Sterling power products Bb1210 User manual

Sterling Power Products

DC/DC Charger Handbook

Part Nos:

BB1210

BB1215

BB1225

BB1240

BB1270

BB12120

BB12200

BB1224120

BB122465

BB1236120

BB124865

BB1248120

INC. BBR

PRIDE IN PERFORMANCE

Colours in use

Sterling Red

RAL 3003

90% Black

White

www.sterling-power.com

www.sterling-power-usa.com

Warranty (2 years return to factory)

Sterling Power

RoHS

compliant

12V

ign

alarm

GND

TEMP1

Temperature sensor

included

latest instructions

Saturn Series, full range

Dimensions 200mm x 130mm x 56mm

Weight 1.0Kg

BB1270

12V - 12V 70A

Battery to Battery Charger

185mm

BB1270

Input voltage range 9V-16V

Rated output power 60A at 13.8V

Rated input current 70A

Quiescent current 10mA

Efficiency rating 92%-94%

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

Dimensions 200mm x 130mm x 56mm

Weight 1.0Kg

Dimensions 309mm x 130mm x 96mm

Weight 2.2Kg

BB12200

Input voltage range 9V-16V

Rated output power 180A at 13.8V

Rated input current 200A

Reverse charging current (max) 60A to 13.4V

Reverse charging voltage <13.4V

Quiescent current 15mA

Efficiency rating 95-98%

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

Dimensions 309mm x 130mm x 96mm

Weight 2.2Kg

Dimensions 270mm x 130mm x 73mm

Weight 1.8Kg

BB12120

Input voltage range 9V-16V

Rated output power 110A at 13.8V

Rated input current 120A

Quiescent current 5mA

Efficiency rating 92%-94%

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

Dimensions 270mm x 130mm x 73mm

Weight 1.8Kg

Bb1248120

Input voltage range 9V-16V

Rated output power 27.5A at 55.2V

Rated input current 120A

Quiescent current 5mA

Efficiency rating 92%-94%

BB1224120

Input voltage range 9V-16V

Rated output power 26A at 57.7V

Rated input current 120A

Quiescent current 5mA

Efficiency rating 95-98%

Reverse charging current 40A at 13.3V

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

Dimensions 270mm x 130mm x 73mm

Weight 1.8Kg

Dimensions 163mm x 130mm x 56mm

Weight 0.8Kg

BB1240

Input voltage range 9V-16V

Max Rated output power 38A at 14.41V ~550W

Max Rated input current 42A at 13.68V ~575W

Quiescent current 5mA

Efficiency rating 95-98%

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

Dimensions 163mm x 130mm x 56mm

Weight 0.8Kg

Dimensions 123mm x 130mm x 56mm

Weight 0.6Kg

123

113

BB1225

Input voltage range 9V-16V

Max Rated output power 24A at 14.41V ~345W

Max Rated input current 26A at 13.68V ~355W

Quiescent current 5mA

Efficiency rating 98%

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

Dimensions 123mm x 130mm x 56mm

Weight 0.6Kg

50% Black for subtitles + bottom right

90% Black for body

RAL 3003 R134 G26 B34

Text, by and large, is size 9.

INLEAF FAQs

NOTES 02

STERLING

POWER

DIMENSION

DRAWING

Dimensions 270mm x 130mm x 73mm

Weight 1.8Kg

12V - 12V 120A

Battery to Battery Charger

sterling-power.com

sterling-power-usa.com

BB12120

instructions

Ultimately, this is something we cannot tell you. There is no purely standardised charge profile for specific

battery types and we cannot be expected to know every single battery on the market. Consult with your

battery specification sheet or with your battery manufacturer and choose a battery type that most closely fits

in with their recommended values. It’s better to be underneath what the manufacturer recommends than to

be over it.

The temperature sensor, on lead acid, will cause temperature compensation, adjusting the charge voltage

up or down depending on the temperature registered at your battery. On lithium charge profiles temperature

compensation does not occur, but our charger will not provide any output if it registers 0DEGC at the battery.

Yes, please. Keep in mind that charging your batteries requires a good circuit. Poor negatives or degrading

negatives will negatively (pun unintended) affect your charge capabilities and our calculations.

Cable too big is better than cable too small! To downstep your cable into our connectors, either consider

using ferrules or dropping the cable size across a contact (fuse holder, bus-bar etc).

If the charger doesn’t seem to be running- check a few things. Make sure you’re not in Vibration Sense

mode (as this will make the unit respond to vibrations ONLY). Make sure you’re getting >13.5V on the POS

IN and NEG of the charger. Make sure the ignition feed (if fitted!) is getting a live signal when it should be.

This can be disabled on the unit itself, covered on page 11.

Check to make sure that your ignition feed line is only live when the vehicle alternator is running. All of our

control signals come from voltages- we will only be on if there’s signals telling us to be on.

If you seem to have pulsing charge ON/OFF, you probably have a problem with the input voltage to the

Saturn charger. Get a voltmeter and sit at the input of the unit and monitor what the input voltage is. If the

input voltage sags a lot when the charger turns on, either you have loss down cable/contacts or your

alternator is insufficient to support the load. If the voltage is triggering down to <11V for an instant, turning

off the charger and then immediately recovering, this is likely being triggered by a faulty resettable fuse on

the POS IN line. Replace or bypass the fuse to verify.

Keep us away from exposed water ingress (we are conformal coated, but be sensible!), keep us away from

faulty items (cheap solar regulators sometimes dump a very high solar voltage onto the DC system- this can

damage electronics like our Saturn charger!), and check our cable connections frequently, to make sure

nothing is vibrating loose.

Sadly not. The calculations the DC/DC charger has to make in order to do its job best means that we need a

stable input. Without a lead acid starter battery or an ALD (Alternator Linearisation Device) on the input, the

alternator voltage can be erratic and severely hamper our charge capabilities. Please follow the install!

It’s safe for your system if it’s rated correctly! There’s lots of different trains of thought for how to properly

rate a BB system- and it is complicated. The guidelines we have followed for years has been rating the

system to up to 80% of what your alternator is rated to. There are exceptions to this rule (cheap alternators

will want a lower limit, and alternators with custom cooling or unique cooling methods may be able to cope

with a higher limit) but 80% or below seems to be the golden point for balancing alternator protection and

charge speed.

Yes, you can combine two of our battery to battery chargers together to combine their output capabilities.

Please install each of them as if the other charger did not exist, IE please do not start trying to wire one

charger into the next.

Either combine them using busbars (to split the input and combine the outputs neatly) or wire them each

entirely individually to avoid the complications and pitfalls of wiring chargers into one another.

What charge profile should I

choose?

What does the temperature

sensor do?

Do I need a common negative?

Cable doesn’t fit!

Charger isn’t doing anything-!

I don’t want reverse charge!

You drained my starter battery!

My charger keeps turning on and

off/the charge current is low!

How do I care for my charger?

Can I come straight off of the

alternator?

Is this safe for my alternator?

/How do I rate the BB for my

system?

Can I parallel multiple?

How?

50% Black for subtitles + bottom right

90% Black for body

RAL 3003 R134 G26 B34

Text, by and large, is size 9.

