F

DIMENSIONS

(WxDxH),MM

98.8x114x47.5

(WxDxH),INCHES

3.9x4.5x1.9

WEIGHT

0.3

LBS

0.7

12 | SAMLEX AMERICA INC.

SECTION 7 | Warranty

2 YEAR LIMITED WARRANTY

TheBBM-1225aremanufacturedbySamlexAmerica,Inc.(the“Warrantor“)iswarrant-

edtobefreefromdefectsinworkmanshipandmaterialsundernormaluseandservice.

Thewarrantyperiodis2yearsfortheUnitedStatesandCanada,andisineffectfrom

thedateofpurchasebytheuser(the“Purchaser“).

WarrantyoutsideoftheUnitedStatesandCanadaislimitedto6months.Forawarranty

claim,thePurchasershouldcontacttheplaceofpurchasetoobtainaReturnAuthoriza-

tionNumber.

ThedefectivepartorunitshouldbereturnedatthePurchaser’sexpensetotheauthor-

izedlocation.Awrittenstatementdescribingthenatureofthedefect,thedateofpur-

chase,theplaceofpurchase,andthePurchaser’sname,addressandtelephonenumber

shouldalsobeincluded.

IfupontheWarrantor’sexamination,thedefectprovestobetheresultofdefective

materialorworkmanship,theequipmentwillberepairedorreplacedattheWarran-

tor’soptionwithoutcharge,andreturnedtothePurchaserattheWarrantor’sexpense.

(ContiguousUSandCanadaonly)

NorefundofthepurchasepricewillbegrantedtothePurchaser,unlesstheWarrantor

isunabletoremedythedefectafterhavingareasonablenumberofopportunitiestodo

so.WarrantyserviceshallbeperformedonlybytheWarrantor.Anyattempttoremedy

thedefectbyanyoneotherthantheWarrantorshallrenderthiswarrantyvoid.There

shallbenowarrantyfordefectsordamagescausedbyfaultyinstallationorhook-up,

abuseormisuseoftheequipmentincludingexposuretoexcessiveheat,saltorfresh

waterspray,orwaterimmersion.

Nootherexpresswarrantyisherebygivenandtherearenowarrantieswhichextend

beyondthosedescribedherein.Thiswarrantyisexpresslyinlieuofanyotherexpressed

orimpliedwarranties,includinganyimpliedwarrantyofmerchantability,tnessforthe

ordinarypurposesforwhichsuchgoodsareused,ortnessforaparticularpurpose,or

anyotherobligationsonthepartoftheWarrantororitsemployeesandrepresentatives.

ThereshallbenoresponsibilityorliabilitywhatsoeveronthepartoftheWarrantoror

itsemployeesandrepresentativesforinjurytoanypersons,ordamagetopersonor

persons,ordamagetoproperty,orlossofincomeorprot,oranyotherconsequential

orresultingdamagewhichmaybeclaimedtohavebeenincurredthroughtheuseor

saleoftheequipment,includinganypossiblefailureofmalfunctionoftheequipment,

orpartthereof.TheWarrantorassumesnoliabilityforincidentalorconsequentialdam-

agesofanykind.

Samlex America Inc. (the “Warrantor”)

www.samlexamerica.com

12 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 13

NOTES

14 | SAMLEX AMERICA INC.

NOTES

14 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 15

NOTES

Contact

Information

TollFreeNumbers

Ph:18005615885

Fax:18888145210

LocalNumbers

Ph:6045253836

Fax:6045255221

Website

www.samlexamerica.com

USAShippingWarehouse

KentWA

CanadianShippingWarehouse

DeltaBC

Emailpurchaseordersto

[email protected]

11001-BBM-1225-0816

Samlex America BBM-1225 Owner's manual

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