BM PRO MiniBoostPRO User manual

TEAMBMPRO.COM
MiniBoostPRO
OWNER’S MANUAL

SAFETY PRECAUTIONS
Please read the Safety Precautions before installing or using the MiniBoostPRO.
Be sure to observe all precautions without fail. Failure to observe these
instructions properly may result in personal damage, or personal injury which
depending on the circumstances may be serious and cause loss of life.
WARNING
Correct installation is the most critical factor in ensuring the safe use of the
MiniBoostPRO. If every consideration of these instructions has been satisfied, the
MiniBoostPRO will be safe to operate.
This product is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have
been given supervision or instruction concerning the use of the appliance by a person
responsible for their safety.
Children shall not play with this product.
Metal conducts electricity. Take care not to drop or touch metal objects onto the battery
terminals, which if contacts the battery terminals, could cause short circuits and may lead
to serious personal injury. Take care to remove unwanted metal objects from the vicinity
of the battery and MiniBoostPRO. Remove any personal metal adornment such as chain,
watch or ring before handling the battery and MiniBoostPRO.
Only charge battery types which are supported by this charger (see “Compatible Battery
Types”).
Batteries are always electrically live and must be treated with extreme caution. They can
supply high, short circuit currents, even if they appear damaged or undamaged.
2

WARNING
Electricity and water do not mix. Keep this product and your battery dry and do not expose
it to water or water vapour. Do not operate this product or battery near any sort of liquid.
Do not operate this product with wet hands.
Do not use this product in environments that are excessively hot, cold, dusty or humid or
where it will be exposed to magnetic fields or long periods of sunshine. Such exposure
may cause the product or your battery to fail, catch fire or explode.
Clean the housing of this product lightly with a dry or moist cotton cloth. Do not
use alcohol, thinners, benzene or any other chemical cleaner. Do not immerse the
MiniBoostPRO in water.
The MiniBoostPRO is a high precision electronic product. It contains no user-serviceable
parts inside. Do not try to dismantle, modify or repair it yourself. Disassembly, service or
repair by an unauthorised person will void the warranty.
Before using this product, check that cable connections to the battery are of correct
polarity.
Product specifications are subject to change and improve without notice.
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CONTENTS
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . 2
ABOUT THE MINIBOOSTPRO . . . . . . . . . . . . . . . . . . . . 6
TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . 6
ADDITIONAL ACCESSORIES REQUIRED FOR INSTALLATION . . . . . . . 6
COMPATIBLE BATTERY TYPES . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION OF PARTS. . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . 8
VENTILATION AND THERMAL CONSIDERATIONS . . . . . . . . . . . 8
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WIRING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 9
CABLE SIZE . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WIRING AND CONNECTIONS . . . . . . . . . . . . . . . . . . . 9
STANDARD INSTALLATION WIRING INSTRUCTIONS . . . . . . . . . . 10
INSTALLATION WITH BATTERYPLUS35-II WIRING INSTRUCTIONS . . . . 11
INSTALLATION WITH ASPOWER WIRING INSTRUCTIONS . . . . . . . . 12
FUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CHARGING DELAY. . . . . . . . . . . . . . . . . . . . . . . . 13
IGNITION DETECT . . . . . . . . . . . . . . . . . . . . . . . . 13
BATTERY CHEMISTRY SELECTION . . . . . . . . . . . . . . . . . 14
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . 16
CHARGING SEQUENCE LED INDICATORS . . . . . . . . . . . . . . 17
BYPASS MODE . . . . . . . . . . . . . . . . . . . . . . . . . 17
PROTECTIVE FEATURES . . . . . . . . . . . . . . . . . . . . . 18
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . 19
SERVICING AND CLEANING . . . . . . . . . . . . . . . . . . . 19
Designed by BMPRO, one of Australia’s leading power solution experts, the BMPRO product
range is proudly designed and manufactured in Melbourne, Australia, and represent a high-
quality product that will provide years of service.
DISCLAIMER: BMPRO accepts no liability for any loss or damage which may occur from the
improper or unsafe use of its products. Warranty is only valid if the unit has not been modified
or misused by the customer.
MANUAL PART 039222
REV 7.0