Frequently asked questions

Table of Contents + Welcome

Legal Guidelines / Warranty Statement

Safety Guidelines

Basic Wiring Diagram / Installation Orientation

Unit Specifications and Recommended Fuse/Cabling (1)

Unit Specifications and Recommended Fuse/Cabling (2)

Understanding your charger (1)

Understanding your charger (2)

Configuring your charger and understanding the display (Battery types)

3 types of product activation

Troubleshooting and fault finding

Understanding your remote

Configuring your remote

Technical drawings (1)

Technical drawings (2)

Sterling Contact information and Catalogues

Recommended cable size chart

Welcome to the Sterling Power Products Owners Handbook for the Saturn product range. To make things easier

for us (and you), we’ve collated everything into one manual. We’re very proud of the Saturn range, they’re

genuinely the best on the market at this time and we’re confident you’ll love the item too.

Please take your time to read and fully understand the contents of this Handbook. These guidelines are

developed with your safety and the products performance in mind and failure to follow or understand these

guidelines may lead to voiding the product warranty or even leading to damage or injury for you or your setup.

If you are unsure of any step or guideline then please consider reaching out to Sterling via our web contact form

or our phone service and we shall offer our support.

Thank you for joining the Sterling family and we hope to serve your travels well.

This manual must be read throughout before installing this electronic device. Do not lose these instructions -

keep them safe. The most up to date instructions can be found on sterling-power.com. Please refer to the latest

instruction manual before contacting Sterling. At Sterling, we endeavour to include all of the product information

that we can think of into the manual.

Installation of the electronic device must be carried out by qualified and trained personnel only. The personnel

must be familiar with the locally accepted guidelines and safety measures.

Your safety is Sterling’s top priority. Please follow all precautions to keep yourself safe. If you believe your unit

requires repair then please contact Sterling or your distributor. Do not attempt to service the unit yourself.

This manual has been written predominantly with 12V nominal voltages in mind. If your input or output voltages

on your BB model are 24V models or higher, simply multiply the numbers until they are in the correct threshold.

IE, if we are making reference of an output voltage being 14.4V, but your BB has a 24V output, multiply the 14.4V

value by two. The charge target voltage then would be 28.8V. The 48V equivalent would be 57.6V.

Introduction

Safety and Legal

Product Information

Troubleshooting

Saturn Remote (BBR)

Technical Drawings

Misc.

Welcome

Using this Manual

Safety note

Converting 12V for 24V, or 48V

INTRODUCTION TABLE OF CONTENTS

CONTENTS PAGE 03

STERLING

POWER

DIMENSION

DRAWING

Dimensions 270mm x 130mm x 73mm

Weight 1.8Kg

12V - 12V 120A

Battery to Battery Charger

sterling-power.com

sterling-power-usa.com

BB12120

instructions

50% Black for subtitles + highlight

90% Black for body

RAL 3003 R134 G26 B34

Text, by and large, is size 9.

SAFETY AND LEGAL

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.

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 require 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 check telephone numbers on www.sterling-power.com

or 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.

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 USA LLC 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,

which vary from state to state. This warranty is in lieu of all other, expressed or implied.

Reproduction, transfer, distribution or storage of part or all of the contents of this document is strictly prohibited. If

you wish to use all of this document, or excerpts from it, Sterling Power must be contacted.

Sterling Power can not accept liability for:

Ÿconsequential damage due to use of this device

Ÿpossible errors in the manuals and the results thereof

Please do not modify the device unless you have been instructed to do so by Sterling Power directly. Product

modification shall be done at Sterling when needed. Warranty shall be voided if personal attempts are made to

modify the device without Sterling’s approval.

Warranty and Terms

Liability

Device Modification

LEGAL GUIDELINES

SAFETY AND LEGAL 04

STERLING

POWER

SAFETY AND LEGAL

Your Sterling Power product should only be utilised for it’s designated purpose. Use the Battery to Battery

Charger ONLY :

For DC to DC power conversion

With fuses protecting both the input and output DC cables

In a well ventilated, dry, dust-free and condensation free environment

When the Owners Handbook has been read and wholly understood

Ensure that the mains supply and battery leads are disconnected before transporting or moving the unit. No

liability can be accepted for damage in transit once equipment has been unpackaged. Store the product in a dry

environment, between –20°C to 60°C.

Refer to the battery manufacturer's manual for information on transportation, stowage, charge rates, recharging

and battery disposal for your battery care.

The device must be switched off during maintenance and all cables removed from the direct feed to or from the

unit. It must also be protected against unexpected switching off. Remove battery connections and ensure unit is

off. If repair is required, only use original parts. Unauthorised attempts to repair Sterling units will lead to the

warranty being voided. Only someone with adequate understanding of electronics and the unit itself should

attempt a repair.

Ensure your connections are good and clean and aim to protect your unit from humidity and water ingress.

Electrical appliances can be heavy. Please do not lift heavy units unassisted.

Ensure that your product is correct for your intent. 12V battery. Incorrect use can lead to damage.

Orientation is not critical to unit function, however may affect water ingress rating.

Install device in a well ventilated space for cooling purposes.

Do not expose the unit to snow, rain, water, spray, condensation, pollution etc, unless it is a waterproof unit. If it is

a waterproof unit, only expose it to situations it is correctly rated for.

Do not cover or obstruct the ventilation.

Device connects to common negative. Common negatives must be earthed.

In case of fire, use fire extinguisher equipment suitable for electrical fires.

Avoid all possibilities of reverse polarity or short circuiting.

Check cabling and connections frequently and ensure the connections are sufficient.

Always protect DC cabling with the appropriate fusing.

Ensure the unit is adequately and safely mounted to prevent displacement and damage.

Always use a professional to install electrical products.

Ensure the product is correctly set up for your battery.

Keep out of reach of children

CROSS VOLTAGE THRESHOLD BATTERY TO BATTERY CHARGERS MUST BE INSTALLED WITH CARE

A COMMON NEGATIVE IS PARAMOUNT TO OPERATION, HOWEVER, BE INCREDIBLY CAREFUL NOT TO

SHORT CIRCUIT OR REVERSE POLARITY ANY EQUIPMENT OR CABLE.

All electrical appliances carry the risk of electrical shock. This equipment is designed to be used in combination

with a permanent energy source (the battery). Always isolate the DC before performing any maintenance or

inspection.

Do NOT remove the panelling to inspect the internals unless expressly told to by Sterling. This is not a product

designed to be user-serviced.

Do NOT use the device in situations where there is danger of gas / dust / vapour explosions, or around potentially

flammable produce.

Product Guidelines

Transport and Storage

General Maintenance

Safety Precautions

Cross Voltage Chargers

READ THIS

WARNING :

SAFETY GUIDELINES

SAFETY AND LEGAL 05

STERLING

POWER

Above is a basic installation diagram for the Saturn series of charger. If a process is not mentioned, it is likely not

paramount to operation. The important notes regarding the install are as follows.

The Positive INPUT line must come from a circuit that has either a starter battery or an Alternator Linearisation

Device included. It cannot come directly off of just an alternator with no accumulator on the same line. Unit will

turn on when either the input voltage is >13.5V or the ignition feed is live.

The Positive OUTPUT typically goes directly to a leisure battery bank, but can go to either a bus-bar or any circuit

that needs to be powered. If you need the Saturn to operate as a power supply, put it into a lithium profile

The NEGATIVE of the unit MUST be common, and as direct as possible. Avoid chassis points where possible.

The starter battery, Saturn and the Leisure battery bank must be all on the same direct-as-possible negative

circuit. Both of the negatives on the Saturn are common.

If your vehicle is Euro-6/features a smart alternator, you will probably need to use the Ignition feed signal.

Alternatively, if you want to signal control the Saturn, you can use the ignition feed. When it is 0V the unit is OFF.

When it is 12V~ the unit is ON.

