Samlexpower BBM-1225 User 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

222.15 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

Table of contents

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