Copyright © 2023
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FAQS AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 20
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 21
WARRANTY TERMS AND CONDITIONS (AUSTRALIA) . . . . . . . . . 22
LIMITED WARRANTY TERMS AND CONDITIONS (USA). . . . . . . . . 24
COMPLIANCE . . . . . . . . . . . . . . . . . . . . . . . . . 25
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ABOUT THE MINIBOOSTPRO
BMPRO’s MiniBoostPRO is a multi-stage DC-to-DC battery charger, that enables
charging a secondary battery from solar panels and / or the towing vehicle’s 12V
electrical system.
Blending both the solar and auxiliary inputs, the MiniBoostPRO provides a
combined maximum charging current of 30A, with a preference to solar for
charging your secondary battery.
When charging, the MiniBoostPRO continually monitors primary, secondary
battery and solar voltage.
COMPATIBLE BATTERY TYPES
The MiniBoostPRO may be used to charge 12V batteries with capacities of 50-
300AH and of the following chemistries: AGM/Wet, Gel and LiFePO4 (lithium).
ADDITIONAL ACCESSORIES REQUIRED FOR INSTALLATION
The following accessories (not supplied) are required to complete installation of
the MiniBoostPRO:
92x 40A Automotive Fuse
92x 2A Automotive Fuse
TERMINOLOGY
Secondary battery refers to either an auxiliary battery installed in the motor
vehicle or a house battery installed in the RV.
Primary battery refers to a cranking battery in the motor vehicle. Connected to
the alternator, it is commonly referred to as an auxiliary input.
Bypass mode is the mode where the primary / input AUX source of power is at
the higher voltage than the secondary / output battery.
Boost mode is the mode where the voltage of the primary battery input source is
less than the secondary / output battery.
WARNING
Do not connect other types of Lithium batteries to the MiniBoostPRO.
Do not connect batteries with capacity less than 50Ah.
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DESCRIPTION OF PARTS
1. Aux LED
Green LED indicates charging
from primary source.
2. Solar LED
Blue LED illuminates when the
MiniBoostPRO charges the
battery from its solar input.
3. Fault LED
Red LED is a warning / fault
indicator.
4. Aux In
Orange cable to connect to the
primary battery positive terminal.
5. Solar In
White cable to connect to the solar
panel positive terminal.
6. Batt Out
Red cable to connect to the
positive terminal of the battery to
be charged (secondary).
7. Common Negative
Black cable to connect to the
solar, primary and the battery’s
secondary negative terminals.
8. Ignition Detect
Blue cable to connect to the
towing vehicle’s ignition.
9. Batt Chemistry
Green cable to configure battery
chemistry and select charging
parameters.
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INSTALLATION INSTRUCTIONS
Installation of the MiniBoostPRO should be carried out only by a certified
installer with caravan electrical experience.
MOUNTING
Securely mount the MiniBoostPRO to any suitably strong flat surface. Install
the MiniBoostPRO inside your caravan or camper trailer, preferably close to the
house battery.
VENTILATION AND THERMAL CONSIDERATIONS
The MiniBoostPRO may be installed in any orientation. To prevent overheating
of the MiniBoostPRO, install the unit in a well-ventilated area that allows for
continuous airflow around the unit. Overheating of the MiniBoostPRO will affect
the optimal operation of the unit.
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WIRING INSTRUCTIONS
WIRING AND CONNECTIONS
To assist with wiring, cable colour codes are labelled on the back of the
MiniBoostPRO. To ensure safe and reliable wiring, wire connections should be
crimped or soldered. All wire connections must be protected by heat shrink to
prevent exposed wires.
The MiniBoostPRO may be used in conjunction with a BMPRO power
management system such as the BatteryPlus35-II or ASPower.
If using a power management system, connect the MiniBoostPRO’s Batt Out
and Common Negative cables to the positive and negative primary input. The
MiniBoostPRO may be wired direct to the secondary battery via a protective
fuse.
CABLE CABLE COLOUR MINIMUM CABLE SIZE
Solar In White 6.0mm or 10 AWG
Aux In Orange 6.0mm or 10 AWG
Batt Out Red 6.0mm or 10 AWG
Common Negative Black 6.0mm or 10 AWG
Ignition Blue 0.34mm or 22 AWG
Batt Chemistry Green 0.34mm or 22 AWG
CABLE SIZE
Cables should be sized to carry 30A. The following table demonstrates the
recommended cable size, ranging up to a total length of 15m from input to
output.
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STANDARD INSTALLATION WIRING INSTRUCTIONS
10