Recommended cabling and fuse sizes are covered on the unit summary/specification pages, pages 7+8.

SIMPLE WIRING DIAGRAM

STERLING

POWER

Basic install diagram

Install summary

Positive Input

Positive Output

Negative

Euro Six / Low Input Voltage

Recommended Cable/Fuses

Any Orientation Suitable

*Label rendered for clarity,

PRODUCT INFORMATION

Air Flow

BASIC INSTALL 06

nothing to change in the setup.

Simply plug cables in and start engine.

Input / starter

battery

Leisure Battery Bank

fuse

12V ignition signal (optional)

Alternator

12V

ign

alarm

GND

Ensure you have the

correct battery to

battery charger for

your install. The

voltage ratings for the

chargers are specific.

Basic installation diagram

Here, we hope to provide a very

basic installation diagram for the

vast majority of installers to

follow.

If a process is not mentioned

here, the chances are that it is

not a pre-requesite to get the

BB1248120 to function.

The default charging profile is a

standard sealed lead acid

charging profile of 57.6V and

53.2V float.

If you wish to charge a lithium

battery, please refer to page 9 to

change the charging profile.

12V ignition signal, required for

Euro 6 / Smart alternator use.

Ignition gives a binary on / off

style signal to control the

BB1248120.

If ignition signal is not used, the

BB needs to see 13.5V on the

input terminal to begin charging

the output battery. When the

input then drops below 12.8V

the BB will stop charging.

Recommended installation

orientation

The BB1248120 can be mounted

in any orientation. However, if

the area is prone to getting wet

or damp, we recommend the first

or second install.

If prone to getting damp

Sideways mounting may

result in pooling of water

at the bottom

UNIT SPECS AND RECOMMENDED CABLING

STERLING

POWER

PRODUCT INFORMATION

BB1270

Input voltage range 9V-16V

Rated output power 60A at 13.8V

Rated input current 70A

Quiescent current 10mA

Efficiency rating 92%-94%

Dimensions 200mm x 130mm x 56mm

Weight 1.0Kg

Terminal diameter 6.1mm

Recommended Input cable 16mm or above (6awg)

Recommended Input fuse 80A

Recommended Output cable 2

16mm or above (6awg)

Recommended Output fuse 80A

BB12200

Input voltage range 9V-16V

Rated output power 180A at 13.8V

Rated input current 200A

Reverse charging current (max) 60A to 13.4V

Reverse charging voltage <13.4V

Quiescent current 15mA

Efficiency rating 95-98%

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

Dimensions 309mm x 130mm x 96mm

Weight 2.2Kg

14mm

BB12120

Input voltage range 9V-16V

Rated output power 110A at 13.8V

Rated input current 120A

Quiescent current 5mA

Efficiency rating 92%-94%

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

Dimensions 270mm x 130mm x 73mm

Weight 1.8Kg

8.9

Bb1248120

Input voltage range 9V-16V

Rated output power 27.5A at 55.2V

Rated input current 120A

Quiescent current 5mA

Efficiency rating 92%-94%

BB1224120

Input voltage range 9V-16V

Rated output power 26A at 57.7V

Rated input current 120A

Quiescent current 5mA

Efficiency rating 95-98%

Reverse charging current 40A at 13.3V

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

Dimensions 270mm x 130mm x 73mm

Weight 1.8Kg

Common to all Saturn range BBs

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

Negative Cable As thick as the IN cable.

BB1210

Input voltage range 9V-16V

Max Rated output power 9A at 14.41V ~130W

Max Rated input current 10A at 13.68V ~136.8W

Quiescent current 5mA

Efficiency rating 98%

Dimensions 123mm x 130mm x 56mm

Weight 0.6Kg

Terminal diameter 5.4mm

Recommended Input cable 2.5mm or above (14awg)

Recommended Input fuse 12-15A

Recommended Output cable 2

2.5mm or above (14awg)

Recommended Output fuse 12-15A

BB1225

Input voltage range 9V-16V

Max Rated output power 24A at 14.41V ~345W

Max Rated input current 26A at 13.68V ~355W

Quiescent current 5mA

Efficiency rating 98%

Dimensions 123mm x 130mm x 56mm

Weight 0.6Kg

Terminal diameter 5.4mm

Recommended Input cable 6mm or above (10awg)

Recommended Input fuse 30A

Recommended Output cable 2

6mm or above (10awg)

Recommended Output fuse 30A

BB1220

Input voltage range 9V-16V

Max Rated output power 19A at 14.41V ~267.9W

Max Rated input current 21A at 13.68V ~287.3W

Quiescent current 5mA

Efficiency rating 98%

Dimensions 123mm x 130mm x 56mm

Weight 0.6Kg

Terminal diameter 5.4mm

Recommended Input cable 4.0mm or above (12awg)

Recommended Input fuse 25A

Recommended Output cable 2

4.0mm or above (12awg)

Recommended Output fuse 25A

BB1240

Input voltage range 9V-16V

Max Rated output power 38A at 14.41V ~550W

Max Rated input current 42A at 13.68V ~575W

Quiescent current 5mA

Efficiency rating 95-98%

Dimensions 163mm x 130mm x 56mm

Weight 0.8Kg

Terminal diameter 5.4mm

Recommended Input cable 4.0mm or above (12awg)

Recommended Input fuse 25A

Recommended Output cable 2

4.0mm or above (12awg)

Recommended Output fuse 25A

BB122465

Input voltage range 9V-16V

Rated output power 30A at 27.4V

Rated input current 65A

Quiescent current 10mA

Efficiency rating 92%-94%

Dimensions 200mm x 130mm x 56mm

Weight 1.0Kg

Terminal diameter 6.1mm

Recommended Input cable 16mm or above (6awg)

Recommended Input fuse 80A

Recommended Output cable 2

6mm or above (10awg)

Recommended Output fuse 40A

PRODUCT INFORMATION 07

UNIT SPECS AND RECOMMENDED CABLING

STERLING

POWER

PRODUCT INFORMATION

PRODUCT INFORMATION 08

BB12200

Input voltage range 9V-16V

Rated output power 180A at 13.8V

Rated input current 200A

Quiescent current 15mA

Efficiency rating 95%-98%

Dimensions 309mm x 130mm x 96mm

Weight 2.2Kg

Terminal diameter 14mm

Recommended Input cable 70mm or above (00awg)

Recommended Input fuse 250A

Recommended Output cable 2

70mm or above (00awg)

Recommended Output fuse 250A

BB12200

Input voltage range 9V-16V

Rated output power 180A at 13.8V

Rated input current 200A

Reverse charging current (max) 60A to 13.4V

Reverse charging voltage <13.4V

Quiescent current 15mA

Efficiency rating 95-98%

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

Dimensions 309mm x 130mm x 96mm

Weight 2.2Kg

14mm

BB12120

Input voltage range 9V-16V

Rated output power 110A at 13.8V

Rated input current 120A

Quiescent current 5mA

Efficiency rating 92%-94%

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

Dimensions 270mm x 130mm x 73mm

Weight 1.8Kg

8.9

Bb1248120

Input voltage range 9V-16V

Rated output power 27.5A at 55.2V

Rated input current 120A

Quiescent current 5mA

Efficiency rating 92%-94%

BB1224120

Input voltage range 9V-16V

Rated output power 26A at 57.7V

Rated input current 120A

Quiescent current 5mA

Efficiency rating 95-98%

Reverse charging current 40A at 13.3V

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

Dimensions 270mm x 130mm x 73mm

Weight 1.8Kg

Common to all Saturn range BBs

Self recovering protections: under voltage protection

input over voltage protection

output over voltage protection

over current protection

charge over temperature

Operational Temperature -20 Deg C -> 60 DegC

Approval CE | UKCA

E-Marking

Cooling method Thermostatically Controlled

Variable low speed fan

BB1224120 12V AND 24V IN

Input voltage range 9V-16V / 18V-32V

Max Rated output power 58A at 28.41V ~1540W

Max Rated input current 120A / 60A

Quiescent current 5mA

Efficiency rating 92-94%

Dimensions 270mm x 130mm x 73mm

Weight 1.8Kg

Terminal diameter 8.9mm

Recommended Input cable 35mm or above (2awg)

