Samlexpower BBM-1225 Owner's manual

Category
Battery chargers
Type
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.
Copyright Notice/Notice of Copyright
Copyright © 2016 by Samlex America, Inc. All rights reserved. Permission to copy, distribute and/or modify this
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
2
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
i
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.
R1
R2
D2D1
INPUT
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={(VpVd)–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
i
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).
i
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
KG
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
11001-BBM-1225-0816
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Samlexpower BBM-1225 Owner's manual

Category
Battery chargers
Type
Owner's manual

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