Battery Owner's Please read this Back-up Manual · should be placed within 7" of the Positive terminal of the battery. Automotive Blade Type of Fuses, Type ATO/ATC may be used. The

BatteryBack-up

BBM-1225

Please read this manual BEFORE installing your inverter

Owner's Manual

2 | SAMLEX AMERICA INC.

oWneR'S MAnUAL | index

section 1Safety Instructions ................................................................ 3

section 2Layout and Dimensions ........................................................ 4

section 3Description and Principle of Operation ................................. 5

section 4Installation .......................................................................... 7

section 5Operation and Protections ................................................... 9

section 6Specifi cations ..................................................................... 11

section 7Warranty ......................................................................... 12

Disclaimer of LiabilityUNLESS 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 copyrightCopyright © 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

• BatteriescontainverycorrosivedilutedSulphuricAcidaselectrolyte.Precautionsshouldbetakentopreventcontactwithskin,eyesorclothing.

• BatteriesgenerateHydrogenandOxygenduringchargingresultinginevolutionofexplosivegasmixture.Careshouldbetakentoventilatethebatteryareaandfollowthebatterymanufacturer’srecommendations.

• Neversmokeorallowasparkorflamenearthebatteries.

• Usecautiontoreducetheriskofdroppingametaltoolonthebattery.Itcouldsparkorshortcircuitthebatteryorotherelectricalpartsandcouldcauseanexplosion.

• Removemetalitemslikerings,braceletsandwatcheswhenworkingwithbatteries.Thebatteriescanproduceashortcircuitcurrenthighenoughtoweldaringortheliketometalandthuscauseasevereburn.

• Ifyouneedtoremoveabattery,alwaysremovethegroundterminalfromthebatteryfirst.Makesurethatalltheaccessoriesareoffsothatyoudonotcauseaspark.


2.1 LaYout

2 1 4 3 5

Fig. 2.1: Input Side Fig. 2.2: Output Side

LegenD:

1.PositiveInputTerminal2.NegativeInputTerminal3.CommonNegativeOutputTerminalforLoadandBattery4.PositiveOutputTerminalforLoad5.PositiveOutputTerminalforBattery

note:Allinputandoutputterminals:Holesize:5mm/0.2";SetScrew:#10,24TPI,5/16"long

2.1 DiMensions114

4.3

2 22.15 35.7

Height: 47.5 mm

22.15

5.5

R2.5

2.9

2.9

9398.8

note:Alldimensionsareinmm.

Fig. 2.3: Dimensions

Section 2 | Layout and Dimensions


Section 3 | Description and Principle of operation

3.1 DescriPtion

Thisunitisusedtoallowany12VDC/24VDCpowersupply(withratedCurrentLimitvalueofupto25A)tofunctionasaDCUninterruptedPowerSource(UPS).Thisunitisapassivedeviceandfunctionsonlyasaninterfacebetweentheexternalpowersupply,thebatteryandtheDCload.Aslongasthepowersupplyisoperatingnormally,itwillsupplytheloadaswellasfloatchargethebattery.

Incasetheoutputofthepowersupplyfails,thebatterywillstartfeedingtheloadimmediatelythus,ensuringuninterruptedDCpowertotheload.Duringthisperiod,thebatterywillstartdischarging.Oncetheoutputofthepowersupplyisresumed,thepowersupplywilltakeovertheloadandwillalsore-chargethebatteryatitsfloatvoltage.

3.2 PrinciPLe oF oPeration

i inFo

Explanationgivenbelowisbasedonuseofexternalpowersupplywith"ConstantCurrentLimit"valueof25A.InaConstantCurrentLimitPower Supply,whentheCurrentLimitvalueisreached,theoutputvoltagewillnot beregulatedandwilldrop.

R1

R2

D2D1

INPUT

INPUT

BATTERY

LOADD1,D2

R1,R2

SCHOTTKY DIODE, 30V/30A

POWER RESISTOR 1R2 (1.2 OHM), 25 WATTS

+

+

+

+

EXTERNALPOWER SUPPLY

+

BATTERY

FUSE F1 32V, 25A (FAST BLOW)

FUSE F232V, 25A (FAST BLOW)

+LOAD

Fig. 3.1: Schematic and Installation Diagram

PleaserefertotheschematicandinstallationdiagramatFig.3.1.



