BM PRO BatteryPlus35-II Series User manual

TEAMBMPRO.COM
BatteryPlus35-II
BatteryPlus35-II-HA
BatteryPlus35-II-SI
BatteryPlus35-II-SR
OWNER’S MANUAL
More information https://www.caravansplus.com.au

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TEAM
BMPRO
.COM
POWERING YOUR ADVENTURES
With over 50 years’ experience in power
solutions combined with manufacturing
and design facilities in Melbourne,
Australia, BMPRO are the leading
experts in RV power management.
Inspired by the great outdoors, we
have created a range of rugged, smart
and reliable products to power your
adventures.
Our range of battery, power and RV
management and control systems gives
you peace of mind when you are on the
road, so that you can relax in even the
most far-flung destinations, knowing
you have control over your power
needs.
To learn more about the BMPRO range
of products, please visit our website
teambmpro.com
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SAFETY PRECAUTIONS
Please read the Safety Precautions before installing or using the BatteryPlus35-II.
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
Ensure that there is a good ventilation from the battery area.
Correct installation is the most critical factor in ensuring the safe use of the BatteryPlus35-II. If
every consideration of these instructions has been satisfied, the BatteryPlus35-II 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 instructions concerning the use of the appliance by a person responsible for their
safety.
Children shall not play with this product. Cleaning and user maintenance should not be performed
by unsupervised children.
Ensure that the product is well ventilated and that if the product has a fan, the fan is not covered or
obstructed.
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 and remove unwanted metal objects from the vicinity of battery and
BatteryPlus35-II. Remove any personal metal adornment such as chain, watch or ring before
handling the battery and BatteryPlus35-II.
Do not attempt to charge non-rechargeable batteries. Charging a non-rechargeable battery may
result in the battery catching fire or possible explosion
Do not replace a damaged mains power cord. If the power cord is damaged, the product must be
discarded.
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.
Before servicing a battery, disconnect the power supply from all power sources.
Only charge battery types which are supported by this charger (see “Compatible Battery Types”)
Do not allow water or other liquids to enter the power supply area.
Do not drop or vigorously shake the product as this may cause damage. Do not shock the product,
its accessories or batteries as this may cause the product or battery to fail, catch fire or explode.
Stay away from magnetic equipment. Radiation may erase the information stored on this product
causing it to become inoperative.
Please note that your battery can only reach top performance level only after it has been fully
charged and discharged two or three times.
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WARNING
CAUTION: Risk of fire.
Do not replace any vehicle fuse with a rating higher than recommended by the vehicle
manufacturer.
This product is rated to draw between 20 and 30 amperes from a 12V vehicle outlet, depending on
your model of BatteryPlus35-II. Ensure that the electrical system in your vehicle can supply this
product without causing the vehicle fusing to open. This can be determined by making sure the fuse
in the vehicle which protects the outlet is rated higher than the maximum ampere drawing current
for your BatteryPlus35-II. Information on the vehicle fuse rating are typically found in the vehicle
operator's manual.
If a vehicle fuse opens repeatedly, do not keep on replacing it. The cause of the overload must be
found. On no account should fuses be patched up with tin foil or wire as this may cause serious
damage elsewhere in the electrical circuit or cause fire.
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS - This manual contains important instructions for
Models BatteryPlus35-II-SR, BatteryPlus35-II-SI, BatteryPlus35-II-HA that shall be
followed during the installation and maintenance.
The nominal voltage of the BatteryPlus35-II is 12V. All models of the BatteryPlus35-
II series are rated to charge lead acid batteries, and the BatteryPlus35-II-HA is also
rated to charge LiFePO4 batteries.
The maximum ambient temperature rating for the BatteryPlus35-II is 50 °C (122 °F).
For 0-10A current, use 18 AWG, 90 °C (194 °F) copper wire.
For 10-20A current, use 14 AWG, 90 °C (194 °F) copper wire.
For 20-30A current, use 10 AWG, 90°C (194 °F) copper wire.
Overcurrent protection for the battery circuit is to be provided by the installer or the
user, whichever is applicable.
