Instalation Instructions
Contents
1. 13 Yellow LED this is an information LED WARNING alarm codes there are 4 alarm codes these are just warnings but will not shut down the product LED state x2 for 24V Yellow LED unit WARNING LED state On solid Low Input voltage check alternator charging is gt 11 0V 1xFlash Lowoutputvoltage 2 x Flash Boost reduction product getting too hot or reduced via the RC Ifnot via RC check the environment in which the product is installed Maybe too hot 3x Flash Remote sense voltage compensation maximised only relevant if the remote sense cable is used Check output cable thickness For safety reasons the remote sense has only the ability to increase the voltage from the product by 1 5V to compensate for output cable s voltage drop any more than this could over heat cables The cable is too thin or the run too long for us to fully compensate for the drop There is no problem as far as safety is concerned just a loss in potential performance ability of the product To fix this check your cable thickness and length is suitable for the current used 4 x Flash high differential voltage between input and output voltage may have an extremely low output battery or a very high drain onit N BWARNING do not shut the product down t gives warnings ina 10 second cycles like that of the shutdown 14 Main DC input from starter battery 15 Green LED for 12V unit yellow for 24V units on when active 16 Remote control c2. Page 5 To setup battery type from first install the input battery must be over 10 0V x 2 for 24V Please choose your battery type before installing so you are ready for the setup If the unit is already installed then there is a slight change at the start of the instructions The unit default setting is sealed lead acid 14 4V 28 8V for 24V Have the lid ready observe the MAGNETIC SWIPE area of the lid There is a small magnet in that area in the lid you will need to hold the lid in such a way as to simply push that area on the label to the area indicated on the main box beside the LEDs There is a magnetic switch located behind the plastic in the main box which reacts to the magnet in the lid do not remove the magnet from behind the lid label As soon as you connect the input live and negative on the unit assuming battery is over 10V x 2 for 24V the setup routine will start The routine is as follows please note with the DC output disconnected due to the reverse polarity safety device the output of the unit is not live so although the setup routine will be active the unit will not work fully until the DC output cable is connected to an output battery bank To adjust a previously installed unit to a different battery chemistry simply remove the input positive or negative and follow the same instructions Battery type information Non sealed lead acid or open lead acid batteries where you can unscrew the lid
3. 60A 120A 240A is advantageous as it protects the DC wiring system from large surges from bow thrusters or large inverters These surges can often exceed the rating of the wires fuses relays and diodes in the system causing permanent damage If you can limit the current to 60A for example you can rate your relays diodes fuses to 80A If your inverter bow thruster takes a surge of 300A only 60A can be drawn down the DC cable instead of 300A 12V 60A model Negative Positive Fan Power Aluminium Heat sink d Key 1 Main positive DC power output to auxiliary battery 2 Low Voltage regenerative braking gt join with 4 optional 3 Ignition feed 4 Auto operation choice gt join with 3 5 12V 40mm DC fan replaceable item if destroyed 6 Positive feed for DC fan 7 Negative feed for DC fan 8 Aluminium heat sink 9 Blue LED Fast charge mode max charge current 10 Yellow LED 2 stage absorption mode 1st stage is at high voltage output yellow and blue LEDs 2nd stage is mid voltage output yellow and green LEDs 11 Green LED charge complete unit on float voltage 12 Red LED unit shutdown These are dangerous alarms and will shut the system down Shut down alarm codes there are 5 shutdown alarms these actually shut the product down and require the charge to be stopped to reset the product The fatal shutdown alarms will not auto reset until the engine is
4. Installation Page 6 Installation 2 Page 7 Operational modes Page 8 Additional information Page 9 Application ideas Page 10 Remote control setup Page 11 Remote control setup Page 12 Warranty statement Battery to Battery Charger series Background Thank you for purchasing the most advanced and powerful battery to battery chargers currently available in the world today Please do not underestimate the affect this device will have on a conventional DC charging system It is important to understand that your existing cables and layout may not be up to dealing with the extra performance from the alternator You ll need to ensure your alternator cables can deal with the actual rating of the alternator and the cable run lengths Why dol need the Battery to Battery charger It is becoming increasingly more common knowledge now that the best way to charge a battery is using a 4 step battery charging curve This cannot be achieved from a standard alternator This system simply attaches between 2 battery banks a starter engine battery and a secondary battery domestic house battery bank It essentially tricks the alternator into working at the maximum rating of the charger This system is designed to use only the surplus power It ensures at all times that the power required to run the primary system of the vehicle or boat is not compromised This surplus power is converted into a higher voltage and is used to charge a s