ExternalpowersupplyisconnectedtothePositiveandNegativeinputterminals.ThebatteryisconnectedtothebatteryterminalsthroughFuse1andtheloadisconnectedtotheloadterminalsthroughFuse2.

ThevoltagefromthepowersupplyisfedthroughtheisolatingSchottkyDiodeD1totheloadandtothebatterythroughthechargingcurrentlimitingresistorsR1andR2.DiodeD1providesisolationbetweenthepowersupplyandthebatterytopreventthebatteryfromfeedingbackintothepowersupplycircuit.D1hasaforwardvoltagedropofupto0.5V.Hence,thevoltageavailabletotheloadandtothebatteryforfloatchargingwillbeupto0.5Vlowerthantheoutputvoltageofthepowersupply.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 fl oat voltage. Assumingthestandbyfloatchargingvoltagesof12V/24VSealedLeadAcid(SLA)Batteriestobe13.5Vto13.8Vand27Vto27.6V(at60ºFto77ºF)respectively,the output voltage of the power supply should be adjusted as follows:

• Power supply Voltage for 12V sLa battery backup: adjust to 14VTheoutputvoltageofthisunitfortheloadandforfloatchargingofthebatterywillbe14Vminusdropofupto0.5VacrossdiodeD1i.e.around13.5V.

• Power supply Voltage for 24V sLa battery backup: adjust to 27.6VTheoutputvoltagefortheloadandforfloatchargingofthebatterywillbe27.6Vminusdropofupto0.5VacrossdiodeD1i.e.around27.1V.

Aslongastheexternalpowersupplyisoperatingnormally,itwillsupplytheloadaswellaschargethebatterythroughresistorsR1andR2,each1.2Ohm,25W(R1andR2areconnectedinparallelandwillprovideanetseriesresistanceof0.6Ohm).

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).

Ifthepowersupplyfails,theloadwillbesuppliedbythebatterythroughtheSchottkyDiodeD2.AsinthecaseofSchottkyDiodeD1,therewillbeaforwardvoltagedropofupto0.5VacrossD2.Thus,whenthebatteryissupplyingtheload,thevoltageseenbytheloadwillbeupto0.5Vlessthanthebatteryvoltage.NotethatSchottkyDiodeD2isconnectedinparallelwithresistorsR1anR2andisusedtobypassresistorsR1andR2whenthebatteryisdischargingthroughtheload.

Maximum battery charging currentLeadAcidBatteriesshouldnotbechargedatveryhighchargingcurrent.Themaximumrecommendedchargingcurrentofabatteryisnormallyrelatedtoit’sAh(AmpereHour)capacity,designatedas“C”(basedon20ADischargeRate).ThemaximumchargingcurrentforanSLAbatteryisnormallyspecifiedwithinarangeofC/5(0.2C)toC/10(0.1C).


battery backup application using 12V, 40-100 ah batteryThisBatteryBackupUnithasbeenpresetforbatterybackupapplicationfora12Vbatteryofapproximately40to100Ahcapacitywiththemaximumchargingcurrentlimitedtoapproximately4A(Atpowersupplyvoltagesetat14.0Vandbatterydischargedto11.1V).

battery backup application using 24V, 40-100 ah batteryWhenusingthisunitinthepresetconditionfor24V,40-100Ahbatterybackupapplication,thechargingcurrentwillincreaseapprox.twotimesto8A(Atpowersupplyvoltagesetat27.6Vandbatterydischargedto22.3V).

calculating Maximum battery charging currentMaximumbatterychargingcurrentib={(Vp – Vd)–Vb} divided by rs……….equation 1

Vp=Outputvoltageofthepowersupply(14Vfor12Vbatteryand27.6Vfor24Vbattery)Vd=ForwardvoltagedropacrossSchottkyDiodeD1(upto0.5V)Vb = Battery voltagers=Equivalentseriesresistance.Inthiscase,R1(1.2Ohm)andR2(1.2Ohm)in

parallel=0.6Ohm(SeeFig3.1).

