Samlexpower BBM-12100 User manual

Battery
Back-up
BBM-12100
Please read this
manual BEFORE
installing your
inverter
Owner's
Manual

2 | SAMLEX AMERICA INC.
OWNER'S MANUAL | Index
SECTION 1
Safety Instructions ................................................................ 3
SECTION 2
Description .......................................................................... 3
SECTION 3
Operation ........................................................................... 4
SECTION 4
Installation .......................................................................... 6
SECTION 5
Specications ....................................................................... 7
SECTION 6
Warranty ........................................................................... 8
Disclaimer of Liability
UNLESS SPECIFICALLY AGREED TO IN WRITING, SAMLEX AMERICA INC.:
1. MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION
PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.
2. ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, DIRECT, INDI-
RECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY
SUCH INFORMATION WILL BE ENTIRELY AT THE USERS RISK.
Samlex America reserves the right to revise this document and to periodically make changes to the content
hereof without obligation or organization of such revisions or changes.
Copyright Notice/Notice of Copyright
Copyright © 2022 by Samlex America Inc. All rights reserved. Permission to copy, distribute and /or modify this
document is prohibited without express written permission by Samlex America Inc.

2 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 3
SECTION 1 | Safety Instructions
1.1 PRECAUTIONS WHEN WORKING WITH BATTERIES
• Batteries contain very corrosive diluted sulphuric acid as electrolyte. Precautions
should be taken to prevent contact with skin, eyes or clothing.
• Batteries generate hydrogen and oxygen during charging resulting in evolution of
explosive gas mixture. Care should be taken to ventilate the battery area and follow
the battery manufacturer’s recommendations.
• Never smoke or allow a spark or ame near the batteries.
• Use caution to reduce the risk of dropping a metal tool on the battery. It could spark
or short circuit the battery or other electrical parts and could cause an explosion.
• Remove metal items like rings, bracelets and watches when working with batteries.
The batteries can produce a short circuit current high enough to weld a ring or the
like to metal and thus cause a severe burn.
• If you need to remove a battery, always remove the ground terminal from the battery
rst. Make sure that all the accessories are off so that you do not cause a spark.
SECTION 2 | Description
2.1 DESCRIPTION
This unit is used to allow any 12 VDC / 24 VDC power supply to function as a DC
Uninterrupted Power Source (UPS). This unit is a passive device and acts only as an
interface between the power supply, the battery and the DC load. As long as the power
supply is operating normally, it will supply the load as well as oat charge the battery.
In case the output of the power supply fails, the battery will start feeding the load
immediately thus ensuring un-interrupted DC power to the load. The battery will start
discharging. Once the output of the power supply is resumed, the power supply will
take over the load and will also re-charge the battery at its oat voltage.

4 | SAMLEX AMERICA INC.
SECTION 3 | Operation
3.1 PRINCIPLE OF OPERATION
R1
R2
D2D1
INPUT
NEGATIVE
INPUT
POSITIVE
BATTERY
POSITIVE
BATTERY
NEGATIVE
LOAD
POSITIVE
D1,D2
R1,R2
SCHOTTKY DIODE, 32CTQ030 BY INTERNATIONAL RECTIFER
POWER RESISTOR 1R2 (1.2 OHM), 25 WATTS
+
+
+LOAD
NEGATIVE
POWER
SUPPLY
RADIO
Fig. 3.1: Schematic Diagram
Please refer to the schematic diagram at Fig. 3.1.
The power supply is connected to the positive and negative input terminals. The battery
is connected to the battery terminals and the load is connected to the load terminals.
The voltage from the power supply is fed through the isolating Schottky diode D1 to the
load and to the battery through the charging current limiting resistors R1 and R2. Diode
D1 provides isolation between the power supply and the battery to prevent the battery
from feeding back into the power supply circuit. D1 has a forward voltage drop of 0.2 (at
< 1A) to 0.4V (at > 10A). Hence, the voltage available to the load and to the battery for
oat charging will be 0.2 to 0.4V lower than the output voltage of the power supply.
In a battery backup application, the battery will normally remain in a fully charged,
standby condition most of the time. It will discharge to the load only when the power
supply fails. Under this standby application, the battery should be charged at the
recommended oat voltage. Assuming the standby oat charging voltages of 12V / 24V
sealed lead acid (SLA) batteries to be 13.5V to 13.8V and 27V to 27.6V ( at 60ºF to 77ºF)
respectively, the output voltage of the power supply should be adjusted as follows:
Power supply voltage for 12V SLA battery backup: 14V
(The output voltage of this unit for the load and for oat charging of the battery
will be 14V minus drop of 0.2V to 0.4V across diode D1 i.e. 13.8V to 13.6V)
Power supply voltage for 24V SLA battery backup: 27.6V
(The output voltage for the load and for oat charging of the battery will be 27.6V
minus drop of 0.2V to 0.4V across diode D1 i.e. 27.4V to 27.2V)