5. this then activates the unit On normal operation when input voltage over 13 3V x2 for 24V The blue LED will light up showing constant current charging then after 1 8 hours depending on state of batteries etc The blue and yellow indicating absorption time 1 then yellow indicating absorption time 2 then green for float battery charged If on start up nothing happens Test the battery voltage It should be above 13 3V to see the unit working start up the engine and ensure you are getting at least 13 5V at the battery If you are getting at least 13 3V at the unit and there is nothing working then the unit is defective If you are not getting 13 3V then the fault is on you power supply Fan replacement The main electrical box is IP68 i e it can be totally submerged in water However the fan is IP55 which cannot so in the event of the fan being destroyed simply replace it These small 40 mm fans are easily found and are low cost to replace Simply fit the correct DC voltage marked on the fan fitted and replace the unit What is regenerative braking Regenerative braking fix function 3 A new very serious issue for auxiliary charging systems has now been introduced in a lot of vehicles and small vans itis called regenerative braking It is a great idea as far as the primary vehicle is concerned as it adds extra MPG to the vehicle s specification However it is an unmitigated disaster as far as the auxili
6. alarm on off old 53 sec e Absorption Condi Temp Menu Change button Quick press back light on Short hold switch between temperatures Out Rem Long press Menu setup Batt sel display Float Unit on off hold gt 3 sec more detailed information Faut below menu scroll nidirection To access the menu and adjust parameters To access the menu and adjust the parameters press and hold the right button Temp Menu Setup until SEL appears approximately 5 seconds then let go bPc shall appear and you can now scroll through all of the 18 parameters unidirectional using the right button only You can enter whichever parameter you wish by pressing the left button Volts Select Certain parameters are adjustable the majority are however just a read out Refer to the chart below To exit from the menu holding down both left and right buttons simultaneously will result in END appearing on the screen This shall ultimately revert back to the home screen Right Button Temp Menu Setup Press button for unit temperature Press button again for battery temperature via batt temp sensor If sensor is not attached then the reading shall be nc non compliant Press again to view unit temperature Setup Menu To eject from menu simply do nothing for 10 sec it will jump out bPc lt SEL bPc display boost current in percent btY displays battery profile type 0 9 This number
7. button to decrease value Hold to accelerate LEd change LED on time 1 600 seconds 0 always on default 60 Press right button b9b to increase in value press left to decrease in value Hold button to accelerate LEd uld display Unit ID uSW display unit software version uld rSW display remote software version 9 a Loc Lock unit lock code 1 to 999 default unlocked WARNING This mode shall lock uSW the unit by virtue of a pass code be careful Press right button to increase value press left TSVV button to decrease value Please release button when on the number you require the software shall store this number then the display shall read loc gt on gt number you have Loc stored To remove loc return to loc and re enter the number release buttons and the display should read loc gt off green backlight Please make a note of this loc code here rSt RES Reset to default values Left button NO right button YES Let go when on YES to l reset only possible only possible if not locked if not locked Page 11 STERLING Customer Service amp Warranty Power Your 100 satisfaction is our goal We realise that every customer and circumstance is unique If you have a problem question or comment please do not hesitate to contact us We welcome you to contact us even after the warranty and return time has passed Product Warra