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CONTENTS
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . 4
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . .5
ABOUT THE BATTERYPLUS35-II. . . . . . . . . . . . . . . . . . . . 8
OPTIONAL ADD-ONS . . . . . . . . . . . . . . . . . . . . . . . . 8
COMPATIBLE BATTERY TYPES . . . . . . . . . . . . . . . . . . . . . 9
DESCRIPTION OF PARTS. . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 13
PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
EARTHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SIMPLE WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . 14
WIRING DIAGRAM WITH OPTIONS . . . . . . . . . . . . . . . . . . 15
VENTILATION, ORIENTATION AND THERMAL CONSIDERATIONS . . . . . . 16
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
MAINS CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LOAD, BATTERY AND EXTERNAL DC INPUT CONNECTIONS . . . . . . . . 18
MAIN CHARGE CONNECTION . . . . . . . . . . . . . . . . . . . . 19
CARAVAN BATTERY CONNECTION . . . . . . . . . . . . . . . . . . 19
REPLACING BATTERIES . . . . . . . . . . . . . . . . . . . . . . 20
USING YOUR BATTERYPLUS35-II . . . . . . . . . . . . . . . . . . . 22
INPUT POWER SOURCES . . . . . . . . . . . . . . . . . . . . . . 22
BATTERY CHARGING AND MANAGEMENT . . . . . . . . . . . . . . . 24
ECO MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
STORAGE MODE . . . . . . . . . . . . . . . . . . . . . . . . . 25
RECOVERY MODE . . . . . . . . . . . . . . . . . . . . . . . . . 25
USING THE BATTERYPLUS35-II AS A POWER SUPPLY . . . . . . . . . . 26
FAULT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . 27
Copyright © 2021
MANUAL PART 036853
REV 7.0
Designed by BMPRO, one of Australia’s leading power solution experts, the BMPRO range of
products are proudly Australian-Made in Melbourne, Victoria 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.
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SERVICING, MAINTENANCE AND STORAGE . . . . . . . . . . . . . . . 28
SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 28
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FAQS AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 29
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CARAVAN LOADS . . . . . . . . . . . . . . . . . . . . . . . . . 29
SOLAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BATTERYPLUS35-II OPERATIONAL STATUS INDICATOR . . . . . . . . . 31
BATTERY CHARGING MANAGEMENT ALGORITHM . . . . . . . . . . . . 32
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 34
COMPLIANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
WARRANTY TERMS AND CONDITIONS . . . . . . . . . . . . . . . . . 38
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ABOUT THE BATTERYPLUS35-II
BMPRO’s BatteryPlus35-II is a battery management system designed specifically
for use in recreational vehicles. The BatteryPlus35-II operates from 100 to 240V
AC mains power supply, towing vehicle auxiliary and solar panel to provide 35A of
current to simultaneously power caravan loads and charge the caravan battery.
The BatteryPlus35-II is available in a range of models to suite any RV and battery
management needs.
FEATURE BP35-II-SI BP35-II-SR BP35-II-HA
In-built Solar 20A - PWM 30A - MPPT 30A - MPPT
Solar Connection Direct to BatteryPlus35-II
Lithium (LiFePO4) Charging No No Yes
Maximum AC Charging Current 20A 20A 30A
OPTIONAL ADD-ONS
To get the most of your BatteryPlus35-II it may be used with the following products
(sold separately) from the BMPRO range:
BC300 + CommLink
External Shunt for integration of additional accessories and high current loads such
as inverters.
RVView Battery Monitor
To monitor battery parameters and charge sources.
Trek Battery Monitor
To gain greater insights into battery usage, the ability to monitor water tank levels
and control water pumps.
Odyssey + OdysseyLink
To monitor battery usage and caravan features (tanks and temperature) and control
caravan loads from an in-built monitor.
MiniBoost
DC-to-DC charge-booster for RV applications.
Table 1: Comparison of features for the models of the BatteryPlus35-II range
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COMPATIBLE BATTERY TYPES
The BatteryPlus35-II is rated to charge battery banks of up to 600Ah in capacity and
of the following battery types:
BATTERY SI SR HA*
Lead Acid
Valve-Regulated (VRLA) Yes Yes Yes
Absorbed Glass Mat (AGM) Yes Yes Yes
Gel Yes Yes Yes
Lithium LiFePO4 No No Yes
Table 2: Batteries compatible for use with the BatteryPlus35-II
* By default, the BatteryPlus35-II-HA is configured to charge lead acid batteries.
WARNING
The BatteryPlus35-II-HA is designed for use with Lead Acid and LiFePO4 Lithium batteries
only. Do not connect other types of Lithium batteriesto the BatteryPlus35-II-HA. BMPRO
Invicta batteries are recommended.
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DESCRIPTION OF PARTS
1. MAINS CABLE
The BatteryPlus35-II is pre-cabled with a permanent mains power supply cord
for use with 240V or 110V input power.