Recommended Input fuse 150A

Recommended Output cable 2

16mm or above (6awg)

Recommended Output fuse 80A

BB12120

Input voltage range 9V-16V

Max Rated output power 110A at 14.41V ~1584W

Max Rated input current 120A

Quiescent current 5mA

Efficiency rating 92-94%

Dimensions 270mm x 130mm x 73mm

Weight 1.8Kg

Terminal diameter 8.9mm

Recommended Input cable 35mm or above (2awg)

Recommended Input fuse 150A

Recommended Output cable 2

35mm or above (2awg)

Recommended Output fuse 150A

BB124865 12V AND 24V IN

Input voltage range 9V-16V / 18V-32V

Rated output power 16A at 54.8V

Rated input current 65A / 32.5A

Quiescent current 10mA

Efficiency rating 92%-94%

Dimensions 200mm x 130mm x 56mm

Weight 1.0Kg

Terminal diameter 6.1mm

Recommended Input cable 16mm or above (6awg)

Recommended Input fuse 80A

Recommended Output cable 2

4mm or above (12awg)

Recommended Output fuse 20A

BB1248120

Input voltage range 9V-16V

Max Rated output power 28A at 57.6V

Max Rated input current 120A

Quiescent current 5mA

Efficiency rating 92-94%

Dimensions 270mm x 130mm x 73mm

Weight 1.8Kg

Terminal diameter 8.9mm

Recommended Input cable 35mm or above (2awg)

Recommended Input fuse 150A

Recommended Output cable 2

6mm or above (10awg)

Recommended Output fuse 40A

The top mounting plate. Composed of 2x 5mm wide mounting feet. There are 2x 5mm wide mounting feet at the

bottom, too.

Location of 2x heat extracting fans. The air is sucked through the BB and the direction of air flow is demonstrated

above.

Display panel. More information on page 9.

Connection blocks. This region is described in more detail overleaf. This is the area where all the physical

installation connections to the BB1248120 are made. Also, this region contains additional 2x 5mm mounting

feet.

UNDERSTANDING YOUR UNIT, PT.1

STERLING

POWER

Faceplate Diagram

GLOBAL AC Input & Active Power Factor Correction

CHARGER MODE

AC Power

Auto Temp Control

Active PFC

Multi Speed Fan

Volts Amps

AUTO CONSERVATION MODES

Fault

Absorption

Stand-by Battery Health Program

Fast Charge Float

DC Output Fault

DC Low Voltage

DC High Voltage Trip

High Charger temp trip

Check Fan

De-sulphation

1 2 3

SETUP

ENTER

CHARGE INFORMATION

Open lead acid

Sealed lead acid

A.G.M

GEL

Calcium / Custom

Lithium (LiFePO4)*

System self test Battery Type

Charger Output

0% 100%

Progressive DIGITAL software control Charger / Powerpack

Preset 1

Preset 2

Sterling Power

1) Ammeter, shows the total current being

produced by the charger.

2) Voltmeter, showing the average voltage being

produced by the charger.

3) Power meter, shows the % power being produced

by the unit and the remaining power available.

4) AC power, shows the AC power is connected and

the product is live. LED flashes if power is available

but the unit is switched off (see on/off later) push

buttons. Setup and up arrow for 5 secs to activate.

5) Auto temp control, shows the battery temp sensor

is connected and operational. If sensor not

connected then the unit will default to a 20 deg C / 69

F charge curve.

6) Shows that the active PFC (Power Factor

Correction is on).

7) Fan speed control, varies depending on temp, 3

speeds.

8) Standby, charger power system power

requirement very low, unit on low float voltage to

prolong battery life.

9) Fast charge unit on constant current mode.

10) OK, unit operating within normal parameters

11) Fault, fatal fault, needs to be returned for repair.

12) Battery type selector, shows which battery

charger curve in operation (adjustable).

13) Buttons to select charge options (see later in

instructions) also used to switch unit off or on in

conjunction with the setup button (see 14).

Off select button press down button for 5 seconds.

On select button press up button for 5 seconds.

14) Button to enter selections. Also, use to switch

unit on/off in conjunction with the up or down button.

15) Battery health program, unit doing a 21 day de-

sulphation cycle.

16) , charger on initial charge cycle.Absorption

17) De-sulphation cycle operational. For safety

reasons only available when on open lead acid

battery type.

18) Float, unit on float charge or power pack mode,

main charge complete.

19) DC output service, output working correctly.

20) DC output low voltage warning, either batteries

are very low / more power is being taken than the

charger can supply / or the charger is defective.

21) High voltage trip, the unit is defective and

tripped itself, or a high back DC voltage has been

detected, like a wind generator reg gone defective.

22) High charger temp, if the unit is positioned in too

hot an environment and over heated, or the fans

have failed.

23) Check fans, if LED on, fans are defective.

24) Case screws to access the wiring of the product.

Battery type High Charge V Float Charge V Maintenance V High Charge V Float Charge V Maintenance V

Flooded/Open Lead acid 14.8 13.6 12.8 14.7 13.4 12.8

Sealed Lead acid 14.4 13.6 12.8 14.6 13.4 12.8

AGM Lead acid 14.3 13.3 13.0 14.6 13.6 13.0

GEL Lead acid 14.0 13.7 13.2 14.4 13.8 13.2

LiFePO4-Lithium 14.2 13.8 13.2 14.4 13.8 13.2

Calcium / Custom 15.1 13.6 13.2 Your choice see custom setup in instructions

Equalization / Desulph 15.5 15.5 15.5 15.5

Preset 1 Profiles Preset 2 Profilesx 2 all voltages for 24V unit x 2.66 for 32 V x 3 for 36V x 4 for 48V

*Label rendered for clarity,

GLOBAL AC Input & Active Power Factor Correction

CHARGER MODE

AC Power

Auto Temp Control

Active PFC

Multi Speed Fan

Volts Amps

AUTO CONSERVATION MODES

Fault

Absorption

Stand-by Battery Health Program

Fast Charge Float

DC Output Fault

DC Low Voltage

DC High Voltage Trip

High Charger temp trip

Check Fan

De-sulphation

1 2 3

SETUP

ENTER

CHARGE INFORMATION

Open lead acid

Sealed lead acid

A.G.M

GEL

Calcium / Custom

Lithium (LiFePO4)*

System self test Battery Type

Charger Output

0% 100%

Progressive DIGITAL software control Charger / Powerpack

High Voltage AC Low Voltage DCWARNING

www.sterling-power-usa.com

Preset 1

Preset 2

www.sterling-power.com

*Lithium must be used in conjunction

with a lithium balancing system.

