STERLING POWER BB12120 Battery to Battery Charger User Guide

STERLING POWER BB12120 Battery to Battery Charger

INTRODUCTION

WELCOME

Welcome to the Sterling Power Products Owners Handbook for the product BB1270, the 12V to 12V battery to the battery charger (70A input rated).
Please take your time to read and fully understand the contents of this Handbook. These guidelines are developed with your safety and the product’s 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.

12V – 12V 70A

This 12V to 12V battery to battery charger is a device typically installed between a starter battery (input) and a house / domestic / service battery (output). The BB1270 is designed to charge up your 12V domestic / service / auxiliary battery from the power generated from your alternator, whilst your engine is running. It is designed to work with vehicles (old/new) and (boats old/new). As this device is 70A rated on the input, we recommend running from an alternator 90A+. This BB charges both lead acid-style batteries and lithium batteries.
Throughout this manual, we will make reference to this product as the ‘BB’. The term ‘12V’ is the nominal voltage, not the specific voltage.

Using this Handbook

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 endeavor to include all of the product information that we can think of in 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.

Safety

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.

Specifications

BB1270

protection output over-voltage protection over current protection charge over temperature
Operational Temperature| -20 Deg C -> 60 DegC
Approval| CE | UK
E-Marking
Cooling method| Thermostatically Controlled
Variable low-speed fan
Dimensions| 200mm x 130mm x 56mm
Weight| 1.0Kg

SAFETY AND LEGAL

Warranty and Terms

Your 100 % satisfaction is our goal. We realize 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 have 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 the warranty. If proof cannot be located a warranty is calculated from the date of manufacture.
• Our warranty covers the 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.
• The 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 arrived 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 organized by yourself. Please do not throw out any shipping or packaging materials. All returns for any reason will require 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 and 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 assume nor authorize 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 with 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.

Copyright and Plagiarism

Copyright © 2021 Sterling Power. All rights reserved.
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.

Liability

Sterling Power can not accept liability for:

• consequential damage due to the use of this device
• possible errors in the manuals and the results thereof

Device Modification

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.

Product Guidelines

Your Sterling Power product should only be utilized for its designated purpose. Use the Sterling Power Pro Charge Ultra 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
Transport and Storage
Ensure that the main 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, storage, charge rates, recharging, and battery disposal for your battery care.
General Maintenance
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 the unit is off. If repair is required, only use original parts. Unauthorized attempts to repair Sterling units will lead to the warranty being voided. Only someone with an 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.

Safety Precautions

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.
Isolate AC wires during installation.
Connect AC to a Residual Circuit Breaker (RCD) and current overload trips.
Sterling recommends Multi-Core Tri Rated AC cable
Install a 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.
The device connects to the 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

WARNING :

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 paneling 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 a danger of gas/dust/vapor explosions, or around potentially flammable produce.

PRODUCT INFORMATION

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- request to get the BB1270 to function.
The default charging profile is a standard sealed lead acid charging profile of 14.4V and 13.3V 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 BB1270.
If the 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 BB1270 can be mounted in any orientation. However, if the area is prone to getting wet or damp, we recommend the first or second install.

SIMPLE WIRING DIAGRAM

BB1270 Diagram

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

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

3. Display panel. More information is on page 9.

4. Connection blocks. This region is described in more detail overleaf. This is the area where all the physical installation connections to the BB1270 are made. Also, this region contains additional 2x 5mm mounting feet.

5. The left large green connector is for direct connection to the input/starter battery. 12V input connection. Ensure the cable thickness is 16mm2 / 2AWG. Ensure this cable is fused at ~80A fuse.

6. 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 a similar sized cable as a positive.

7. The right large green connector is for direct connection to the output/leisure battery. 12V output connection.
   Ensure the cable thickness is 16mm2 / 2AWG. Ensure this cable is fused at ~80A fuse.

8. This 12V output provides a 12V signal at 50mA. This can be used to trigger an operation / or provide a 12V signal.
   This 12V signal shall only become life if the Ground connector (11) is connected to the common negative rail.

9. Ignition feed connector. The BB1270 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 the ignition is turned off. Once the BB1270 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.

10. 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 action if the BB were to a fault. Ground connector (11) must be connected to the common negative rail for this alarm output to operate. More information is on page 11.

11. Ground. To utilize 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.

12. Vibration sensor on / off switch. Default off. If turned on, the BB1270 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 model comes with cautions, please read page 10. Switching between on / off can be done at any time. There may be a 10-second delay in unit operation between switches – no need to reset/reconnect the BB.

13. 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 for 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 stops charging if the sensor detects 0DegC or lower.