2. LOAD TERMINAL BLOCK – COMMON NEGATIVE CONNECTION
Negative wire connection return point for the caravan’s 12V loads.
3. LOAD OUTPUTS – 15A X 2 POSITIVE CONNECTIONS
Used for connecting the positive wire of the 12V loads, outputs 1 & 2
4. LOAD OUTPUTS – 10A X 12 POSITVE CONNECTIONS
Used for connecting the positive wire of the 12V loads, outputs 3 – 14
Figure 1: BatteryPlus35-II. Compatible for all models
WARNING
Do not replace a damaged power supply cord. If the power cord is damaged, the
BatteryPlus35-II must be discarded. Ensure that the AC mains source always has an earth
terminal.
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5. AUX+
Connection point for external DC input positive.
6. BATT+
Connection point for battery positive terminal. Attach fuse to Batt+ wiring.
7. BATT-
Connection point for battery negative terminal.
8. NOT USED
9. RESET (MASTER RESET BUTTON)
Press the Master Reset Button if any part of the system is unresponsive or not
operating correctly during or after installation
10. CAN BUS COMMUNICATION CONNECTOR
To connect to and power BMPRO accessories (BC300 + CommLink External Shunt
or OdysseyLink) or monitors (RVView or Trek).
11. REMOTE SWITCH TERMINAL BLOCK (RSW)
Terminal block for connecting an optional remote switch. This switch is used to
disconnect the loads from all power.
Terminals are labelled according to their designated load output
Table 3: Designated terminal-load outputs
TERMINAL OUTPUTS LOAD RATING
1Tablet / Spare 15A
2Spare 15A
3-9 Spare 10A
10 Light 1 10A
11 Light 2 10A
12 Light 3 10A
13 Pump 1 10A
14 Pump 2 10A
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14. SOLAR PANEL CONNECTION
Connection used for solar panel input.
15. +BRK BATTERY OUTPUT (40A MATCH RATED)
16. SYSTEM STATUS INDICATOR
Indicates the operational status of the BatteryPlus35-II.
12. MOUNTING HOLE (X4)
13. LOAD OUTPUT STATUS INDICATORS
LED COLOUR LOAD OPERATIONAL STATUS
GREEN Loads operating normally
FLASHING RED Fault with load
OFF Load is off
Table 4: LED Status Indicators
This output is an uncontrolled 15th output with a maximum current rating of 40A.
This is specifically designed for loads which do not need to be isolated or have a
current rating higher than the inbuilt circuit protection of the individual outputs
and have a current rating less than 40A. This may include, but not be limited to:
9BMPRO SwayControl
9BMPRO Trailsafe (+)
9Heaters
9Stereo memory
WARNING
Loads connected to +BRK output will not turn offeven during ECO mode or Storage mode.
To maintain good health of the battery during low voltage, manually turn these loads off.
Exceeding 40A total load current may turn offsome of the load outputs 1-14. All loads
connected on this output must be individually fused.
WARNING
If braking systems are already connected to the +BRK output, non-braking loads must use
a separate output.
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INSTALLATION INSTRUCTIONS
EARTHING
As the BatteryPlus35-II is positive sensing for current monitoring, this allows for
chassis earthing of both the battery and the negative of DC 12V appliances.
Note: All DC 12V positive cables must be wired to outputs 1-14 or the 40A battery
output connection.
Loads greater than 15A
For DC 12V appliances that may draw greater than 15A, such as inverters, both
positive and negative must be wired directly to the new battery negative on the
BC300 to ensure the current is seen by the BatteryPlus35-II and the correct
information displayed, such as the State of Charge and Time Remaining.
Refer to our website for more information on this product: https://teambmpro.com/
products/bc300-commlink-external-shunt/
PERSONNEL
Installation is to be carried out only by suitably qualified personnel.
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SIMPLE WIRING DIAGRAM
Lights,
Pump etc
Negative Output Positive Output
40A Max Fuse
AUX+ BATT+BRK+
Solar+
Solar-
40A Max Fuse
40A Max Fuse
Heaters
Stereo
Memory
BRK+
Auxiliary
with Isolation Relay
BATT-
Unregulated RV Solar
Panels 18-25V
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AUX+ BATT-
BATT+BRK+
Solar+
Solar-
Unregulated RV Solar
Panels 18-25V
CAN BUS
OdysseyLink
RVView Trek
Battery Monitors:
40A Max Fuse
40A Max Fuse
40A Max Fuse
SwayControl
TrailSafe
Heaters Stereo
Memory
BRK+
MiniBoostPRO
(only with BC300
connected)
BATT+
MiniBoost
AUX+
AC
Inverter
40A Max Fuse
WIRING DIAGRAM WITH OPTIONS
Isolation Relay
Odyssey
Pin 1
Lights,
Pump etc
Negative Output Positive Output
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VENTILATION, ORIENTATION AND THERMAL CONSIDERATIONS
The preferred orientation is with the load connection at the bottom and located
so that there is a minimum of 80mm of free air space from all vented sides of the
BatteryPlus35-II. This allows for the lowest operating temperature of the internal
electronics and the highest reliability of the product.
