samlex-america BGW-40 Battery Guard Waterproof Owner’s Manual

: June 9, 2024
: samlex-america

Table of Contents

DESCRIPTION
INSTALLATION
OPERATION
CONFIGURE/PROGRAMMING
PROGRAMMING TABLE
TECHNICAL DATA
WIRING DIAGRAM
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

Battery Guard Waterproof BGW-40 / BGW-60
OWNERS MANUAL

DESCRIPTION

The Battery Guard Waterproof BGW40/60 (hereafter referred to as the BGW) is an intelligent, user programmable, fully waterproof battery guard. The BGW has additional options for a remote off switch and an alarm output for connecting a buzzer, LED strip or relay. To ensure low losses, the BGW is provided with two threaded rod and nut connections; input+ and output+. The other connections (Minus-, Remote Off-, Config-input and Status/alarm output) are connected via 6.3 mm faston connectors. The BGW is equipped with a bright status LED displaying the different functional stages. The BGW features an “automatic board system detection”, this enables to automatically detect if the BGW is connected to a 12 V or a 24 V system.

INSTALLATION

Install the BGW on a cooling (metal) surface allowing to dissipate the heat generated. Use a maximum cable length of 50 cm between the battery and the BGW will ensure accurate monitoring the battery voltage.
Please note!

The product may only be installed by qualified electricians who are fully aware of the requirements for working with high battery voltages.
The use of poor/ bad connection material and/or wires that are too thin can damage the BGW.
A short circuit between the battery’s positive and negative terminals can cause serious damage to the system.
Always use fuses of the correct value.
Use a 1.5 mm2 cable with 1 A fuse from the battery (-) to the BGW for the negative (–) connection. Use this connection only for the BGW!

WIRING DIAGRAM (please see last page)

OPERATION

Input voltage protection
The input voltage protection values (undervoltage threshold, undervoltage reset, overvoltage threshold and overvoltage reset) can be set by the user.
Please see “CONFIGURE/Programming” how to set these values. Under voltage If the BGW’s input voltage drops below the under voltage threshold for 15 seconds, the status/ alarm output will turn on. The LED will also indicate under voltage. The BGW will shut down one minute later and the alarm output and LED will turn off.
When the BGW’s input voltage exceeds the reset threshold for 5 seconds, the BGW will turn back on, and the LED will indicate that the BGW is active again.

Overvoltage
The BGW will shut down if the input voltage exceeds the overvoltage threshold for 0.5 seconds. The status/ alarm output and LED will flash/switch with a frequency of 1 Hz.

Overcurrent protection
The current through the BGW is constantly monitored.
If an excessive current flows through the BGW for too long, the BGW will shut down to prevent damage to both the BGW and the connected equipment.
The BGW will turn on again after 1 minute.

Temperature protection
The BGW will shut down immediately if its temperature exceeds 85 °C. The LED will indicate a fault. The BGW will turn on again after 1 minute if
the temperature has dropped below 75 °C.

Ground Loss protection
The BGW will shut down if it detects that the minus (–) is disconnected on the supply (battery) side. The LED will indicate a fault. The BGW will turn on again after 1 minute.

Remote off
A switch can be installed between the OFF input and the minus (–) to manually disable the BGW output.
The BGW will shut down immediately when the connection is made. The BGW will turn on when the connection has been disconnected.

LED
The LED has two functions. One is to indicate the BGW’s status. The different stages are explaned in the LED STATUS below. The other is to configure/ programme the BGW. This operation is described in the section “CONFIGURE/Programming”.

LED STATUS	STAGE EXPLAINED
Led is on.	BGW has enabled (switched on) the output.
Two short blinks (then off for a longer period).	BGW is disabled because the

remote off has been
activated.
One blink (1 second on and 1 second off).| Under voltage or overvoltage detected.
Three short blinks (then off for a longer period).| BGW has been shut down for one minute due to one
of the following causes: Ground loss, temperature
protection, current protection, low output voltage.
LED is off.| BGW has been shut down due to under voltage.

CONFIGURE/PROGRAMMING

To enter the configure/programming mode, a connection has be made between the CONFIG input and the Minus (–). The LED will blink one
time when the connection has been made for approx. 2 seconds. Once this is done, the connection has to be disconnected.
The same connection can be made briefly (short) again to set the correct position from the programming table. The LED will light up as feedback.
At that point, program position #1 is selected. The user can briefly (short) make the connection again to select programme position #2, etc., etc..
If no connection is made for approx. 4 seconds, the LED will display the set state again. (Example: programme position #4 is set by a user, the LED will blink 4 times)
Two types of settings are available. Positions 1 through 10 set the under voltage threshold and reset values. Positions 11 and 12 set the overvoltage
threshold and reset values. These settings must be selected individually.
The programmed positions are also retained when the battery voltage is disconnected.