14. Not applicable/local use only

LED panel

• Lead Acid Charging Profiles

• Orange LED status:

• Fast flashing = Bulk / Fast Charge

• Slow flashing = Absorption

• Solid = Float

• Lithium Charging Profiles

• Orange LED status:

• Fast flashing = Bulk / Fast Charge

• Slow flashing = Absorption

• Orange LED status:

• Fast flashing = Low battery voltage, the battery needs a good charge

• Slow flashing = Medium battery voltage, mid charge.

• Solid = Good battery voltage, nearer charge completion.

Battery Type Select

When the 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 battery type you, want to wait until the LED stops flashing – after a few seconds the flashing stops and the LED stays on solid – this confirms the setting.

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 rising 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 triggers voltages. If the charger is in float and the output battery voltage is dragged below the following voltages the charger shall go back to absorption.

• Lead I = 12.6V
• Lead II = 12.7V
• AGM I = 12.4V
• AGM II = 12.8V
• Lithium I = 13.4V
• Lithium II = 13.2V

Lithium* = live output voltage, ideal for waking up BMSs on batteries. Please ensure your lithium battery has an internal or external BMS. If you want a float voltage please use Lead or AGM profiles.
If the temperature sensor is connected, no voltage compensation on lithium profiles. If the temperature sensor detects 0 Deg C – BB stops charging.

Automatic Mode (Default)

This mode is the simplest way to install the BB1270, however, is not the most effective if you are using this BB on a modern vehicle that has regenerative braking (Euro 6 engine or newer).
To activate the BB, you require 13.5V+ on the input terminal. You shallachieve 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.

Input voltage
Charger on – 13.5 -> 16V
Charger off – <12.8V

Input voltage + ign feed.
Charger on – 11V -> 16V
Charger off – <10V

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 –

1. Remove ignition cable from ign connector.
2. Press and hold the SETUP button for around 15 seconds until the 3 LED battery types flash at the same time.
3. Release button and charger revert to Automatic Mode.

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 as an ignition signal and is designed for installers to do away with having to run an ignition feed.
WARNING, if the vibration signal activates BB, shall 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.

Input voltage + vib. sense.
Charger on – 11V -> 16V
Charger off – <10V

Troubleshooting & Faults

Troubleshoot – checks to ensure the BB is installed correctly and receiving the correct input and output voltages.

What output current rates to expect at lower input voltages

Fault LED – shall come on solid, if a fault is detected.
This LED is red in color.
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.

Firstly, ensure the BB1270 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 the alternator is working. We also recommend turning off any loads (inverters etc.).
How to test if the BB is charging:
With the 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 14V+ 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 13V-14V (but rising) then you could have a situation where the output batteries were very low in charge (or large incapacity) and the charger shall be charging at maximum current. Provided this output voltage continues rising the BB is charging.
If your output voltage is less than 13V and your input voltage is healthy, it could be three things:

1. You have a large load on your output bank – turn the load off.
2. The BB may have entered a fault state and 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 the vehicle for a drive and measure the alternator’s voltage and set up the BB to suit these needs. All vehicle manufacturers have their own software/characteristics for regen. braking. Resort to running ignition signal to BB to ensure BB operates irrespective of 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 the starter battery then check continuity between the starter battery and BB input terminal.
Automotive or Marine: If your alternator’s voltage is 0-13V (starter battery voltage) then the alternator may have failed. Or, requires increased rpm of the 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 a 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, and 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 the engine on I ensure the cable
thickness between input and starter
the battery is sufficient.| The fault shall clear automatically
when the 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 the engine on I ensure the cable
thickness between input and starter
the battery is sufficient. —12V at ignition| The fault shall clear automatically
when the input voltage rises above 11V + live ignition / vibration signal
Output Over-Voltage Protection
(output OVP)| the output voltage has exceeded 0.6V+ on top of the set
absorption voltage.| check loads or chargers on the output
battery. C.heck where high V is
coming from| When the 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 the voltage drops below 15.5V
the BB shall turn on and resume
charging after 30 seconds.
Over Temperature Protection
(OTP)| The 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
maybe old, clogged up.| When the fan is operational the fault
the light turns off.

www.sterling-power.com
www.sterling-power-usa.com
Warranty (2 years return to factory)
Copyright © 2021
Sterling Power
All Rights Reserved

References

• Sterling Power USA, Marine Grade AC Battery Chargers, Marine Battery Isolator, Advanced Alternator Regulators, DC Powered Battery Chargers & Alternator Powered Battery Chargers, Pro Connect Advanced Battery Relays, BB Chargers, Current Limiting Units
• Sterling Power Products
• Sterling Power USA, Marine Grade AC Battery Chargers, Marine Battery Isolator, Advanced Alternator Regulators, DC Powered Battery Chargers & Alternator Powered Battery Chargers, Pro Connect Advanced Battery Relays, BB Chargers, Current Limiting Units
• Sterling Power Products

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