samlexpower BGW-60 Battery Voltage Protector User Manual
- May 15, 2024
- samlexpower
Table of Contents
Samlexpower BGW-60 Battery Voltage Protector
DESCRIPTION
The Battery Voltage Protector BGW 40/60 (hereafter referred to as the BGW) is
an intelligent, user-programmable, waterproof battery voltage protector
device. 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 fast-on
connectors. The BGW is equipped with a bright status LED displaying the
different functional stages. The BGW features an “automatic board system
detection”, which enables it 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 it to dissipate the heat generated. Using a maximum cable length of 50 cm between the battery and the BGW will ensure accurate monitoring of 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 the first 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” for how to set these values.
Undervoltage
If the BGW’s input voltage drops below the undervoltage threshold for 15
seconds, the status/ alarm output will turn on. The LED will also indicate
undervoltage. 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 explained in the LED STATUS below. The other is to
configure/program 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).| Undervoltage 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, and low output voltage.
The LED is off.| BGW has been shut down due to undervoltage.
CONFIGURE/PROGRAMMING
To enter the configure/programming mode, a connection has to 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, and the LED will blink 4 times) Two types of settings are available. Positions 1 through 10 set the Undervoltage 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| Thres- hold| Reset| Thres- hold|
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| Thres- hold| Reset| Thres- hold|
Reset
11| 16| 15.8| 32| 31.6
12| 15.4| 15.2| 30.8| 31.4
TECHNICAL DATA
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 @ 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 CONNECTION
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 mm2
Faston plug| 6.3 mm
MECHANICAL
Mounting hole (Ø)| 4.2 mm
Distance between mounting holes (centre to centre)| 50 mm, ± 1 mm
Weight| 155 g
Dimensions (HWL)| 327262 mm
ZIP 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 a 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 @ 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 CONNECTION
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 mm2
Faston plug| 6.3 mm
MECHANICAL
Mounting hole (Ø)| 4.2 mm
Distance between mounting holes (centre to centre)| 50 mm, ± 1 mm
Weight| 155 g
Dimensions (HWL)| 327262 mm
ZIP 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 a fuse in the minus (-) line.
WIRING DIAGRAM
Battery Voltage
Protector
Models: BGW-40
Please read this manual BEFORE operating the units.