8. by yellow LED 2 on b Output voltage from unit yellow LED 7 on c Voltage at end of remote sense wire if used indicated by yellow LED 7 flashing 2 In conjunction with the remote panel voltage button 1 If on this showing the voltage reading displayed is the input voltage If in conjunction with temperature button 8 this shows unit temperature 3 LCD screen showing digits Also red screen WARNING Green screen all ok Blue Charging 4 LED 4 5 6 emulate the 3 charge indicators on the main box 4 blue constant current 5 Absorption 6 Float 7 In conjunction with Voltage button 1 If on this is showing that the voltage reading displayed is the output voltage If flashing then the voltage displayed reading is the voltage at the end of the remote sense cable if used In conjunction with temperature button 8 display shows battery temperature 8 Temperature information selection by pushing this button you can select 2 temperatures a Unit temperature indicated by LED 2 and screen showing C for degrees Celsius or F for degrees Fahrenheit depending on your setup b Battery temperature indicated by LED 7 on selection and screen showing C for degrees Celsius or F for degrees Fahrenheit depending on your setup 9 Fault reference light on will also show a fault number on the screen please reference this number against the fault E01 High voltage input E02 High voltage outpu
9. denotes which charging profile the btY charger is set to Ref table labelled Battery Chemistry Selection on COU coU displays cut off voltage the voltage at which the unit stops boosting 13 4V loU display input output base voltage 12 24V loU CIF change from celcius to fahrenheit or back default celcius Press right button to change between Fahrenheit FAH and Celsius cEL CIF buC turn Buzzer on off default on Left button for off and right button for on Asc Autoscroll on off default off Left button for off and right button for on buc con change contrast value from 0 to 7 default 3 Left button down and right button up ASc bLc change backlight colour off lt auto gt green gt red gt blue default auto To change right button goes from off gt blue and left button goes blue gt off con bLt change backlight time 1 600 seconds 0 always on default 60 Right button ii goes up the values left button goes down the values Hold button to accelerate bLc br9 change voltage from to green backlight 8 0 13 3V default 12 4V Press right bLt button to increase value press left button to decrease value Hold to accelerate b9b change voltage from green to blue backlight 12 4 16 0V default 13 4V Press right bro button to increase value press left
10. live feed must be re established and regen braking the input voltage must be above 12 2V 10 second delay This mode complements Regen Braking SmartAlts 3 Regenerative braking Ignition feed activation WARNING This mode could potentially drain battery Initial input voltage 13 3V to activate Below 12 2V unit enters sleep Above 12 2V unit is on w ignition feed live 10 second delay Page 7 Miscellaneous information Battery temperature sensing Simply connect one of the enclosed temperature sensors to a battery terminal post negative or positive and to the 2x small terminals marked battery temperature There is no polarity on these wires The output voltage will be reduced in accordance with manufacturer s battery charging temperature curves and in the event of the battery temperature increasing due to battery failure If it exceeds 60 deg C which is a major problem the unit will switch off the charging There is a power temperature reduction algorithm which will reduce the units output if the temperature rises to Battery Temperature 65 degC Charger Temperature 90 degC Start up and test procedure x2 for 24V When the unit is first connected it will run the start up procedure as long as the battery is above about 6V After the start up procedure if the input voltage is still low the unit goes onto sleep mode all lights off The unit will remain in sleep until the input voltage exceeds 13 3V x 2 for 24V
11. of the battery and are able to be topped up with water these are by far the best type for fast charging and long life max voltage 14 8V Gel Exide spec This program is as per the recommendation of Exide set at a voltage of 14 4V for about 10 12 hours The unitthen drops to float Gel U S A spec For some reason unknovvn to us the American gel manufactures vvant a different charging profile than the European ones Don task us why if in doubt ask the battery supplier Gels have a max charging voltage of 14 1V Sealed lead acid A G M This is set to a maximum charge voltage of 14 4V with a software program to match most of these battery types some AGM batteries only want 14 1V if so set the unit to the American gel setting If in doubt ask the battery supplier LiFePOa cells must only be used in conjunction with a Battery Balancing System N B Reverse Polarity protection has been disabled in lithium profile Charging profile Information displayed on top 3 LEDs on main unit Fast charge High absorptions constant current charge rate constant Lower absorptions mode voltage mode voltage mode Stage 1 Stage 2 Stage 3 LED LED LED 6 N lt charge rate constant Float Power pack if voltage drops Backlash voltage If mode constant duetoheavy charger power exceeded voltage full current load in excess and battery discharge accessibility offunit current unit resets to stage 1 Stage 4 LE
12. up into your auxiliary battery system ensuring steady power charging regardless of the vehicle s voltage variations Page 8 b ru z 20077 2195 UBD y yueq As neq xne ns uroq m An 4 Aieyeq 9 uz 4 3838 45 1105 Old gt yueq A yeq urew y olul s wnwxew y insu o eoq y uo J mod snidins ile asin O pue yueg Ajayeq abe 4 A e ABU Aew jeog e H UAM UOHE E SUL ajdwis e SAOUS S U 2 TA a 5 PVO S Ud Z NEO upuJ z yueq xne ns uroq 5 E yueq A yeq 1 8 syueq A yeq x z o YSIM NOA J uonele sul a dWIS Asayjeq yueq 4 e s leuon ppv ANOQ H BE yueq As eq xne ns uroq i J IdS ul5uz 1145 Old 4 e o yueq e ppe o uohelle su yueq As neq xne ns uloq 10 p X y Wed Ue puEoqino JO pseoqui eoq jews e uo Ul S S Hulbieyo uonelle sul 15 psepue s S UI U pue SUEA S LLO S EO S UI U l lU A s ul U pseogyno s ulBu szeoq OU WO syueq As neq o p sn ued yun 5141 s