Assumingthevoltagesoffullydischarged12Vand24Vbatteriestobe11.1Vand22.3Vrespectively(atDischargeRateofaroundC/10(0.1C)Amps),themaximumchargingcurrentswillbeasfollowsasper equation 1:

For 12 V battery backup=(14V–0.5V–11.1V)dividedby0.6Ohm= 4aFor 24 V battery backup=(27.6V–0.5V–22.3V)dividedby0.6Ohm=8a

Section 4 | installation

4.1 instaLLation DiagraM anD DiMensions

Fig3.1showstheinstallationdiagram.DimensionaldetailsaregivenatFig2.3.

4.2 cabLe siZing, terMination anD Fusing

Thesizeofthecablesusedtoconnectthepowersupply,thebatteryandtheloadtothisunitwilldependuponthemaximumvalueofthecurrentflowandthelengthofthecablerun.Currentflowingthroughacablewillproduceanundesirablevoltagedropalongthelengthofthecable.Thevoltagedropisproportionaltotheresistanceofthecable.Higherresistanceproduceshighervoltagedrop.Theresistanceofthecableincreasesasthecablebecomesthinner.Similarly,theresistanceincreaseswiththelengthofthecable.Itisdesirabletolimitthevoltagedropto2%whichwillbe0.24Vfor12Vbatteryand0.48Vfor24Vbattery.



Section 4 | installation

Abatterycansupplyveryheavycurrentincaseofshortcircuitinthepathacrossitsterminals.Thiscancauseoverheatingofthecables/connecteddevice(s)andconsequentriskofmeltedinsulationandpossibilityoffire.Hence,forsafety,afastactingfuseofappropriatecurrentcapacityshouldbeconnectedinserieswiththePositivecableandshouldbeplacedwithin7"ofthePositiveterminalofthebattery.AutomotiveBladeTypeofFuses,TypeATO/ATCmaybeused.

ThefollowingTablegivestherecommendedsizesofcableandfusesforexternalpowersupplyratedat25A.

table 4.1 sizing of cable and Fuses

currentcable Length

up to 3 ftcable Length

up to 6 ft Fuses F1, F2

25A #12AWG #8AWG 32V,25A

Theterminalshaveatubularholeofdiameter5mmwithsetscrewforconnectingtheinputandoutputcables.Ifthebareendofamulti-strandedcableisuseddirectly,thesetscrewmaynotpinchallthestrandsfirmlyandwillresultinalooseconnectionwhichwillcausevoltagedropandexcessiveheating.For a fi rm connection, the cable ends should be terminated with suitable pin type of terminal.

4.3 aDJusting outPut VoLtage oF eXternaL Power suPPLY

Beforetheexternalpowersupplyisconnectedtothisunit,itistobeensuredthattheoutputvoltageofthepowersupplyisadjustedtotherequiredvoltageasexplainedunderSection3.2.

4.3 connections

Switchoffthepowersupply.ConnectthePositiveandNegativeoutputofthepowersupplytotheinputterminalsoftheunitmarked“INPUT+”and“INPUT–”respectively(1,2inFig2.1).

ConnecttheDCloadtotheterminalsmarked“LOAD+”and“LOAD–”(4,3inFig2.2)

Connectthebatterytotheterminalsmarked“BATTERY+”and“BATTERY–”(5,3inFig2.2)

! caution!Ensurecorrectpolarityofallconnections.


Section 5 | operation and Protections

5.1 oPeration

! caution! Pleaseensurethattheratedoutputcurrentofthe12VDCor24VDCpower

supplyisonlyupto25A. AsalreadystatedatinSection3.1,thisunitisapassivedeviceandfunctionsonlyasaninterfacebetweentheexternalpowersupply,thebatteryandtheDCload.

SwitchONtheexternalpowersupplytopowerontheloadandalsotostartchargingthebattery.IfthepowersupplyfailsorisswitchedOFF,theloadwillbeimmediatelyfedbythebattery.Whentheloadissuppliedbythebattery,thebatterywillstartdraininganditsvoltagewillcontinuetodrop.Duringthistime,thevoltageattheLoadTerminals(4&3,Fig2.2)willbeupto0.5VlowerthanthevoltageattheBatteryTerminals(5&3,Fig2.2)duetotheForwardVoltageDropacrosstheinternalSchottkyDiodeD2.

