STERLING POWER BB1210 DC DC Charger Handbook Instruction Manual

: August 6, 2024
: STERLING POWER

BB1210 DC DC Charger Handbook

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Product Specifications:

Part Numbers: BB1210, BB1215, BB1225, BB1240, BB1270, BB12120,
BB12200, BB1224120, BB122465, BB1236120, BB124865, BB1248120 INC.
BBR
Temperature sensor included
For more information, visit www.sterling-power.com or
www.sterling-power-usa.com

Product Usage Instructions:

Choosing the Charge Profile:

Consult your battery specification sheet or manufacturer to
select a charge profile that aligns with their recommendations.
It’s safer to be below the manufacturer’s values than exceeding
them.

Temperature Sensor Function:

The temperature sensor adjusts the charge voltage based on the
battery’s temperature. For lithium batteries, no temperature
compensation occurs, but the charger won’t output if it detects 0°C
at the battery.

Common Negative Requirement:

Ensure a common negative connection for optimal charging
performance. Poor negative connections can impact charging
efficiency. Maintain a good circuit for effective charging.

Cable Connection Tips:

If the cable doesn’t fit, remember that a slightly larger cable
is better than a smaller one. Use ferrules or reduce the cable size
to fit into the connectors properly.

Troubleshooting Charger Issues:

If the charger isn’t operating:

Ensure you are not in Vibration Sense mode.
Check for >13.5V on the positive and negative terminals of
the charger.
Verify the ignition feed is receiving a live signal when
necessary.

Disabling Reverse Charge:

You can disable reverse charge on the unit itself, refer to page
11 of the manual for instructions.

Pulsing Charge or Low Current:

If experiencing pulsing charge or low current, monitor the input
voltage to the charger. Check for voltage drops or insufficient
alternator support. Ensure input voltage remains stable for proper
charging.

Positive and Negative Connections:

The positive output connects to a leisure battery bank or any
circuit needing power. The negative must be common and direct for
all components to operate effectively.

Frequently Asked Questions (FAQ):

What charge profile should I choose?

Refer to battery specifications or manufacturer recommendations
for selecting the appropriate charge profile.

What does the temperature sensor do?

The temperature sensor adjusts charge voltage based on battery
temperature.

Do I need a common negative?

Yes, maintain a common negative connection for optimal charging
performance.

Cable doesn’t fit! What should I do?

Use ferrules or reduce cable size to properly fit into
connectors.

Charger isn’t working, what should I check?

Ensure not in Vibration Sense mode, check voltage on terminals,
and verify live signal on ignition feed.

How can I disable reverse charge?

Refer to page 11 of the manual for instructions on disabling
reverse charge.

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latest instructions
Part Nos: BB1210 BB1215 BB1225 BB1240 BB1270 BB12120 BB12200 BB1224120 BB122465 BB1236120 BB124865 BB1248120 INC. BBR
TEMP1
Temperature sensor included

cRomopHliaSnt
www.sterling-power.com www.sterling-power-usa.com
Warranty (2 years return to factory) Copyright © 2023 Sterling Power All Rights Reserved

Sterling Power Products
DC/DC Charger Handbook Saturn Series, full range

STERLING POWER INLEAF FAQs

What charge profile should I choose?

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.

What does the temperature The temperature sensor, on lead acid, will cause temperature compensation, adjusting the charge voltage sensor do? 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.

Do I need a common negative? 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 doesn’t fit! 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).

Charger isn’t doing anything-! 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.

I don’t want reverse charge! This can be disabled on the unit itself, covered on page 11.

You drained my starter battery! 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.

My charger keeps turning on and off/the charge current is low!

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.

How do I care for my charger?

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.

Can I come straight off of the Sadly not. The calculations the DC/DC charger has to make in order to do its job best means that we need a alternator? 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!

Is this safe for my alternator? /How do I rate the BB for my
system?

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.

Can I parallel multiple? 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.

How? 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.