13. D 2 to support Stage 5 LED I Ti me depending on battery size type state of charge and charger battery ratio Digitally processed Blue LED flash Battery Chemistry selection and Charge Absorption Float Min Boost Max Boost Switch position volts volts volts mins mins 1 Gel 14 0 13 85 13 7 60 600 2 AGM 14 1 13 75 13 4 60 480 3 Sealed 14 4 14 15 13 6 120 480 4 Gel Il 14 4 14 0 13 8 720 1440 5 AGM II 14 6 14 1 13 7 60 480 6 Flood open 14 8 14 0 125 60 480 7 Calcium 151 14 3 13 6 60 360 8 De sulphation 15 5 0 0 240 240 9 LiFePOs 14 4 13 8 13 8 30 30 Note Actual voltage shall be 0 1V 100mV higher within the first 3 minutes Page 6 Unit operational mode Standby sleep and off modes Standby only happens when Sleep the unit goes into sleep mode Off to remove power in ignition mode when the when a low input voltage threshold has from unit completely ignition is off and the input been breached This varies between remove negative or voltage is above 13 3V Blue functions Typically when the input positive input cable LED flashes continually and 4x voltage drops below 13 0V the unit There is no off function green LEDS are lit To get out of enters sleep mode after a 120 second per se Removing povver standby turn ignition on and delay The blue LED flashes once for vvill not resetthe settings ensure above 13 3V on the 10ms every 60 seconds input 1 Automatic activation default s
14. ary battery charging system is concerned In order to increase efficiency of vehicle s fuel consumption on vehicle s start up the idea is to only charge the battery with enough power to safely restart the engine Once this has been achieved after a few minutes then the alternator drops its voltage from about 14 8V to about 12 6V leaving space in the battery The idea is that at 12 6V the alternator has sufficient voltage to power the engine systems without accessing the battery power yet not enough voltage to charge the battery fully When the brakes are applied on the vehicle the alternator s voltage ramps up quickly to boost large amounts of power into the space left in the battery This loads up the alternator which helps out the vehicle s braking and adds a spurt of power to the batteries Once the braking is removed then the voltage drops again and that free power boosted into the batteries is then used by the vehicle Once it has used up the 12 6V the alternator simply takes over This is great for the primary vehicle and does what it says it does but means the auxiliary battery system simply cannot get effectively charged The solution is our new Battery to Battery charger As mentioned it has both an auto setting and an ignition setting If you have a regenerative braking system simply select the ignition setting and even when the vehicles electrics drops to 12 6V or lower we simply take that voltage and boost it
15. e yellow LED will fast flash for 5 seconds during this time is your window of opportunity to adjust the battery type With the lid removed and in your hand swipe the magnet built in against the area as marked on the drawing Simply hold the lid magnet against the box in this area if you have made correct contact with the magnetic internal switch during the 5 seconds the yellow is flashing the yellow LED will go off and the red LED will flash hold this area this shows you have hit the spot magnetic switch and you are now ready to adjust Please note aS soon as you do this any pre stored battery type setting is removed and we start from battery type 1 GEL USA refer to table on the RHS To adjust remove the lid from the magnetic swipe area the red light will go out to show you have lost attachment with the reed switch and the blue LED will flash once This shows the unit is now set to battery type Re swipe the magnet for the second time and the red LED will come back on Remove the magnet and wait the blue LED will flash twice You are now on battery type 2 AGM see below Continue this procedure until you reach the number of flashes you require On reaching your number then simply wait about 15 seconds and wait for the unit to show 2 LEDs green and red and it will lock that setting The unit then restarts the start up sequence which will show the new battery setting number of blue flashes At this point yellow fla