5.2 Protecting the batterY against DeeP Discharge

Forlongerlife,LeadAcidBatteriesshouldnotbeallowedtodischargemorethan80%.Forexample,a12V/24VloadedbatteryatloadcurrentofC/10Amps(CistheAhcapacity)willbe100%dischargedataround11V/22Vand80%dischargedat11.5V/23V.

Itisrecommendedthatasuitable“LowVoltageDisconnectDevice”,alsocalled“BatteryGuard”,maybeusedinserieswithPositivelineoftheloadforprotectionagainstdeepdischargeofthebattery.battery guard, Model no. bg-40, made by samlex america, inc. may be considered.

5.3 oVerLoaD anD short circuit Protection

i inFo

Explanationgivenbelowisbasedonuseofexternalpowersupplywith“ConstantCurrentLimit”valueof25A.InaConstantCurrentLimitedPowerSupply,whentheCurrentLimitvalueisreached,theoutputvoltagewillnotberegulatedandwilldrop.

Iftheloadtriestodrawcurrenthigherthanthecurrentlimitvalueoftheexternalpowersupply(25A),theoutputvoltageoftheexternalpowersupplywillnotberegulatedandthevoltageattheLoadTerminals(4&3,Fig2.2)willdrop.Portionofoverloadcurrentbeyondthecurrentlimitvalueoftheexternalpowersupply(25A)willnowbefedfromthebatteryandthebatterywillstartdrainingatthisdifferentialcurrent.ThevoltageattheBatteryTerminals(5&3,Fig2.2)willstartdroppingandwillbeequaltothevoltagecorrespondingtostateofdischargeofthebattery.ThevoltageattheLoadTerminals(4&3,Fig2.2)willbeupto0.5VbelowthevoltageattheBatteryTerminals(5&3,Fig2.2).External25AFuse(F2)ontheloadsidewillblow.


Incaseofshortcircuitontheloadside,theexternal25AFuse(F2)ontheloadsidewillblowbecauseofveryhighadditionalcurrentsuppliedbythebattery(Additionalbatterycurrentsuppliedintotheshortcircuitontheloadside=Shortcircuitcurrentminus25Afromtheexternalpowersupply).

i inFo

OvercurrentprotectionprovidedbyafuseisdeterminedbyitsTimeversusCurrentCharacteristic.Forexample,basedontheTimeCurrentCharacteristicsof32V,25ABladeFuseTypeATC-25fromCooperBussmann,thefusecanpassextremelyhighcurrentsforshorterdurationsasfollowsandwillblowat25Acontinuousfor>100sec:

• 550Afor10ms • 170Afor100ms • 40Afor1sec • 25Acontinuous(for>100sec)

5.4 Protection against reVerse PoLaritY oF batterY connection

! caution!Pleaseensurethatthepolarityofbattery/loadconnectionisnotreversed.Thisunitdoesnotprovideprotectiontotheexternalpowersupply/loadagainstreversepolarityconnection.Thisprotectionhastoprovidedbytheuserincasethepowersupply/loaddonothaveintegralprotectionagainstreversepolarity.Damagetotheexternalpowersupply/loadduetoreversepolarityofbattery/loadconnectionisnotcoveredbywarranty.

Section 5 | operation and Protections


Section 6 | Specifications

note: Specificationsaresubjecttochangewithoutnotice.

MoDeL no. bbM-1225inPut

INPUTVOLTAGEFROM EXTERNALPOWERSUPPLY 14VDCfor12VBattery/27.6VDCfor24VBattery

INPUTCURRENTFROM EXTERNALPOWERSUPPLY Uptomaximumof25A

outPut

outPut VoLtage ExternalPowerSupplyisONand issupplyingpowertotheLoad

andchargingtheBackUpBattery.

Load terminals: Upto0.5Vlessthan

InputVoltage

battery terminals (battery fully charged): Upto0.5Vlessthan

InputVoltage

battery terminals (battery not

fully charged): Voltage equivalent toStateofCharge ofthebattery

outPut VoLtage ExternalPowerSupplyisOFF.

BackupBatteryissupplyingthe Loadandisgettingdischarged.

Load terminals: Upto0.5Vless

than voltage on Battery Terminals

battery terminals: Voltage equivalent toStateofCharge ofthebattery

outPut currentExternalPowersupplyisON

andissupplyingpowertothe LoadandchargingtheBattery.