Safety Certified by: TUV

Built and tested to

UL 1236 SB

CSA C22.2-107.2

RoHS

compliant

CEC

approved

Pro Charge ULTRA

Sterling Power

Warm air

out

Cooling

Air flow

Quick LED feature guide

Lithium battery Use

this charger must not be used to

charge lithium battery cells by itself

( ie lithium cells only with no BMS ) .

You cannot charge lithium cells on

their own. You must have a

B M Sattery anagement ystem

attached to built into the or

batteries for safety.

No Battery charger can act as a BMS,

that is an independent operation

for Lithium batteries .

Figure 3.01A

RATING

LNG

+++

12 13 14 15 16 17

PRODUCT INFORMATION

Air Flow Air Flow

The left large green connector is for direct connection to the input / starter battery. 12V input connection. Ensure

the cable thickness is 25mm2+. Ensure this cable is fused at ~150A fuse.

These 2 central connectors are for common negative cable. For convenience, use the left GND to connect to the

input battery’s negative and use the right GND connector to connect to the output battery’s negative. Use similar

sized cable as positive.

The right large green connector is for direct connection to the output / leisure battery. 12V output connection.

Ensure the cable thickness is 25mm2+. Ensure this cable is fused at ~150A fuse.

This 12V output provides a 12V signal at 50mA. This can be used to trigger an operation / provide a 12V signal.

This 12V signal shall only become live if the Ground connector (11) is connected to the common negative rail.

Ignition feed connector. The BB12110 can be operated based on an ignition signal - this is recommended if you

have a smart alternator (Euro 6 engine). Wire a feed from your ignition into this terminal. Ensure that this feed is

~12V when the ignition is live and goes to 0V when ignition is turned off. Once the BB121100 receives its first

successful ignition signal it shall render the unit dependent on an ignition signal going forward. Therefore, the BB

shall not operate based purely on input voltage coming from the input battery but based on whether your ignition

is live or not. You can reset this feature by removing the ignition feed and pressing / holding the front button down

for 15 seconds and letting go.

Alarm. If the BB faults - this alarm connector shall put out a live 12V | 100mA. Therefore, you can wire in an

audible 12V alarm or a 12V light / LED to convey a fault. These are optional fits. You can also use this connector

to relay a 12V signal to another device to prompt an action if the BB were to fault. Ground connector (11) must be

connected to the common negative rail for this alarm output to operate.

Ground. To utilise connectors 8 or 10, a ground / negative (0V) feed needs to be connected here. For the ignition

feed connector to operate, a negative feed is NOT required.

Vibration sensor on / off switch. Default off. If turned on the BB12110 shall begin charging when the vibration

sensor detects 2x vibration events. This shall override the ignition signal and allow you to install the BB without

the need to install an ignition signal. This is also an operational method if you have a smart alternator / Euro 6

engine (or younger). This mode comes with cautions, please read page xx. Switching between on / off can be

done at anytime. There may be a 10 second delay in unit operation between switches - no need to reset /

reconnect the BB.

temperature sensor connector. Here is where to install a temperature sensor TEMP1.

Not applicable / local use only

UNDERSTANDING YOUR BB12110, PT.1

STERLING

POWER

BB12110 Diagram

10.

12.

13.

14.

PRODUCT INFORMATION

Air Flow Air Flow

*Label rendered for clarity,

5 6 7

8910

Input / starter

battery Domestic / House

Output Battery

12V

ign

alarm

GND

12V

ign

alarm

GND

The left large green connector is for direct connection to the input / starter battery. 12V input connection. Ensure

the cable thickness is 35mm2 / 2AWG. Ensure this cable is fused at ~150A fuse.

These 2 central connectors are for common negative cable. For convenience, use the left GND to connect to the

input battery’s negative and use the right GND connector to connect to the output battery’s negative. Use similar

sized cable as positive.

The right large green connector is for direct connection to the output / leisure battery. 12V output connection.

Ensure the cable thickness is 10mm2 / 8AWG. Ensure this cable is fused at 40A fuse.

This 12V output provides a 12V signal at 50mA. This can be used to trigger an operation / provide a 12V signal.

This 12V signal shall only become live if the Ground connector (11) is connected to the common negative rail.

Ignition feed connector. The BB1248120 can be operated based on an ignition signal - this is recommended if

you have a smart alternator (Euro 6 engine). Wire a feed from your ignition into this terminal. Ensure that this

feed is ~12V when the ignition is live and goes to 0V when ignition is turned off. Once the BB1248120 receives its

first successful ignition signal it shall render the unit dependent on an ignition signal going forward. Therefore,

the BB shall not operate based purely on input voltage coming from the input battery but based on whether your

ignition is live or not. You can reset this feature by removing the ignition feed and pressing / holding the front

button down for 15 seconds and letting go.

Alarm. If the BB faults - this alarm connector shall put out a live 12V | 100mA. Therefore, you can wire in an

audible 12V alarm or a 12V light / LED to convey a fault. These are optional fits. You can also use this connector

to relay a 12V signal to another device to prompt an action if the BB were to fault. Ground connector (11) must be

connected to the common negative rail for this alarm output to operate. More information on page 11.

Ground. To utilise connectors 8 or 10, a ground / negative (0V) feed needs to be connected here. For the ignition

feed connector to operate, a negative feed is NOT required.

Vibration sensor on / off switch. Default off. If turned on, the BB1248120 shall begin charging when the vibration

sensor detects 2x vibration events. This shall override the ignition signal and allow you to install the BB without

the need to install an ignition signal. This is also an operational method if you have a smart alternator / Euro 6

engine (or younger). This mode comes with cautions, please read page 10. Switching between on / off can be

done at anytime. There may be a 10 second delay in unit operation between switches - no need to reset /

reconnect the BB.

Temperature sensor connector. Here is where to install the temperature sensor - TEMP1. Connect the terminal

end of the temperature sensor to the negative terminal of the output battery. If in a Lead or AGM setting the

temperature sensor compensates the voltage being delivered by the charger based on sensor temperature. If in

a lithium setting, there is no voltage compensation. In lithium, the charger stop charging if sensor detects 0DegC

or lower.

Not applicable / local use only

UNDERSTANDING YOUR UNIT, PT.2

STERLING

POWER

Base Diagram

10.

12.

13.

14.

PRODUCT INFORMATION

*Label rendered for clarity,

5 6 7

8910

1314

This LED shall turn on when the BB has engaged the reverse charge circuit, charging the input battery. The

reverse charge circuit engages when the output battery is >13.5V / 27V / 54V

To remove this feature, press and hold the Select button for 20 seconds - after you see the LEAD AGM and

Lithium LEDs stop flashing then release. You can now use the Select button to toggle the Reverse Charging

LED on / off. On = reverse charge. Off = no reverse. Then simply leave it to settle to confirm your selection.

To manually force the reverse charge process, simply press the Select button 4 times in a row. The Reverse

charging LED should come on.

This section displays what battery type you are currently in. To configure this :

When charger is on, press and hold the Select button for 5 seconds until the LEDs flash. Then, press the

Select button to toggle through the 6 different battery types - the flashing orange LED shall depict the

battery type. Type 2 LED shall light up to display the second profiles of the battery types. Once you have the

LED on the target battery type, stop pressing the button and wait until the LED stops flashing - after a few

seconds the flashing stops and the LED stays on solid - this confirms setting.

Lithium* = live output voltage, ideal for waking up BMS on batteries. Please ensure your lithium battery has

an internal or external BMS. If temperature sensor is connected, no voltage compensation on lithium profiles

occurs, instead charge is disabled if the batteries are measured at 0DEGC.