16. econdary battery bank using a digitally controlled programmable 4 step charging curve This unit is also totally isolated thus the starter battery cannot discharge through this system even in the event of the unit failing How does the unit work The unit monitors the engine start battery This unit will not start until the battery voltage exceeds about 13 3V x2 for 24V After that it pulls the engine battery down to no less than 13 3V This enables the engine battery to still receive a small charge and ensures the alternator works at its full potential The unit takes the 13 3V into the control box and then boosts this up to a maximum of 15 5V selectable Page 2 chemistry profiles between 14 0 15 5V consult battery manufacturer A rule of thumb Higher voltages result in faster charging and lower voltage result in slower charging After a period of time calculated by the software when the auxiliary batteries are full the system will float the batteries at approximately 13 5V x2 for 24V It always ensures the engine battery comes first Other features included in this system are battery temperature sensors remote battery sensors and a fully automatic sleep sensor which switches the unit off when the engine has stopped A remote panel is available as an optional extra Advantages of this unit 1 Installation Simply connect between two battery banks e g starter and house 2 No direct connections to the standa
17. eep uoneolddvy Yueq Ja sniu moq e l l S S BuiBseuo yids S nsix Page 9 Other application ideas see fig 1 4 previous page Fig 1 Most common installation simply connect the charger between the starter battery and the secondary house bow thruster bank The starter battery stays between 13 14V and the secondary goes to 14 1V 15 1V This setup is especially good when the secondary battery is distant from the starter like a bow thruster Fig 2 This option shows the use of the charger in conjunction with a split charging system Here an additional battery bank is present simply drop the charger between secondary battery and this additional battery The charger can also transform a single output charger into a dual output Fig 3 This option shows a situation on many boats or camper vehicles where there may be 3x battery banks Simply put 2x chargers on and they will ensure both banks are catered for It is immaterial if one bank is further away than another Fig 4 This option focuses on charging a large house bank from multiple charging sources Whether the charge comes from a generator engine or old single stage battery charger a battery to battery charger shall provide a much improved charging rate from these sources to the extensive house bank Remote control panel see next page 1 Voltage select Pressing this button allows you to view 3 voltages a Input voltage to unit indicated
18. etting This is the mode most people will use The product comes with the auto and ignition linked together This means that there are no external activation requirements for the product When the input voltage goes above 13 3V alternator or battery charger is working then the unit will simply engage and boost the output When the input voltage drops below 13 0V but above 12 2V the unit shall remain on boost for another 120 seconds If the input voltage remains between 12 2V and 13 0V for more than 120 seconds the unit shall go into sleep mode If the input voltage drops below 12 2V within this 120 second time frame the unit shall immediately go into sleep If input voltage is then to rise immediately to between 12 2V and 13 0V the 120 second timer shall continue To get out of sleep mode an input voltage of 13 3V must be reached To reset the 120 second timer the input voltage must exceed 13 6V for over 5 seconds If this threshold is not met then sleep mode would resume immediately if the voltage drops below 13V again This mode complements Regen Braking Smart Alts 2 Ignition feed activation with automatic on off This mode is a basic ignition feed There is no 120 second timer When you have a live ignition feed 12V The unit simply activates when the input To Ignition feed voltage is 13 3V It shall then enter sleep mode if the M input voltage drops below 13 2V If live feed is turned off Low V the unit enters s
19. ich vary from state to state This warranty is in lieu of all other expressed or implied Sterling Power Products Ltd Sterling Power USA Unit 8 Wassage way Warranty Service Center Hampton lovett ind est 406 Harold Dow Highway Droitwich Suite 4 Worcestershire Eliot ME 03903 ENGLAND WR9 ONX Phone 207 226 3500 Tel 01905 771771 Fax 207 226 3449 Fax 01905 779434 www sterling power usa com www sterling power com Page 12
20. languages xox xx xx STERLING lt POWER un VVaterproof Battery to Battery Charger 60A 180A models p k User Manual Regenerative Braking Friendly or RBG Smart Alternator Regenerative Braking Friendly Absorption Condi H Charge Float Sterling Power Products in Unit Audible alarm on off Out Rem o hold gt 3 sec Batt Temp Optional remote control instructions inside BBVV1260 60A 12V to 12V BBW12120 120A 12V to 12V IP68 Waterproof Electronics Fan is IP65 74 1x temp sensor Magnetic field warning There is a small magnet fitted in the lid of this product under the label marked magnetic area With the vast majority of installations BBW12180 180A 12V to 12V this will have no effect on anything however New model from March 2015 this magnet may influence a magnetic For latest instructions regarding susceptible product such as a magnetic this model refer to compass Please check your magnetic sensitive products after installation of this device If there is an adverse effect then you can peel back the lower section of the label on the lid of the product and remove the magnet sterling power com Revised February 2015 46 compliant Copyrights 1993 2013 Sterling Power Ltd All Rights Reserved Contents Page Page 2 About the battery to battery charger Page 3 Annotated diagram of unit with key Page 4 Basic wiring diagram Page 5