Load terminals: •=RatedAmpsof

ExternalPowerSupplyminus Battery

ChargingCurrent•Maxlimit=25A

battery terminals

(battery Fully charged):

Upto0.1%ofAh capacityofBattery

battery terminals (Discharged battery):

•12VBattery: Upto4A(at11.1V)

•24VBattery: Upto8A(at22.3V)

outPut currentExternalPowerSupplyis

OFFandExternalBatteryis supplyingpowertotheLoad.

Load terminals: Maximumlimit=25A

otherEXTERNALBACKUPBATTERY LeadAcid:12V/24V,40Ahto100Ah

enVironMentOPERATINGTEMPERATURERANGE 0°Cto40°C/32°Fto104°F

DiMensions(WxDxH),MM 98.8x114x47.5

(WxDxH),INCHES 3.9x4.5x1.9weight

KG 0.3LBS 0.7


Section 7 | Warranty

2 Year LiMiteD warrantY

TheBBM-1225aremanufacturedbySamlexAmerica,Inc.(the“Warrantor“)iswarrant-edtobefreefromdefectsinworkmanshipandmaterialsundernormaluseandservice.Thewarrantyperiodis2yearsfortheUnitedStatesandCanada,andisineffectfromthedateofpurchasebytheuser(the“Purchaser“).

WarrantyoutsideoftheUnitedStatesandCanadaislimitedto6months.Forawarrantyclaim,thePurchasershouldcontacttheplaceofpurchasetoobtainaReturnAuthoriza-tionNumber.

ThedefectivepartorunitshouldbereturnedatthePurchaser’sexpensetotheauthor-izedlocation.Awrittenstatementdescribingthenatureofthedefect,thedateofpur-chase,theplaceofpurchase,andthePurchaser’sname,addressandtelephonenumbershouldalsobeincluded.

IfupontheWarrantor’sexamination,thedefectprovestobetheresultofdefectivematerialorworkmanship,theequipmentwillberepairedorreplacedattheWarran-tor’soptionwithoutcharge,andreturnedtothePurchaserattheWarrantor’sexpense.(ContiguousUSandCanadaonly)

NorefundofthepurchasepricewillbegrantedtothePurchaser,unlesstheWarrantorisunabletoremedythedefectafterhavingareasonablenumberofopportunitiestodoso.WarrantyserviceshallbeperformedonlybytheWarrantor.AnyattempttoremedythedefectbyanyoneotherthantheWarrantorshallrenderthiswarrantyvoid.Thereshallbenowarrantyfordefectsordamagescausedbyfaultyinstallationorhook-up,abuseormisuseoftheequipmentincludingexposuretoexcessiveheat,saltorfreshwaterspray,orwaterimmersion.

Nootherexpresswarrantyisherebygivenandtherearenowarrantieswhichextendbeyondthosedescribedherein.Thiswarrantyisexpresslyinlieuofanyotherexpressedorimpliedwarranties,includinganyimpliedwarrantyofmerchantability,fitnessfortheordinarypurposesforwhichsuchgoodsareused,orfitnessforaparticularpurpose,oranyotherobligationsonthepartoftheWarrantororitsemployeesandrepresentatives.

ThereshallbenoresponsibilityorliabilitywhatsoeveronthepartoftheWarrantororitsemployeesandrepresentativesforinjurytoanypersons,ordamagetopersonorpersons,ordamagetoproperty,orlossofincomeorprofit,oranyotherconsequentialorresultingdamagewhichmaybeclaimedtohavebeenincurredthroughtheuseorsaleoftheequipment,includinganypossiblefailureofmalfunctionoftheequipment,orpartthereof.TheWarrantorassumesnoliabilityforincidentalorconsequentialdam-agesofanykind.

samlex america inc. (the “warrantor”)www.samlexamerica.com


noteS


noteS


noteS

contact information

TollFreeNumbersPh:18005615885Fax:18888145210

LocalNumbersPh:6045253836Fax:6045255221

Websitewww.samlexamerica.com

USAShippingWarehouseKentWA

CanadianShippingWarehouseDeltaBC

[email protected]

11001-BBM-1225-0816

Documents

Battery Owner's Please read this Back-up Manual · should be placed within 7" of the Positive terminal of the battery. Automotive Blade Type of Fuses, Type ATO/ATC may be used. The