As the BB can measure both current and voltage it shall make an intelligent decision as to when to transfer from

absorption to float mode. This algorithm detects both the rate of rise of voltage and the rate of decline of current.

If the target absorption voltage has been met and the current has dropped to a few amps the charger shall

transfer to float mode.

If the output voltage at the Saturn charger is pulled down by 0.7V from the float voltage, the absorption charge

process will restart automatically.

The fault LED will illuminate if the Saturn charger has detected a problem. Consult the troubleshooting page

at the back of this manual to see what has gone wrong and how to resolve it.

PRODUCT INFORMATION

Orange LED status:

Fast flashing = Bulk / Fast Charge

Slow flashing = Absorption

Solid = Float

LED panel

Charging Status :: 1)

Reverse Charging :: 2)

Disabling Reverse Charging

Jump Start Assist

Battery Type Select

Battery type profiles:

These profiles are with 12V

configuration in mind.

For 24V output chargers,

multiply the values by 2.

For 48V output chargers,

multiply the values by 4

Lithium profile properties

Absorption Timers

Going from Float to Absorption

ITEM CONTROLS AND UNDERSTANDING

FRONT PANEL, BATTERY TYPE 11

STERLING

POWER

Lithium

Type 2

O/P Batt. Volt.

LED sequence

Battery Type

Absorption (V)

Float (V)

Lead I

14.4V

13.3V

Lead II

14.6V

13.5V

AGM I

14.2V

13.1V

AGM II

14.7V

13.6V

Lithium I*

14.4V

13.8V

Lithium II*

14.2V

13.6V

Absorption time lengths:

As the BB can measure both

current and voltage it shall make

an intelligent decision as to when

to transfer from absorption to float

mode. This algorithm detects both

the rate of rise of voltage and the

rate of decline of current. If the

target absorption voltage has

been met and the current has

dropped to a few amps the

charger shall transfer to float

mode.

Float to absorption trigger

voltages. If the charger is in float

and the output batteries voltage is

dragged below the following

voltages the charger shall go back

to absorption.

Lead I = 50.4V

Lead II = 50.8V

AGM I = 49.6V

AGM II = 51.2V

Lithium I = 53.6V

Lithium II = 52.8V

Reverse Charge

Multiply voltages by 2 for 24V, 4 for 48V.

ENGAGEMENT MODES

Automatic Mode (Default)

This mode is the simplest way to install

the Saturn charger, however, not the

most effective if you are using this BB

on a modern vehicle that has

regenerative braking or a poor input

voltage (Euro 6 engine or newer).

To activate the BB, you require 13.5V+

on the input terminal. You shall

achieve this voltage by charging up

your input battery (starter battery) with

an alternator (for example).

When the input voltage drops below

12.8V (when you turn your engine off),

the BB shall turn off and go to sleep.

SATURN RANGE INSTALLS, 3x ENGAGEMENT METHODS

ENGAGEMENT MODES 12

STERLING

POWER

SHAREV

SHAREV SHARE EV

SHAREV

12V

ign

alarm

GND

Alternator

5-32V ignition signal = ON

0V = OFF

12V

ign

alarm

GND

Alternator

12V

ign

alarm

GND

Alternator

13.5V+ on

<12.8V off

11V+

Input / starter

battery

Input / starter

battery

Input / starter

battery

Ignition feed Mode

(requires 12V signal feed)

In this mode you control the BB based

on an ignition signal. Whenever this

signal line is live (5V-32V) the unit will

be online.

The Saturn charger will work with this

ignition signal all the way down to an

input voltage of 11.0V, at which point it

will automatically turn off to protect

your starter battery.

The Ignition feed engagement gives

you the most binary on/off control of

the charger, but can also lead to your

starter battery being discharged if the

ignition line is live but the starter

battery is not supported with a charger

or alternator feed at the same time.

Vibration sense

Switch position ON.

This mode requires the BB to detect 2

vibration events in order for it to turn on

and charge. For example, turning an

engine on shall provide sufficient

vibration to get the BB to begin

charging.

This mode essentially acts like an

ignition signal and is designed for

installers to do away with having to run

an ignition feed.

WARNING, if vibration signal activates

BB may drag starter battery voltage to

below 11V. Possible flat starter

battery! The BB does monitor the input

battery and shall turn off after 2

minutes if the voltage does not climb

up.

on off

11V+

on off

select switch position ‘on’ at

anytime to engage vibration

mode.

By applying a live signal to the ignition connector you put the BB into ignition dependent

mode. The BB shall NOT work unless it has a live ignition signal - even if you remove the

ignition feed cable and provide 13.5V+ onto the input terminal.

To reset the BB back to Automatic Mode, ensure BB is on -

I) Remove ignition cable from ign connector.

II) Press and hold SETUP button for around 15 seconds until the 3 LED battery

types flash at the same time.

III) Release button and charger reverts to Automatic Mode.

Input voltage + vib. sense.

Charger on - 11V -> 16V

Charger off - <10V

Output Battery Bank

NOTE :: Engagement voltages and

disengagement voltages are x2 for

24V input units. The below is

written and designed with 12V input

installs in mind.

BB124865

Domestic / House

Output Battery 48V

Lead Acid or Lithium

SIMPLE WIRING DIAGRAM

STERLING

POWER

Basic installation diagram

Here, we hope to provide a very

basic installation diagram for the

vast majority of installers to

follow.

If a process is not mentioned

here, the chances are that it is

not a pre-requesite to get the

BB124865 to function.

The default charging profile is a

standard sealed lead acid

charging profile of 57.6V and

53.2V float.

If you wish to charge a lithium

battery, please see overleaf.

Charging modes

In default mode, the BB needs to

see 13.5V on the input terminal

to begin charging the output

battery. When the input then

drops below 12.8V the BB will

stop charging.

12V ignition signal, required for

Euro 6 / Smart alternator use.

Ignition gives a binary on / off

style signal to control the

BB124865. Connect ignition

cable to ‘ign’ connector If ignition .

signal has been applied to the

BB the BB shall remain

dependent up a live ignition to

operate. Do a factory reset to

restore BB to default settings.

Vibration sensor mode. This

requires you to switch the

Vibration sensor switch on. If the

unit detects a vibration event the

BB shall turn on and begin

charging.

Factory reset - hold

Select button for 15

seconds

Recommended installation

orientation

The BB124865 can be mounted

in any orientation. However, if

the area is prone to getting wet

or damp, we recommend the first

or second install.

*Label rendered for clarity,

PRODUCT INFORMATION

Air Flow Air Flow

80A

fuse

20A

fuse

6-10mm2 / 8-10AWG cable

Alternator

If prone to getting damp,

this mounting option may

result in pooling of water at the bottom

16mm2 / 6AWG cable

common negative

nothing to change in the setup.

Simply plug cables in and start engine.

More detailed information overleaf.

sterling-power.com

RoHS

compliant

Online full instruction manual PDF

Input voltage

Charger on - 13.5 -> 16V

Charger off - <12.8V

Input voltage + ign feed.

Charger on - 11.6V -> 16V

Charger off - <11V

Input voltage + vib. sense.