4 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 5
SECTION 3 | Operation
As long as the power supply is operating normally, it will supply the load as well as
charge the battery through resistors R1 and R2, each 1Ohm, 35W ( R1 and R2 are
connected in parallel and will provide a net series resistance of 0.5 Ohm).
NOTE: Please note that as the power supply is required to feed the load as well as
charge the battery, the current rating of the power supply should be at least 20% more
than the sum of the maximum load current and the maximum charging current.
If the power supply fails, the load will be supplied by the battery through the Schottky
diode D2. As in the case of diode D1, there will be a forward voltage drop of 0.2 to 0.4V
across D2. Thus, when the battery is supplying the load, the voltage seen by the load
will be 0.2 to 0.4V less than the battery voltage. Note that diode D2 is connected in
parallel with the resistors R1 an R2 and is used to bypass the resistors R1 and R2 when
the battery is discharging through the load.
3.2 MAXIMUM BATTERY CHARGING CURRENT
The maximum recommended charging current of a battery is normally related to it’s AH
(Ampere Hour) capacity, designated as “C” (based on 20A discharge rate). The maximum
charging current for an SLA battery is normally specied as C/20 ( 0.05C).
Battery backup application using 12V, 100 AH battery
This battery backup unit has been preset for battery backup application for a 12V
battery of approximately 100 AH capacity with the maximum charging current limited
to approximately 5A.
Battery backup application using 24V, 100 AH battery
When using this unit in the preset condition for 24V, 100 AH battery backup application,
the charging current will increase to 10A.
Calculating maximum battery charging current
Equation 1: Ib = {(Vp – Vd) – Vb}
Rs
Ib = Maximum charging current
Vp = The output voltage of the power supply
Vd = Forward voltage drop across D1 (0.2V for < 1A and 0.4V > 10A)
Vb = Battery voltage at fully discharged condition (Normally 11.4V for 12V and 22.8V for 24V)
Rs = Equivalent series resistance (In this case, two 1 Ohm in parallel = 0.5 Ohm)
Example:
Assuming that the voltages of fully discharged 12V and 24V batteries are 11.4V and
22.8V respectively, the maximum charging currents will be as follows as per Equation 1:
For 12V System: Ib = (14V – 0.2V – 11.4V) ÷ 0.5 Ohm = 4.8A, or ~5A
For 24V System: Ib = (27.6V – 0.2V – 22.8V) ÷ 0.5 Ohm = 9.2A, or ~10A

6 | SAMLEX AMERICA INC.
4.1 CABLE SIZING, TERMINATION AND FUSING
The size of the cables used to connect the power supply, the battery and the load to
this unit will depend upon the maximum value of the current ow and the length of
the cable run. Current owing through a cable will produce an undesirable voltage
drop along the length of the cable. The voltage drop is proportional to the resistance of
the cable. Higher resistance produces higher voltage drop. The resistance of the cable
increases as the cable becomes thinner. Similarly, the resistance increases with the length
of the cable. It is desirable to limit the voltage drop to 3%.
Fuse in the battery circuit
A battery can supply very heavy current in case of short circuit in the path across its
terminals. This can cause overheating of the cables / connected device(s) and consequent
risk of melted insulation and possibility of re. Hence, for safety, a very fast acting fuse
of appropriate current capacity should be connected in series with the positive cable and
should be placed as close as possible to the positive terminal of the battery.
The following Table gives the recommended sizes of cable and fuses:
Current
Cable Length
up to 5 ft
Fuse Type
(Bussmann Type#)
100A #2 AWG 125A, Type ANN-125
50A #6 AWG 60A, Type ANN-60
40A #6 AWG 50A, Type ANN-50
25A #8 AWG 35A, Type ANN-35
The terminals have a tubular hole of diameter 8mm with set screw for connecting the
input and output cables. If the bare end of a multi-stranded cable is used directly, the
set screw may not pinch all the strands rmly and will result in a loose connection which
will cause voltage drop and excessive heating. For a rm connection, the cable ends
should be terminated with suitable pin type of terminal.
CONNECTIONS
Before the power supply is connected to this unit, ensure that the output voltage of
the power supply is adjusted to the required oat voltage of the battery as described in
Section 3.1.
!
CAUTION!
Ensure correct polarity of all connections.
1) Switch off the power supply.
2) Connect the positive and negative output of the power supply to the input terminals
of the BBM-12100 marked “INPUT POSITIVE” and “INPUT NEGATIVE” respectively
4) Connect the DC load to the terminals marked “LOAD POSITIVE” and “LOAD NEGATIVE”
5) Connect the battery to the terminals marked “BATTERY POSITIVE” and “BATTERY NEGATIVE”
SECTION 4 | Installation