21. leep To turn unit on again turn on live regen braking feed and ensure input voltage is above 13 3V there will be a 10 second delay When you would use this feature If the starter and house bank are connected via a voltage sensitive relay as well as this charger whereby a high voltage 13 3V is relayed from the house bank back to the starter bank this charger shall remain on thus ultimately depleting both batteries This mode does not complement Regen Braking 3 Regenerative braking Ignition feed activation This mode is similar to 2 above Ignition feed to 12V Auto Link Ignition Low V regen braking 1 Automatic activation default setting automatically on at 13 3V Off 120 seconds after input voltage drops below 13 0V and above 12 2V Sleep mode deactivates at 13 3V 120 second timer reactivates at 13 6V for 5 seconds Auto 2 Ignition Feed Activation With live feed 12V the unit turns on at 13 3V input voltage Goes into sleep when below 13 2V When live feed is removed the unit enters sleep Unit turns on again when live feed is re established and input voltage is 13 3V there is a 10 second delay Auto and link Auto w Low V Initial activation input voltage is To Ignition feed Link 13 3V However the sleep voltage is below 12 2V If m ignition feed is cut at any voltage the unit enters sleep To Low V get out of sleep the
22. nput Voltage Warning 11 0V Low Output Voltage Warning 11 0V Minimum Output Voltage gt 4 0V Battery Temperature Compensation 18mV C High Battery Temperature Alarm 55 C High Voltage Drop Alarm gt 1 5V between out battery Low Input Voltage Warning 11 0V Low Output Voltage Warning 11 0V Minimum Output Voltage gt 4 0V Battery Temperature Compensation 18mV C Page 10 Volts Select Button Quick guide Quick press back light on Short hold switch between voltages you want to select long press switch buzzer on off temporary In Unit more detailed information below Remote control cut hole diameter 54mm Remote Control The home screen displays the output voltage from the unit If crc is displayed at any point simply ignore continue as you were all this mean is that the remote has received a corrupt readout signal from the charger merely momentary Please note 24V only operations you setup as 12V l e if you want to set a voltage for example 26V you set in the parameters for 13V Remote Buttons Left Button Volts Select Press button for output voltage Press button again for remote sense voltage If remote sense voltage cable is not connected then the display is 0 0V with a red backlight Press button again to revert back to home screen input voltage Hold button for 4 seconds to set alarm to off repeat procedure to turn alarm to on H Charge Audible
23. nty Each product manufactured by Sterling Power comes with at least a 2 year limited factory warranty Certain Products have a warranty period of time greater than 2 years Each product is guaranteed against defects in material or workmanship from the date of purchase At our discretion we will repair or replace free of charge any defects in material or workmanship that fall within the warranty period of the Sterling Power product The following conditions do apply The original receipt or proof of purchase must be submitted to claim warranty If proof cannot be located a warranty is calculated from the date of manufacture Our warranty covers manufacture and material defects Damages caused by abuse neglect accident alterations and improper use are not covered under our warranty Warranty is null and void if damage occurs due to negligent repairs Customer is responsible for inbound shipping costs of the product to Sterling Power either in the USA or England Sterling Power will ship the repaired or warranty replacement product back to the purchaser at their cost If your order was damaged in transit or arrives with an error please contact us ASAP so we may take care of the matter promptly and at no expense to you This only applies for shipping which was undertaken by our company and does not apply for shipping organised by yourself Please do not throw out any shipping or packaging materials All returns for any reason will req
24. onnection 17 Remote battery sense wire to compensate for voltage drop in cable optional does not need to be used 18 Battery temperature sensor optional fit if not used product will work on default of 20 deg C setting 19 Battery temperature sensor optional if not used product will work on default of 20 deg C setting 20 Unit negative 21 M4 stainless steel insert for lid Page 3 optional remote control Basic Battery installation drawing Absorption Condi H Charge Float In Unit Audible alarm on off hold gt 3 sec t Unit on off hold gt 3 sec Fault Out Re Bat 3 option operational choices Fuses Fuses are there to protect cable runs through bulkheads etc A fuse should be rated to about 40 50 higher than the maximum current expected E g for a 60A product use about an 80A 45 fuse The fuse should be within o 200m of the battery oE Soars S Eos x Battery Temp sensor Eo a is actually in the ring terminal ooo Best connect to neg terminal ocd O0 ENGINE STARTER BATTERY Auxiliary battery bank WHAT CABLE TO USE IN mm sq A charger or inverter up to cable run distance 0 1 5 meters 1 5 4 meters 0 25A 6 mm sq 10 mm sq 25 45A 16 mm sq 25 mm sq 45 85A 25 mm sq 35 mm sq 85 125A 35 mm sq 50 mm sq 125 180A 50 mm sq 70 mm sq gl 180 330A 70 mm sq 90 mm sq If there is a problem obtaining fo