Charger on - 11.6V -> 16V

Charger off - <11V

Charging modes

input output

Reverse Charging Feature -

There is nothing to setup with regards the reverse charging feature. Provided there is over 52.8V/54.0V on the leisure

battery (lead / lithium) and the starter battery is below 13V the BB shall allow approximately ~18A (12V) or 10A (24V)

to flow back to the starter battery up to about 13.4V (float voltage) or 26.8V. It simply allows the starter battery to

remain topped up when there is surplus energy in the domestic battery. This feature will NOT drain your domestic

battery - it simply takes surplus. Once your alternator / engine turns on or you provide the BB with an ignition signal

the BB reverts to normal charging of the leisure battery. To remove this feature, see overleaf.

temperature sensor - optional ﬁt

sterling-power-usa.com

For Negatives

PLEASE USE DIRECT CABLING

DO NOT USE CHASSIS POINTS

Temperature sensor included - optional fit.

- Allows for temp voltage compensation for

lead acid batteries. No temp comp. for

lithium.

- 0 Deg C trip for charging lithium.

- High temperature trip protection.

- connect to negative terminal of domestic

battery.

12V/24V to 48V Battery to Battery

Charger 60A / 30A input | 13A output

BB124865

12V = 16mm2 / 6AWG cable 24V = 10mm2 / 8AWG cable

8-35V ignition signal (optional)

(x2 for 24V)

Input / starter

battery 12V / 24V

TROUBLESHOOTING

TROUBLESHOOTING 13

STERLING

POWER

Firstly, ensure the BB1248120 is wired up correctly. Ensure negatives are common and the BB charger’s

negative is connected to the starter battery’s negative - avoid connecting to chassis negative. Voltages between

common negatives should be ~0V.

Secondly, to test the BB, remove (or turn off) any secondary charging source like AC to DC battery chargers or

solar chargers going to the battery banks. Leave the primary charger connected (alternator) - ensure alternator

is working. We also recommend turning off any loads (inverters etc.).

How to test if the BB is charging:

With engine running (alternator charging), what is the voltage on the input terminal of the BB? What is the

voltage on the output terminal of the BB? Measure these voltages at the BB’s terminals, not at the batteries

terminals.

By default, the BB requires 13.5V+ to turn on and get going. If you are getting alternator voltage at the input

terminal (~14V) and 56V+ on the output terminal the chances are your BB is working fine. If little to no current is

passing through the charger at these voltages then the batteries are either full or they are duff. If the output

voltage is between 52V-56V (but rising) then you could have a situation where the output batteries were very low

in charge (or large in capacity) and the charger shall be charging at maximum current. Provided this output

voltage continues rising the BB is charging. Or, you may have a load equal to or more than the charger

If your output voltage is less than 52V and your input voltage is healthy, it could be three things:

1) You have a large load on your output bank - turn load off.

2) The BB may have enter a fault state an stopped charging.

3) The BB is not working / failed.

If your input voltage is less than 13V, it could be several things:

Automotive: Your alternator’s voltage is at less than 13V (the alt. is regenerative braking mode -

sometimes expected on modern Euro 5/6+ engines) - take vehicle for drive and measure alternator’s voltage

and set up the BB to suit these needs. All vehicle manufactures have their own software / characteristics for

regen. braking. Resort to running ignition signal to BB to ensure BB operates irrespective to fluctuating input

voltage.

Automotive or Marine: If your alternator’s voltage is ~14V then check continuity between the

alternator’s B+ terminal and the starter battery. If you are getting ~14V on starter battery then check continuity

between starter battery and BB input terminal.

Automotive or Marine: If your alternator’s voltage is 0-13V (starter battery voltage) then alternator may

have failed. Or, requires increase rpm of engine, possible belt slip.

Is your output voltage slightly higher or lower than expected - even with no loads / chargers on?

Check if you have the temperature sensor connected. If so, no problems leaving it there, it is simply voltage

compensating for when the temperature at the sensor is lower or higher than the benchmark 20DegC (69F). If

lower, then the voltage shall rise and vice versa. The further from 20DegC in either direction leads to proportional

increase or decrease in the voltage.

If the voltage at your output battery is 0.3V lower (or more) than at the output of the BB - this is likely due to poor /

thin cabling. And / or, due to voltage drop across fuses / fuse holder / isolation switch / relay / diode etc.. between

the output of the BB and your output battery. Beef up the cable, clean connections, ensure connections are as

tight as possible, remove unnecessary devices (such as isolation switches, relays or diodes) - these are really

not required here.

Problem

Possible Cause

Suggested solution

Recovery Condition

Low Voltage Disconnect (LVD)

on input - in Auto Mode

input voltage is lower than

12.8V or no ignition signal is

detected.

Turn engine on | ensure cable

thickness between input and starter

battery is sufficient.

The fault shall clear automatically

when input voltage rises above

13.5V.

Low Voltage Disconnect (LVD)

on input - in Ignition / Vibration

Mode

input voltage is lower than

10V and/or no ignition signal

is detected.

Turn engine on | ensure cable

thickness between input and starter

battery is sufficient. ~12V at ignition

The fault shall clear automatically

when input voltage rises above 11V

+ live ignition / vibration signal

Output Over Voltage Protection

(output OVP)

output voltage has exceeded

0.6V+ on top of set

absorption voltage.

check loads or chargers on output

battery. Check where high V is

coming from

When output voltage drops below

0.3V on top of set absorption

voltage the BB resumes charge.

Input Over Voltage Protection

(input OVP)

input voltage has exceeded

16V.

likely alternator voltage has gone

too high. If Euro 6 vehicle - this is

okay, BB shall reboot when V drops.

When voltage drops below 15.5V

the BB shall turn on and resume

charging after 30 seconds.

Over Temperature Protection

(OTP)

Charger’s internal

temperature is too high

Check input and output exhausts for

blockages. 10mm

When charger temperature reduces

charging resumes

Fan Fault

Failed fan

objects may be jamming the fan, fan

may be old, clogged up.

When fan is operational the fault

light turns off.

Troubleshoot - checks to ensure the

BB is installed correctly and receiving

the correct input and output voltages.

Fault LED - shall come on solid, if a

fault is detected.

This LED is red colour.

The fault can be a single fault or

multiple faults. There are 6 faults that

can be detected - all of which are

mentioned in this table.

Operation%

100

input voltage

>13.6V

12.8V - 13.6V

<12.8V

What output current rates to expect

at lower input voltages

TROUBLESHOOTING AND PROBLEM RESOLUTION

Verify Install : Negatives

Pre-Troubleshooting

Measure Voltages

Saturn Engagement

Requirements

Charger is ﬁne :

Output voltage correct, but not

reaching batteries

Input voltage healthy but output

voltage low

Input voltage low/struggling

Euro 6:

Loss down cable

Weak or failed alternator

Output voltage higher than

expected

Lower output current than

expected

Fault Table

As with all things, if you suspect a problem, please ensure the install is correct. Ensure negatives are common

where possible and the BB charger’s negative is connected to the starter battery’s negative - avoid connecting to

chassis negative. Voltages between common negatives should be ~0V.

Ensure that all other charge sources (Solar, AC/DC, Wind) are isolated so as to not affect upcoming readings.

Turn on your engine and, with a multimeter, measure the voltage on the INPUT and OUTPUT terminals of the

Saturn charger, using the units negative as reference. Record these numbers down. If you do not know how to

measure voltages with a multimeter, please call for an electrician.

The Saturn will turn on automatically when the input voltage is >13.5V if in auto-voltage sense. If an ignition feed

has been inserted to the unit, the Saturn will turn on when the input voltage is >11V and the Ignition feed is >5V.

If your input voltage is >13.5V and your output voltage is 13V-14.6V and rising towards the profile target voltage,

chances are the unit is working correctly. Check voltage at leisure batteries to ensure it’s the same.

