BM PRO MiniBoostPRO User manual

TEAMBMPRO.COM
OWNER’S MANUAL
MiniBoostPRO
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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 and control
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 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
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.
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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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Copyright © 2021
MANUAL PART 035998
REV 4.0
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.
CONTENTS
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . 4
ABOUT THE MINIBOOSTPRO . . . . . . . . . . . . . . . . . .8
TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . 8
ADDITIONAL ACCESSORIES REQUIRED FOR INSTALLATION . . . . . 8
COMPATIBLE BATTERY TYPES . . . . . . . . . . . . . . . . . 8
DESCRIPTION OF PARTS. . . . . . . . . . . . . . . . . . . . 9
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . .10
VENTILATION AND THERMAL CONSIDERATIONS . . . . . . . . . 10
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . 10
WIRING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . .11
CABLE SIZE . . . . . . . . . . . . . . . . . . . . . . . . 11
WIRING AND CONNECTIONS . . . . . . . . . . . . . . . . . 11
WIRING INSTRUCTIONS FOR STANDARD INSTALLATION . . . . . . 12
WIRING INSTRUCTIONS WITH BP35 . . . . . . . . . . . . . . 13
WIRING INSTRUCTIONS WITH J35 . . . . . . . . . . . . . . . 14
FUSING . . . . . . . . . . . . . . . . . . . . . . . . . .15
IGNITION DETECT . . . . . . . . . . . . . . . . . . . . . . 15
BATTERY CHEMISTRY SELECTION . . . . . . . . . . . . . . . 16
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BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . .18
PROTECTIVE FEATURES . . . . . . . . . . . . . . . . . . . .20
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . .21
SERVICING AND CLEANING . . . . . . . . . . . . . . . . . .22
FAQS AND TROUBLESHOOTING . . . . . . . . . . . . . . . . .23
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . .24
WARRANTY TERMS AND CONDITIONS . . . . . . . . . . . . . .26
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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.
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.
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
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).
Do not connect other types of Lithium batteries to the MiniBoostPRO.
Do not connect batteries with capacity less than 50Ah.
WARNING
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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.
y
X
U
V
W
x
uvw
Figure 1: The MiniBoost PRO
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INSTALLATION INSTRUCTIONS
Installation of the MiniBoostPRO should be carried out only by a certified
installer with caravan electrical experience.
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.
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.
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WIRING INSTRUCTIONS
CABLE SIZE
Cables should be sized to carry 30A. Table 1 demonstrates the
recommended cable size, ranging up to a total length of 15m from input to
output.
Table 1: Recommended Cable Size
CABLE CABLE COLOUR MINIMUM CABLE SIZE
Solar In White 6.0mm2or 10 AWG
Aux In Orange 6.0mm2or 10 AWG
Batt Out Red 6.0mm2or 10 AWG
Common Negative Black 6.0mm2or 10 AWG
Ignition Blue 0.34mm2or 22 AWG
Batt Chemistry Green 0.34mm2or 22 AWG
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 or J35.
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.
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WIRING INSTRUCTIONS FOR STANDARD INSTALLATION
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WIRING INSTRUCTIONS WITH BP35
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WIRING INSTRUCTIONS WITH J35
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Table 2: Ignition Detect
IGNITION AUXILIARY VOLTAGE THRESHOLD
Off12.6V
On (+12V) 12.0V
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 offor the ignition wire is not utilised in the installation, the
MiniBoostPRO will start charging when the primary battery voltage is above
12.6V (refer to Table 2).
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).
Users must place the fuse as close as possible to the battery.
Fuse protection is required even if no BMPRO battery management system is
installed.
WARNING
Do not connect the ignition cable to the battery positive terminal indefinitely
when the MiniBoostPRO is not charging.
WARNING
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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 (Table 3).
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.
Figure 3: Selecting the 12V AGM/ WET Battery
Figure 2: Selecting the 12VGel Battery
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.
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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.
Figure 4: Selecting the 12V LiFePO4
Table 3: 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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BATTERY CHARGING
The MiniBoostPRO features a multi-stage charging profile to charge your
house battery. These stages are boost/blending/boost charge and solar/
bypass/ blending bypass. 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 (Table 4).
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.
The MiniBoostPRO may get warm while the battery is being charged.
CAUTION
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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
Table 4: LED charging flash sequence
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PROTECTIVE FEATURES
The MiniBoostPRO has the following 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.
Over Temperature 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
The Overload Protection ensures that the MiniBoostPRO cannot deliver
excessive current to the secondary battery.
Over Voltage and Under Voltage Protection
The MiniBoostPRO’s Over Voltage and Under Voltage 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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