INSTALLATION WITH BATTERYPLUS35-II WIRING INSTRUCTIONS
11

INSTALLATION WITH ASPOWER WIRING INSTRUCTIONS
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IGNITION DETECT
The MiniBoostPRO is equipped with an ignition detect cable, which is designed
to prevent your primary battery from excessive discharge and detects when the
vehicle alternator is turned on. If the ignition detects the alternator is running,
the MiniBoostPRO will start charging the secondary battery when the primary
battery voltage is above 12V. If the ignition is detected as off or the ignition wire
is not utilised in the installation, the MiniBoostPRO will start charging when the
primary battery voltage is above 12.6V.
CHARGING DELAY
If the secondary battery voltage is between 14V and 15V, indicating that the
secondary battery is being charged from another source, the MiniBoostPRO will
wait 15 minutes before starting to charge.
FUSING
Fuse protection of the MiniBoostPRO is required at the primary positive
terminals, battery positive terminals, battery chemistry selection cable and the
ignition detect cable.
The MiniBoostPRO’s recommended fuse for the primary positive and battery
positive terminals is an automotive fuse (rating 40A) and for the battery
chemistry and ignition detect cables, is an Automotive fuse (rating 2A).
The fuse must be placed as close as possible to the battery.
IGNITION AUXILIARY VOLTAGE THRESHOLD
Off 12.6V
On (+12V) 12.0V
WARNING
Fuse protection is required even if no BMPRO power management system is installed.
WARNING
Do not leave the ignition cable connected to the battery positive terminal when the
MiniBoostPRO is not charging.
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BATTERY CHEMISTRY SELECTION
The MiniBoostPRO’s green battery chemistry cable is used to select the battery
chemistry. Setting the correct battery chemistry ensures that the appropriate
voltage levels are set for charging.
Selecting 12V Gel Battery
When using the MiniBoostPRO to charge a 12V Gel Battery, connect the green
wire to the battery negative terminal or connect to the common negative. This
will set the output voltage at 14.2V.
Battery Chemistry Voltage Levels
BATTERY
CHEMISTRY
BULK-ABSORPTION
VOLTAGE
BATTERY CHEMISTRY CABLE
CONNECTION POINT
Gel 14.2V Battery Negative Terminal
AGM/Wet 14.4V Floating/Unconnected
LiFePO4 14.6V Battery Positive Terminal
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Selecting 12V AGM/WET Battery
When using the MiniBoostPRO to charge a 12V AGM/Wet Battery, terminate the
green wire, leaving unconnected. This will set the output voltage at 14.4V.
Selecting 12V LiFePO4 Battery
When using the MiniBoostPRO to charge a 12V LiFePO4 Battery, connect the
green wire to the secondary / output battery positive terminal. This will set the
output voltage at 14.6V.
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BATTERY CHARGING
The MiniBoostPRO features a multi-stage charging profile to charge your house
battery. These stages are bulk, absorption and float. This enables the charge to
deliver the maximum current, until the terminal voltage has risen to the battery’s
pre-set level.
Bulk
Bulk is the MiniBoostPRO's primary charging stage where approximately 80% of
charging occurs. This enables the charger to deliver the maximum current, until
the terminal voltage has risen to the battery’s pre-set level.
Absorption
Absorption ensures that the MiniBoostPRO's battery’s voltage is kept at its pre-
set level. During this stage, the current is gradually reduced to less than 2A for 2
minutes. This allows the battery to absorb more power.
Float
Float is the final stage of the battery charging profile. This keeps the
MiniBoostPRO's battery at optimum charge, without overcharging or damaging
the battery and allowing the battery to remain continuously connected to the
charger.
The MiniBoostPRO returns from Float to Bulk/Absorption depending on the
modes. This includes if the output current is more than 10A for more than 2
minutes or if the secondary battery voltage is below 13.1V - this normally applies
when a load is detected on the secondary battery.
The charging stage is indicated by the LED flash sequence of the charging LEDs
on the MiniBoostPRO.
When charging from auxiliary, the green aux LED illuminates. When charging
from solar, the blue solar LED illuminates. If both the auxiliary and solar
are providing the charging current, both the blue and green LED illuminate
simultaneously. The green auxiliary LED will only flash every 5 seconds, if the
battery is good and no sources are available for charging.
CAUTION
The MiniBoostPRO may get warm while the battery is being charged.
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SOURCE MODE LED DESCRIPTION
Aux
Charging Solid green light
Float Flashing green light
Solar
Charging Solid blue light, flashing
green light, solid red light
Float Flashing blue light, flashing
green light, solid red light
Blending
Solar & Aux
Charging Solid blue and green lights
Float Flashing blue light and
flashing green light
None Battery Good Flashing green light every 5
seconds
CHARGING SEQUENCE LED INDICATORS
BYPASS MODE
The MiniBoostPRO will operate in bypass mode when input voltage is greater
than or equal to battery voltage.
Output will shut off in bypass mode if the input voltage is higher than the voltage
required for charging the battery.
17