NOTES 02

STERLING POWER INTRODUCTION TABLE OF CONTENTS

Introduction 02 Frequently asked questions 03 Table of Contents + Welcome

Safety and Legal 04 Legal Guidelines / Warranty Statement 05 Safety Guidelines

Product Information 06 07 08 09 10 11 12

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 13 Troubleshooting and fault finding

Saturn Remote (BBR) 14 Understanding your remote 15 Configuring your remote

Technical Drawings 16 Technical drawings (1) 17 Technical drawings (2)

Misc. 18 Sterling Contact information and Catalogues 19 Recommended cable size chart

Welcome 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.

Using this Manual

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.

Safety note 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.

Converting 12V for 24V, or 48V

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.

CONTENTS PAGE 03

STERLING POWER
SAFETY AND LEGAL LEGAL GUIDELINES
Warranty and Terms 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.
Copyright and Plagiarism Copyright © 2023 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: Y consequential damage due to use of this device Y 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.
SAFETY AND LEGAL 04

STERLING POWER SAFETY AND LEGAL SAFETY GUIDELINES

Product Guidelines

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

Transport and Storage 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.

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 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.

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. 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 Chargers CROSS VOLTAGE THRESHOLD BATTERY TO BATTERY CHARGERS MUST BE INSTALLED WITH CARE READ THIS A COMMON NEGATIVE IS PARAMOUNT TO OPERATION, HOWEVER, BE INCREDIBLY CAREFUL NOT TO SHORT CIRCUIT OR REVERSE POLARITY ANY EQUIPMENT OR CABLE.
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 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.

SAFETY AND LEGAL 05

STERLING POWER
PRODUCT INFORMATION SIMPLE WIRING DIAGRAM Basic install diagram

*Label rendered for clarity, .

Air Flow
12V ignition signal (optional)

12V ign
alarm GND

nothing to change in the setup. Simply plug cables in and start engine.

Alternator

fuse

Input / starter battery

Ensure you have the correct battery to battery charger for your install. The
voltage ratings for the chargers are specific.

fuse
Leisure Battery Bank

Install summary 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.

Positive Input 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.

Positive Output 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

Negative 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.

Euro Six / Low Input Voltage 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 Cable/Fuses Recommended cabling and fuse sizes are covered on the unit summary/specification pages, pages 7+8.

Any Orientation Suitable

If prone to getting damp Sideways mounting may result in pooling of water at the bottom

BASIC INSTALL 06

STERLING POWER

PRODUCT INFORMATION UNIT SPECS AND RECOMMENDED CABLING

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 Approval
Cooling method

-20 Deg C -> 60 DegC CE | UKCA E-Marking Thermostatically Controlled Variable low speed fan

Input voltage range Max Rated output power Max Rated input current Quiescent current Efficiency rating

Negative Cable Reverse charge quiescent
BB1210 9V-16V 9A at 14.41V ~130W 10A at 13.68V ~136.8W 5mA 98%

As thick as the IN cable. 1.5-6W (dependent on rating)

Input voltage range Max Rated output power Max Rated input current Quiescent current Efficiency rating

BB1215 | BB1220 9V-16V 19A at 14.41V ~267.9W 21A at 13.68V ~287.3W 5mA 98%

Dimensions Weight

123mm x 130mm x 56mm 0.6Kg

Dimensions Weight

123mm x 130mm x 56mm 0.6Kg

Terminal diameter Recommended Input cable Recommended Input fuse Recommended Output cable Recommended Output fuse

6.1mm 2.5mm2or above (14awg) 12-15A 2.5mm2or above (14awg) 12-15A

Terminal diameter Recommended Input cable Recommended Input fuse Recommended Output cable Recommended Output fuse

6.1mm 4.0mm2or above (12awg) 25A 4.0mm2or above (12awg) 25A

Input voltage range Max Rated output power Max Rated input current Quiescent current Efficiency rating

BB1225 9V-16V 24A at 14.41V ~345W 26A at 13.68V ~355W 5mA 98%

Input voltage range Max Rated output power Max Rated input current Quiescent current Efficiency rating