The final enclosure must provide adequate ventilation to the outside world (or larger
internal cavity) to prevent excessive heating of the air within the enclosure.
At normal room temperature (25°C), the unit is rated to provide full power in both
vertical and horizontal orientations. At elevated temperatures of up to 50°C, the
output current is de-rated to 32A.
The BatteryPlus35-II has over-temperature protection and will shut down if
its internal temperature rises above the safe level. The BatteryPlus35-II will
automatically restart once it has cooled to an acceptable level.
WARNING
The enclosure air temperature can easily exceed 50°C if adequate ventilation is not
provided.
WARNING
Do not install the BatteryPlus35-II in a compartment where flammable material is stored,
such as petrol or LPG.
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MOUNTING
The BatteryPlus35-II should be securely mounted to a suitably rigid surface, using
the four pre-drilled mounting holes.
MAINS CABLE
The BatteryPlus35-II is pre-cabled and fitted with a mains plug. Ensure that the
connections to the mains supply are in accordance with the national wiring rules, and
that the earth connection is installed. For more information, refer to the Mounting
section.
The mains cable must be at least 80mm away from the output cables. For information
on wiring, refer to the Wiring Diagram section.
The plug must be accessible during installation. If this is not possible, an accessible
mains disconnection switch must be incorporated in the mains wiring where the plug
is connected.
Figure 2: Mounting Diagram
WARNING
If the supply cord is damaged, it must not be replaced and the appliance should be
scrapped.
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Wire Size
DC cables must be sized to carry the maximum full load current and to not exceed the
system volt drop requirements. The following cable sizes are recommended. When
running wires, if they pass through panels or wall, ensure the wires are protected
from damage by sharp edges. The use of cable glands is recommended.
Table 5: Wire Size Recommendations
CURRENT MINIMUM WIRE SIZE
0-10A 1.0mm2or 18 AWG
10-20A 3.0mm2or 14 AWG
20-30A 5.5 mm2or 10 AWG
LOAD, BATTERY AND EXTERNAL DC INPUT CONNECTIONS
Up to 14 loads may be connected. Loads are attached using female spade Quick
Connects (QC). See Figure 4: Quick Connect Dimensions.
All load negative returns must be connected directly to the BatteryPlus35-II negative
terminals only.
Figure 3: Quick Connect Dimensions
6.8mm
The wiring method used with the installation shall be in accordance with National
Electrical Code ANSI/NFPA 70.
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MAIN CHARGE CONNECTION
The following inputs / outputs require fork type connections:
Aux+ / Batt+ / Batt- / BRK+
Figure 4: Fork Terminal Dimensions
CARAVAN BATTERY CONNECTION
Max.
8.2mm
Min.
3.6mm
WARNING
A fuse must be installed in the positive connection of the battery. This fuse MUST be as
close as possible to the battery. This fuse protects against short circuits and reverse
battery conditions. A fuse rating no greater than 40A must be used.
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After fitting a new battery to the BatteryPlus35-II, make sure that it is configured in
your battery monitor.
Correctly configuring the battery capacity and profile will ensure that the
BatteryPlus35-II will select the best charging parameters for the caravan battery in
use, and the software accurately estimates battery usage.
REPLACING BATTERIES
Figure 5: Wiring the battery to the
BatteryPlus35-II.
To protect against short-circuits and
reversed battery connections, install
a 40A fuse as close as possible to the
battery’s positive terminal.
WARNING
Before using a battery other than that which was installed at the caravan dealership,
consult with the battery manufacturer for a detailed description of the installation, uses
and maintenance of the battery. Verify that the type and capacity of the battery or batteries
used are compatible for use with the BatteryPlus35-II.
WARNING
Sparks have the potential to cause an explosion if combustible gases are present.
The following procedures are designed to minimise the risk of spark generation while
connecting or disconnecting the battery. The positive terminal of the battery MUST NOT be
connected to the chassis.
WARNING
Do not install a battery in the same compartment where flammable material is stored, such
as petrol.
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