PROGRAMMING TABLE

12V	24V

UNDERVOLTAGE (V)
Position| Threshold| Reset| Threshold| Reset
1| 10.5| 12| 21| 24
2| 10| 11.5| 20| 23
3| 9.5| 11.5| 19| 23
4| 11.25| 13.25| 22.5| 26.5
5| 11.5| 13.8| 23| 27.6
6| 10.5| 12.8| 21| 25.6
7| 11.5| 12.8| 23| 25.6
8| 11.8| 12.8| 23.6| 25.6
9| 12| 13| 24| 26
10| 10| 13.2| 20| 26.4
OVERVOLTAGE (V)
Position| Threshold| Reset| Threshold| Reset
11| 16| 16.| 32| 31.6
12| 15.| 15.| 31.| 31.4

Factory default

TECHNICAL DATA

| BGW-40| BGW-60
---|---|---
ELECTRICAL
Input voltage range| 6 … 35 V
Maximum continuous output current (@25 °C)| 40 A| 60 A
Peak current (@25 °C)| 300 A (± 0.7 sec)
Voltage drop| 40 mV @ 40 A| 60 mV 4 60 A
Current Output active| 3.2 mA
Consumption Output inactive| 3.2 mA
Voltage accuracy| 2%
Current accuracy| 10%
Maximum status/alarm output load| 100 mA
INPUT & OUTPUT CONNECTOIN
Minimum wire diameter| 10 mm2| 16 mm2
Bolt size| M6
Cable lugs| Cable lugs must match the cable diameter used.
FASTON CONNECTIONS
Minimum wire diameter| 1.5 mm,
Faston plug| 6.3 mm
MECHANICAL
Mounting hole (0)| 4.2 mm
Distance between mounting holes (centre to centre)| 50 mm, ± 1 mm
Weight| 155 g
Dimensions (WW1)| 327262 mm
IP Code| IP66
Housing material| PU552
Housing colour| Black
Cooling concept| Convection and conduction.
GENERAL
Operational ambient temperature| -10 °C … +40 °C
Storage temperature| -25 °C … +85 °C
Operational air humidity| Up to 95%, non-condensing.
Galvanic insulation| No
Remote contact switch-off| Yes
PROTECTION
Overcurrent/Short circuit| Yes (after 1 minute restart).
Overheating, shutdown| Above 85 °C (after 1 minute restart).
Polarity protection| Yes, with fuse in the minus (-) line.
ELECTRICAL
Input voltage range| 6 … 35 V
Maximum continuous output current (@25 °C)| 40 A| 60 A
Peak current (@25 °C)| 300 A (± 0.7 sec)
Voltage drop| 40 mV @ 40 A| 60 mV 4 60 A
Current Output active| 3.2 mA
Consumption Output inactive| 3.2 mA
Voltage accuracy| 2%
Current accuracy| 10%
Maximum status/alarm output load| 100 mA
INPUT & OUTPUT CONNECTOIN
Minimum wire diameter| 10 mm2| 16 mm2
Bolt size| M6
Cable lugs| Cable lugs must match the cable diameter used.
FASTON CONNECTIONS
Minimum wire diameter| 1.5 mm,
Faston plug| 6.3 mm
MECHANICAL
Mounting hole (0)| 4.2 mm
Distance between mounting holes (centre to centre)| 50 mm, ± 1 mm
Weight| 155 g
Dimensions (WW1)| 327262 mm
IP Code| IP66
Housing material| PU552
Housing colour| Black
Cooling concept| Convection and conduction.
GENERAL
Operational ambient temperature| -10 °C … +40 °C
Storage temperature| -25 °C … +85 °C
Operational air humidity| Up to 95%, non-condensing.
Galvanic insulation| No
Remote contact switch-off| Yes
COMPLIANCE
Safety & EMC| CE ; UCKA ; RoHS
Emissions: EN61000-6-3:2007
Immunity: EN 61000-6-2:2005
PROTECTION
Overcurrent/Short circuit| Yes (after 1 minute restart).
Overheating, shutdown| Above 85 °C (after 1 minute restart).
Polarity protection| Yes, with fuse in the minus (-) line.