BB1240 9V-16V 38A at 14.41V ~550W 42A at 13.68V ~575W 5mA 95-98%

Dimensions Weight

123mm x 130mm x 56mm 0.6Kg

Dimensions Weight

163mm x 130mm x 56mm 0.8Kg

Terminal diameter Recommended Input cable Recommended Input fuse Recommended Output cable Recommended Output fuse

6.1mm 6mm2or above (10awg) 30A 6mm2or above (10awg) 30A

Terminal diameter Recommended Input cable Recommended Input fuse Recommended Output cable Recommended Output fuse

6.1mm 10.0mm2or above (8awg) 50A 10mm2or above (8awg) 50A

Input voltage range Rated output power Rated input current Quiescent current Efficiency rating

BB1270 9V-16V 60A at 13.8V 70A 10mA 92%-94%

Input voltage range Rated output power Rated input current Quiescent current Efficiency rating

BB122465 9V-16V 30A at 27.4V 65A 10mA 92%-94%

Dimensions Weight

200mm x 130mm x 56mm 1.0Kg

Dimensions Weight

200mm x 130mm x 56mm 1.0Kg

Terminal diameter Recommended Input cable Recommended Input fuse Recommended Output cable Recommended Output fuse

6.1mm 16mm2or above (6awg) 80A 16mm2or above (6awg) 80A

Terminal diameter Recommended Input cable Recommended Input fuse Recommended Output cable Recommended Output fuse

6.1mm 16mm2or above (6awg) 80A 6mm2or above (10awg) 40A

PRODUCT INFORMATION 07

STERLING POWER

PRODUCT INFORMATION UNIT SPECS AND RECOMMENDED CABLING

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 Cooling method

CE | UKCA E-Marking Thermostatically Controlled Variable low speed fan

Input voltage range Rated output power Rated input current Quiescent current Efficiency rating

BB124865

12V AND 24V IN

9V-16V / 18V-32V

16A at 54.8V

65A / 32.5A

10mA

92%-94%

Dimensions Weight

200mm x 130mm x 56mm 1.0Kg

Terminal diameter Recommended Input cable Recommended Input fuse Recommended Output cable Recommended Output fuse

6.1mm 16mm2or above (6awg) 80A 4mm2or above (12awg) 20A

Input voltage range Max Rated output power Max Rated input current Quiescent current Efficiency rating

BB1224120

12V AND 24V IN

9V-16V / 18V-32V

58A at 28.41V ~1540W

120A / 60A

5mA

92-94%

Dimensions Weight

270mm x 130mm x 73mm 1.8Kg

Terminal diameter Recommended Input cable Recommended Input fuse Recommended Output cable Recommended Output fuse

8.9mm 35mm2or above (2awg) 150A 16mm2or above (6awg) 80A

Input voltage range Rated output power Rated input current Quiescent current Efficiency rating

BB12200 9V-16V 180A at 13.8V 200A 15mA 95%-98%

Dimensions Weight

309mm x 130mm x 96mm 2.2Kg

Terminal diameter Recommended Input cable Recommended Input fuse Recommended Output cable Recommended Output fuse

14mm 70mm2or above (00awg) 250A 70mm2or above (00awg) 250A

Input voltage range Max Rated output power Max Rated input current Quiescent current Efficiency rating

BB12120 9V-16V 110A at 14.41V ~1584W 120A 5mA 92-94%

Dimensions Weight

270mm x 130mm x 73mm 1.8Kg

Terminal diameter Recommended Input cable Recommended Input fuse Recommended Output cable Recommended Output fuse

8.9mm 35mm2or above (2awg) 150A 35mm2or above (2awg) 150A

Input voltage range Max Rated output power Max Rated input current Quiescent current Efficiency rating

BB1248120 9V-16V 28A at 57.6V 120A 5mA 92-94%

Dimensions Weight

270mm x 130mm x 73mm 1.8Kg

Terminal diameter Recommended Input cable Recommended Input fuse Recommended Output cable Recommended Output fuse