25. r example 90 mm sq cable simply use 2 x 50 mm 99 sgor3x35mm sq The cable is simply copper and all you require 15 the copper It does not matter if it is one thick cable or 10 thin cables as long as the square area adds up Product performance is improved with thicker cables if in doubt double up Determines operational mode for unit 1 Automatic operation 2 Ignition feed 3 Regenerative braking ignition option See next page for information regarding setup and application Page 4 Installation Set this unit as you would any other high power battery charger Fit it as close to the starter batteries as possible in a cool dry and well ventilated space As with the most ideal conditions on a boat the cool well ventilated partis a bit of wishful thinking With this in mind you may notice that the unit comes with a heat sink and a cooling fan If you have to fit it in a hot engine room then it should be okay but try to fit it low down on the bulk head as it will be a little cooler there than at the top of the engine room Wiring refer to simple diagram on previous page page x connect the output positive cable first to the house domestic for example Then the input positive cable starter battery then the negative common negative Remember the unit is voltage sensitive Thus If the input voltage is above 13 3V due to alternator generator or charger the unit shall start and begin boosting you can eliminate the
26. rd engine alternator or to the outboard Thus on new installations there is no extra wiring for a split charging system 3 This unit ensures the engine battery is kept full to start the vehicle while using as much surplus power as possible to boost into the auxiliary system 4 Multiple units can be used for example if you have a 100A alternator and 3 battery banks engine domestic and bow thruster then 2 of these can be used to run the bow thruster and the domestic system Their internal programs will adjust their charging patterns to accept the other unit The unit shall ensure only the excess power is used and the primary system is not placed in jeopardy 5 Ensures there is no voltage rise on the engine management system Likewise it ensure no alarms nor damage to the main system be it an outboard a car or a boat 6 There are no vehicle warranty issues as you are not connected to the main engine management system 7 This charger isolates both battery banks and prevents any feedback through the unit 8 Compensates for large voltage drops in long cable runs with the use of a sense cable 9 Can both boost charge or voltage reduce if required Sometimes alternators sustain a voltage that is too high for the batteries this unit drops the voltage down Current limiting feature The ability to current limit is a very important aspect of this product s design Being able to limit the current to the rating of the product
27. shing LED will come on and you are given the opportunity to adjust if still not correct If content then ignore leave alone and allow the setup to complete and the unit shall store the settings 1 Select the battery type on your auxiliary battery system The input battery chemistry is of no relevance to this process Remember it is the voltages which are more important than our battery types After installation test the voltage from the unit is the desired voltage Ensure you remove at least 1 wire from the battery temperature sensor as the product voltage may be higher if in cold climate or lower if in warn climate than the pre conceived voltage The voltage requirements of the battery company will override our recommendations as itis them who are supporting the battery warranty Heat sink 12V 40 mm i Side profile Magnetic swipe area the magnetic reed switch is behind the plastic case in this area Flash Battery Chem Mid V Float V 13 8 13 7 1 GEL 14 0 2 AGM 14 1 13 7 13 4 3 SEALED 14 4 14 1 13 6 4 GELII 14 4 14 0 13 8 5 AGM Il 14 6 14 1 13 7 6 OPENLEADACID 14 8 14 0 13 3 7 CALCIUM 15 1 14 3 13 6 8 DESULPHATION 15 5 N A N A 9 LiFePO4 14 4 13 8 13 8 LiFePOa cells must only be used in conjunction vvith a Battery Balancing System N B Reverse Polarity protection has been disabled in lithium profile Voltages shall be 0 1V higher for the first 3 mins