6 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 7
SECTION 5 | Specications
NOTE: Specications are subject to change without notice.
MODEL NO. BBM-12100
INPUT
INPUT VOLTAGE 14 VDC for 12V Battery
27.6 VDC for 24 Battery
INPUT CURRENT Maximum 100A
OUTPUT
CHARGE VOLTAGE
0.4V Less than the Input Power Suppy Voltage
13.6 VDC for an Input Voltage of 14 VDC
27.2 VDC for an Input Voltage of 27.6 VDC
LOAD CURRENT Maximum 95A for 12V Battery
Maximum 90A for 24V Battery
BATTERY CHARGE CURRENT Maximum 4.8A for 12V Battery
Maximum 9.2A for 24V Battery
OTHER
EXTERNAL BACK UP BATTERY Lead Acid: 12V/24V, 40Ah to 100Ah
ENVIRONMENT
OPERATING TEMPERATURE RANGE 0°C to 40°C / 32°F to 104°F
DIMENSIONS
(W x D x H), MM 150.8 x 187 x 65
(W x D x H), INCHES 5.9 x 7.4 x 2.6
WEIGHT
KG 1.0
LBS 2.2

8 | SAMLEX AMERICA INC.
SECTION 6 | Warranty
2 YEAR LIMITED WARRANTY
The BBM-12100, manufactured by Samlex America, Inc. (the “Warrantor“) is warranted
to be free from defects in workmanship and materials under normal use and service.
The warranty period is 2 years for the United States and Canada, and is in effect from
the date of purchase by the user (the “Purchaser“).
Warranty outside of the United States and Canada is limited to 6 months. For a warranty
claim, the Purchaser should contact the place of purchase to obtain a Return Authoriza-
tion Number.
The defective part or unit should be returned at the Purchaser’s expense to the author-
ized location. A written statement describing the nature of the defect, the date of pur-
chase, the place of purchase, and the Purchaser’s name, address and telephone number
should also be included.
If upon the Warrantor’s examination, the defect proves to be the result of defective
material or workmanship, the equipment will be repaired or replaced at the Warran-
tor’s option without charge, and returned to the Purchaser at the Warrantor’s expense.
(Contiguous US and Canada only)
No refund of the purchase price will be granted to the Purchaser, unless the Warrantor
is unable to remedy the defect after having a reasonable number of opportunities to do
so. Warranty service shall be performed only by the Warrantor. Any attempt to remedy
the defect by anyone other than the Warrantor shall render this warranty void. There
shall be no warranty for defects or damages caused by faulty installation or hook-up,
abuse or misuse of the equipment including exposure to excessive heat, salt or fresh
water spray, or water immersion.
No other express warranty is hereby given and there are no warranties which extend
beyond those described herein. This warranty is expressly in lieu of any other expressed
or implied warranties, including any implied warranty of merchantability, tness for the
ordinary purposes for which such goods are used, or tness for a particular purpose, or
any other obligations on the part of the Warrantor or its employees and representatives.
There shall be no responsibility or liability whatsoever on the part of the Warrantor or
its employees and representatives for injury to any persons, or damage to person or
persons, or damage to property, or loss of income or prot, or any other consequential
or resulting damage which may be claimed to have been incurred through the use or
sale of the equipment, including any possible failure of malfunction of the equipment,
or part thereof. The Warrantor assumes no liability for incidental or consequential dam-
ages of any kind.
Samlex America Inc. (the “Warrantor”)
www.samlexamerica.com

8 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 9
NOTES

10 | SAMLEX AMERICA INC.
NOTES

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NOTES

Contact
Information
Toll Free Numbers
Ph: 1 800 561 5885
Fax: [phone]
Local Numbers
Ph: 604 525 3836
Fax: [phone]
Website
www.samlexamerica.com
USA Shipping Warehouses
Kent, WA
Plymouth, MI
Canadian Shipping Warehouse
Richmond, BC
Email purchase orders to
[email protected]
11001-BBM-12100-0322