8.9mm 35mm2or above (2awg) 150A 6mm2or above (10awg) 40A

PRODUCT INFORMATION 08

STERLING POWER
PRODUCT INFORMATION UNDERSTANDING YOUR UNIT, PT.1 Faceplate Diagram 1 2
Air Flow

*Label rendered for clarity, .
Air Flow

12V ign
alarm GND

3
4
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 air flow is demonstrated above.
3. Display panel. More information 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 BB1248120 are made. Also, this region contains additional 2x 5mm mounting feet.
PRODUCT INFORMATION 09

STERLING POWER
PRODUCT INFORMATION UNDERSTANDING YOUR UNIT, PT.2 Base Diagram

*Label rendered for clarity, .

14

13

5 67

8 9 10 11 12

5. 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.

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 similar sized cable as positive.

7. 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.

8. 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.

9. 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.

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 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.

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.

12. 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.

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 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.

14. Not applicable / local use only

PRODUCT INFORMATION 10

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

STERLING POWER
PRODUCT INFORMATION ITEM CONTROLS AND UNDERSTANDING

LED panel Charging Status :: 1)

Orange LED status:

Fast flashing = Bulk / Fast Charge

Slow flashing = Absorption

Solid

= Float

1

2

ROe/PveBrsaett.CVhoalrt.ge

3

Type 2 Lithium

Reverse Charging :: 2) 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

Disabling Reverse Charging 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.

Jump Start Assist To manually force the reverse charge process, simply press the Select button 4 times in a row. The Reverse charging LED should come on.

Battery Type Select

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.

LED sequence
Battery type profiles:

Battery Type Lead I

Absorption (V) 14.4V

Float (V) 13.3V

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

Lead II AGM I AGM II Lithium I*

14.6V 14.2V 14.7V 14.4V

13.5V 13.1V 13.6V 13.8V

Lithium II*

14.2V

13.6V

Lithium profile properties

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.

Absorption Timers

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 Going from Float to Absorption 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.

FRONT PANEL, BATTERY TYPE 11

STERLING POWER

ENGAGEMENT MODES SATURN RANGE INSTALLS, 3x ENGAGEMENT METHODS

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.

Alternator
Input / starter battery

13.5V+ on <12.8V off

12V ign alarm GND

NOTE :: Engagement voltages and disengagement voltages are x2 for 24V input units. The below is written and designed with 12V input installs in mind.
Output Battery Bank

12V ign alarm GND

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.

5-32V ignition signal = ON 0V = OFF
Alternator

11V+

Input / starter battery

Output Battery Bank

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.

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.

Input voltage + vib. sense. Charger on – 11V -> 16V Charger off – <10V
on off
select switch position `on’ at anytime to engage vibration mode.

This mode essentially acts like an ignition signal and is designed for installers to do away with having to run an ignition feed.

Alternator

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.

Input / starter battery

12V ign alarm GND

on off
11V+

Output Battery Bank
ENGAGEMENT MODES 12

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

STERLING POWER TROUBLESHOOTING TROUBLESHOOTING AND PROBLEM RESOLUTION

Verify Install : Negatives 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.

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

Measure Voltages 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.

Saturn Engagement The Saturn will turn on automatically when the input voltage is >13.5V if in auto-voltage sense. If an ignition feed Requirements has been inserted to the unit, the Saturn will turn on when the input voltage is >11V and the Ignition feed is >5V.

Charger is fine : 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.

Output voltage correct, but not reaching batteries

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.

Input voltage healthy but output voltage low

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.

Input voltage low/struggling Euro 6:

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.

Loss down cable 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.

Weak or failed alternator 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.

Output voltage higher than Check if the temperature sensor is fitted. If the temperature sensor is fitted, you may simply be going through expected temperature compensation. If it is not fitted, check for other chargers being active, or check voltmeter calibration.

Lower output current than This is likely due to a sagging input voltage. If our input voltage cannot be sustained above 13.5V we will expected automatically downrate to 85% or 65% operation. Input voltage must recover (13.8V) to return to full power.

input voltage Operation%