If the output voltage from the charger seems to be correct (IE it has reached absorption 14.4V correctly) but you

do not have the same voltage at your batteries, you either have significant volt-drop down the output circuit (IE

poor contacts, thin cable, poor continuity) or the leisure battery simply is not connected (wiring mishap, blown

fuse). Check the system until voltage at the output of the charger and voltage at the destination are equitable.

If your output voltage is less than what you would expect it to be, there are a few possibilities

A) Your battery was very depleted and is still drawing power. Watch to see if the output voltage is rising.

B) You may have a heavy load on the leisure battery, pulling all of the power from the charger immediately,

. simply turn off the associated load.

C) The Saturn may be in a fault state, or potentially has failed.

D) The Saturn may not be online. Check LEDs on the item and ensure they are lit. If the input voltage is good but

. the charger is not responding, it may be in vibration sense or ignition feed modes.

If your input voltage is low when the engine is on (<13.5V) there are a few possibilities.

Modern automotives may have smart alternators or Euro 6 systems. By default (and to save fuel economy)

these alternators will only engage when the starter battery or starter system is in need of power. To overcome this

limitation, install the ignition feed to the unit.

If the voltage at your starter battery is being maintained at a healthy ~14V, but the input voltage at the Saturn is

significantly lower, you either have significant loss in the circuit or you have a continuity error. Check contacts

and ensure that the cable is thick enough to resolve this volt-drop.

If the voltage at the starter battery is also low and it is not due to the Euro 6 nature of the vehicle, it is likely that the

alternator simply cannot support the load. This is either due to the Saturn item being too powerful for the

associated alternator at current RPM, or the alternator having deteriorated/failed.

Check if the temperature sensor is fitted. If the temperature sensor is fitted, you may simply be going through

temperature compensation. If it is not fitted, check for other chargers being active, or check voltmeter calibration.

This is likely due to a sagging input voltage. If our input voltage cannot be sustained above 13.5V we will

automatically downrate to 85% or 65% operation. Input voltage must recover (13.8V) to return to full power.

Multiply voltages by 2 for 24V, 4 for 48V.

STERLING

POWER

The BB remote control (BBR) is designed to be used with Sterling Power’s range of Buck Boost Battery to

Battery Chargers (red casing with white text). The BBR is both a passive display of information and a remote

control that can input and modify the behaviour of the BB.

The remote comes with 4m of extension cable and the appropriate adapter. The remote can be flush mounted,

surface mounted or recess mounted. The tabs on the wings of the remote control can be taken off and 4x screw

holes can be used.

The remote is powered from the BB, so will only be live

when the charger is live.

Welcome

Installation

Power

Diagram

2 main display screens

Making functional changes

Settings

connect cable to this port on BB

Backlight on/oﬀ

Press and hold 4+ seconds

(then let go) to enter MENU

Press enter to make selection

Up and Down cursor keys to scroll

Output charge voltage

Battery Charge Proﬁle

Output charge current

Charge status

When the remote is connected to the BB, the remote will display the settings that are presently programmed into

the BB. With the remote connected, changes can be made using the display interface.

LEAD1 BULK

14V 40A

IGN&VIB: OFF

BATT_Temp: --

press arrows to toggle

default screen supplementary screen

informs if: ignition feed or vibration mode on/oﬀ

Batt_Temp - display temperature at sensor (if connected)

Below is a list of functions that can be selected by the remote control. More information overleaf.

To access and adjust settings, press and hold the button for 4+ seconds and let go. You can then toggle

through settings by using the arrow keys, and selecting settings by pressing enter.

ŸBattery type - here you can change battery type, you can also select user defined setting (custom) - the

custom profile is adjusted in the User Defined 1 and 2 settings below.

ŸEQ Mode - Enabling EQ mode shall put the BB into a desulphation cycle. Warning high voltage.

ŸFloat on/off - Here you can turn off float mode - only available in lithium

ŸIgn - Ignition mode, you can toggle whether the BB is in ignition mode or not. (on/off)

ŸBacklight - Here you can adjust how long the backlight stays on after you press a button (All, 10s-

250seconds).

ŸSet Current - here you can adjust the current levels to 65%, 85% or 100%.

ŸUser defined setting 1 - here you can adjust absorption voltage, float voltage and absorption time lengths

ŸUser defined setting 2 - here you can adjust absorption voltage, float voltage and absorption time lengths

ŸSAVE AND EXIT - This is CRITICAL if you want to save the settings you have changed, they will otherwise

be forgotten.

BBR SATURN CHARGER REMOTE CONTROL

BBR 14

BBR SATURN CHARGER REMOTE CONTROL

STERLING

POWER

Press ENTER - toggle between LEAD 1 +2, AGM 1+2 and both the lithium profiles or the User Defined Settings

1+2. This can be set further down the menu list.

This mode puts the BB into a desulphation charge voltage of 15.5V (only appears when in LEAD mode) - use

toggle up and down to adjust.

This mode turns float mode on or off (only available when in LITHIUM) - use toggle up and down to adjust

If the BB has been put into ignition feed mode, here you can take the BB out of ignition feed mode. Simply toggle

up and down with arrows to select the desired on/off.

Backlight timer can be set here. After you press a button the remote, you can define how long the screen remains

on for. 10s - 250 seconds. There is also an ‘ALL’ selection. This means the screen is on all the time, whilst the

charger is running. On all the time shall allow you to view what the BB is doing whilst driving and the BB charging.

The default current setting for the BB range is 100% - meaning that the performance default is full power. If you

wish to reduce the performance of the BB, here you can set to 85% or 65% charge rate. Examples of why you

may wish to reduce performance:

1) if you have solar panels and the weather is good, by reducing the power of the BB, you shall conserve fuel.

2) The alternator is better suited running at slightly lower current than what was expected.

3) It may be recommended by your battery supplier to charge the battery up at a slightly lower current. If one of

your lithium batteries within your leisure battery bank fails, you may be exceeding the C rating of the remaining

batteries.

4) future proofing. If you have installed a high powered BB, in the assumption that one day you shall put a larger

alternator on and/or more batteries in your system. You can reduce the power for the immediate install and

increase the performance of the unit at a later date.

If you enter User define1 set you can customise the charge profile and absorption time length. The first measure

to adjust is the absorption voltage (14.0-15.5V) - use the cursor keys to adjust up or down the absorption voltage,

then press ENTER. The next option is float (12.6V - 14.0V) - use the cursor keys to adjust and press ENTER. The

last option is absorption time length in hours (0.5hr - 6.0hrs) - press enter to confirm. Once you have confirmed

go back up to Battery type and select ‘user define1'.

If you enter User define2 set you can customise the charge profile and absorption time length. The first measure

to adjust is the absorption voltage (14.0-15.5V) - use the cursor keys to adjust up or down the absorption voltage,

then press ENTER. The next option is float (12.6V - 14.0V) - use the cursor keys to adjust and press ENTER. The

last option is absorption time length in hours (0.5hr - 6.0hrs) - press enter to confirm. Once you have confirmed

go back up to Battery type and select ‘user define2'.

If you have made changes within the SETUP procedure and you wish to save these settings - you must press

ENTER on Save and Exit.

If you have made changes within the SETUP procedure and you DO NOT wish to save these settings - you must

press ENTER here.

Battery type

EQ mode

Turn Float on or off

IGN

Backlight

Set current

User define1 set

User define2 set

Save and Exit

No Save and Exit

BBR dimensions - not to scale

52.5 mm

70mm

99mm

110mm

90mm

21mm

14mm

BBR 15