28. switched off and the input voltage drops below 13 3V for a few minutes Then the system will reset it is important that the fault be rectified before restarting the engine LED state x2 for 24V Red LED unit shutdown LED state On solid Highinputvoltage 1 x Flash High output voltage this could be caused by a product malfunction or possible high voltage feedback from other charging sources onthe output battery bank 2x Flash High temperature trip the unithas overheated this could be due to a fan failure or simply installed in too hot an environment It is unlikely under normal operations and the unit has a temperature performance reduction algorithm in the software to prevent this from tripping 3 x Flash High Battery Temp trip in event of a battery overheating unlikely under normal operations Nevertheless this unit has a temperature performance reduction algorithm in the software to preventunnecessary over charging when battery is hot 4x Flash Out Batt not recognised possible reverse polarity The unit will not engage this is a safety protection circuit If the installation is new then check the battery is not reverse polarity or if the battery is below 4V the unit will not recognise it In this case it may be necessary to jump start the second battery from the first battery a 12V 120A model ou Negative Positive Fan Power Alum m Heat sink Aluminium Heat sink tw RF
29. t E03 High unit temperature E04 High battery temperature E05 No output voltage Preset voltages x2 for 24V models Minimum input voltage the unit will run at 13 0V Switch off and sleep mode happens below 12 8V for at least 15 minutes Power consumption on sleep mode is 5 mA 0 005A Maximum input voltage trip 15 5V Maximum output voltage trip 15 5V All voltages refer to a default temperature of 20 deg C If the battery temperature sensor is fitted these voltages will be less dependant on the battery temperature WARNING If all LEDs flash and the fan is running there is a fault and the unit needs to be disconnected and returned to factory WARNING The battery temperature sensor adjusts the charger voltage according to the temperature on the batteries The voltage will be higher or lower than the default value In case of very low temperatures the voltage could exceed 15V easily Check your equipment if it is capable Or else disconnect the temperature sensor Technical data Input voltage range 11 16VDC Output voltage range 13 15 1VDC Maximum inputcurrent 60A 10 Min Input Voltage to Charge Boost 13 3V default 12 2V regenerative braking Unit sleep mode 0 2V below Input Voltage High Input Voltage Alarm 16 0V High Output Voltage Alarm 16 0V Temp compensation High Unit Temperature Alarm 100 C High Battery Temperature Alarm 55 C High Voltage Drop Alarm gt 1 5V between out battery Low I
30. uire a proof of purchase with the purchase date The proof of purchase must be sent with the returned shipment If you have no proof of purchase call the vendor who supplied you and acquire the appropriate documentation To make a claim under warranty call our customer care line number can be found on www sterling power com and www sterling power usa com We will make the best effort to repair or replace the product if found to be defective within the terms of the warranty Sterling Power will ship the repaired or warranty replacement product back to the purchaser if purchased from us in England or USA Please review the documentation included with your purchase Our warranty only covers orders purchased from Sterling Power We cannot accept warranty claims from any other Sterling Power distributor Purchase or other acceptance of the product shall be on the condition and agreement that Sterling Power USALLC and Sterling Power LTD shall not be liable for incidental or consequential damages of any kind Some states may not allow the exclusion or limitation of consequential damages so the above limitations may not apply to you Additionally Sterling Power USA and Sterling Power LTD neither assumes nor authorizes any person for any obligation or liability in connection with the sale of this product This warranty is made in lieu of all other obligations or liabilities This warranty provides you specific legal rights and you may also have other rights wh
31. voltage sensitive aspect by adding an ignition fed cable refer to next page for operational modes Setup routine 1 All LEDs will come on to confirm the LEDs are okay 2 The fan will ramp up in speed to confirm the speed control is okay 3 All LEDs and fans off 4 Blue LED will flash 1 9 times to show what the unit battery chemistry is actually set to depending on battery type as per label If you are happy with this setting then do nothing if you are not happy then simply wait and the yellow LED will start to flash 5 The yellow LED flashes for approximately 5 seconds then during this time frame you must start the battery chemistry adjustment procedure using the magnetic swipe area in the lid of the unit read below for additional information This is the only window of opportunity available to adjust the battery type on the unit After the yellow light stops flashing the unit is locked into that battery type If you fail to set the product up to the correct battery chemistry the first time and need to try again do not worry To reset the system to try again simply remove the positive input cable or the negative cable i e kill the power to the product and on re attachment the startup procedure will start again Do this as many times as it takes to get the correct battery chemistry setting Programming the battery chemistry type for the output battery typically house domestic auxiliary During setup procedure th
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