PROTECTIVE FEATURES
The MiniBoostPRO has built-in protection features:
Spark Free Protection
If the MiniBoostPRO is not connected to a secondary battery, the unit provides
prevention of sparking in the case of accidental short circuit on the output side.
Reverse Polarity Connection Protection
In the case of a reverse polarity connection protection on either inputs or the
output, the MiniBoostPRO will automatically prevent any internal damage.
Overtemperature Protection
If the MiniBoostPRO detects higher than expected internal temperatures, it will
automatically limit the charging output to protect the unit until the temperature
reduces to a suitable level.
Overload Protection
Overload protection ensures that the MiniBoostPRO cannot deliver excessive
current to the secondary battery.
Overvoltage and Undervoltage Protection
The MiniBoostPRO’s overvoltage and undervoltage protection feature prevents
the overcharging or excessive discharge of the primary or secondary batteries.
This keeps the batteries healthy for as long as possible.
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FAULT CODES
If there is a fault with the MiniBoostPRO set-up that prevents the battery from
charging, the red fault LED will illuminate and flash a code to describe the fault.
NOTE: The solid green LED may or may not be on in addition to the red flashing
LED if there is a fault. The type of fault will only be indicated by the red flashing
LED.
FAULT FLASHING
SEQUENCE SOLUTION
No source and
secondary battery
voltage <12.1V
Red Single
Flash
The battery requires charging. Connect the
MiniBoostPRO to auxiliary and/or solar source to
begin battery charging.
Secondary battery
voltage <8V Red Flash x2
The secondary battery is not connected or needs
to be replaced with a healthy battery with voltage
between 8 -14V.
Secondary battery
voltage >15V Red Flash x3
The secondary battery is overcharged or is not
a 12V battery. Check power connections to the
MiniBoostPRO.
Auxiliary input
voltage >15V Red Flash x4 Check the primary input source with a suitable
service provider.
Solar input voltage
>25V Red Flash x5 Check the solar panel’s open circuit voltage is
between 9 and 25V.
SERVICING AND CLEANING
This product contains hazardous voltages and energy hazards that may cause
death or injury. Only qualified service personnel may service the MiniBoostPRO.
Do not attempt to service the MiniBoostPRO yourself, OR dismantle, modify
or repair the MiniBoostPRO yourself; this will void your warranty. If your
MiniBoostPRO requires servicing, please consult your BMPRO dealer or visit
teambmpro.com for assistance.
Use a dry or moist cotton cloth to lightly remove dust or dirt from the
MiniBoostPRO. Do not immerse the MiniBoostPRO in water. Do not use alcohol,
thinners, benzene or any other chemical cleaner as these products may degrade
the housing surface.
19

FAQS AND TROUBLESHOOTING
Need more help troubleshooting your MiniBoostPRO?
Contact our customer service team online at at teambmpro.com/technical-
support
Can I use the MiniBoostPRO inside my engine bay?
The MiniBoostPRO cannot be used inside an engine bay as it is rated to IP20.
Does the MiniBoostPRO connect to home solar panels?
No, the MiniBoostPRO will not connect if the voltage rating of your home solar
panels is over 25V.
Can I run my appliances directly from MiniBoostPRO without any battery being
connected to it?
The MiniBoostPRO works only when the battery is connected to the output. You
can connect your appliances to MiniBoostPRO, but the secondary battery will
have to be connected at the same time.
Can I cut MiniBoostPRO leads shorter for practical wiring?
This is not recommended as this could degrade the MiniBoostPRO’s
functionality. Refer to recommendation of a service centre.
Is the MiniBoostPRO housing electrically isolated?
No, as this is due to the MiniBoostPRO’s housing being physically and
electrically connected to the negative terminal. Always be cautious of accidental
connections from the housing to the battery positive terminal.
At what point will the MiniBoostPRO begin solar charging?
If the battery just been connected, the battery will begin charging from solar.
If the battery was fully charged to the float stage, it will restart solar charging
once the voltage drops below 13V.
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