Sterling Power Products BB1210

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Sterling Power Products

DC/DC Charger Handbook

Part Nos:

BB1210

BB1215

BB1225

BB1240

BB1270

BB12120

BB12200

BB1224120

BB122465

BB1236120

BB124865

BB1248120

INC. BBR

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RAL 3003

90% Black

White

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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

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Overview

Function Description
Important Technical Specifications (Common to all Saturn range BBs)
Model-Specific Specifications
Usage Features
Maintenance Features

The Sterling Power Saturn Series is a range of DC/DC battery-to-battery chargers designed to efficiently charge a leisure battery bank from a starter battery or alternator. These bidirectional chargers are suitable for various vehicle types, including those with Euro 6 smart alternators, and offer robust protection features.

Function Description:

The primary function of the Saturn Series chargers is to convert DC power from an input source (typically a starter battery or alternator) to a regulated DC output for charging a secondary (leisure) battery bank. The bidirectional capability allows for reverse charging, where the leisure battery can charge the input battery if needed. The chargers feature intelligent algorithms to optimize charging based on battery type (Lead Acid, AGM, Lithium) and conditions, ensuring efficient and safe power transfer. They can operate in automatic voltage sense mode, ignition feed mode, or vibration sense mode, providing flexibility for different installation scenarios. A remote control (BBR) is available to monitor and configure the charger's settings, including battery type, charge profile, and current limits.

Important Technical Specifications (Common to all Saturn range BBs):

Self-recovering protections: Under voltage, input over voltage, output over voltage, over current, and charge over temperature protection.
Operational Temperature: -20°C to 60°C.
Approval: CE | UKCA | E-Marking.
Cooling method: Thermostatically controlled variable low-speed fan.
Negative Cable: As thick as the IN cable.

Model-Specific Specifications:

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/fuse: 2.5mm² (14awg) / 12-15A
- Recommended Output cable/fuse: 2.5mm² (14awg) / 12-15A
BB1215 (Not detailed in specs table, but listed in part nos): Likely similar to BB1210/BB1225 in form factor, with an intermediate current rating.
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/fuse: 4.0mm² (12awg) / 25A
- Recommended Output cable/fuse: 4.0mm² (12awg) / 25A
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/fuse: 6mm² (10awg) / 30A
- Recommended Output cable/fuse: 6mm² (10awg) / 30A
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/fuse: 4.0mm² (12awg) / 25A
- Recommended Output cable/fuse: 4.0mm² (12awg) / 25A
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/fuse: 16mm² (6awg) / 80A
- Recommended Output cable/fuse: 16mm² (6awg) / 80A
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/fuse: 16mm² (6awg) / 80A
- Recommended Output cable/fuse: 6mm² (10awg) / 40A
BB124865:
- Input voltage range: 9V-16V / 18V-32V (12V and 24V IN)
- 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/fuse: 16mm² (6awg) / 80A
- Recommended Output cable/fuse: 4mm² (12awg) / 20A
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/fuse: 35mm² (2awg) / 150A
- Recommended Output cable/fuse: 35mm² (2awg) / 150A
BB1224120:
- Input voltage range: 9V-16V / 18V-32V (12V and 24V IN)
- 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/fuse: 35mm² (2awg) / 150A
- Recommended Output cable/fuse: 16mm² (6awg) / 80A
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/fuse: 35mm² (2awg) / 150A
- Recommended Output cable/fuse: 6mm² (10awg) / 40A
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/fuse: 70mm² (00awg) / 250A
- Recommended Output cable/fuse: 70mm² (00awg) / 250A

Usage Features:

Battery Type Selection: Users can select from various battery types (Lead I, Lead II, AGM I, AGM II, Lithium I*, Lithium II*) to match their leisure battery, ensuring optimal charging profiles. Lithium profiles disable voltage compensation from the temperature sensor and stop charging if the sensor detects 0°C or lower.
Bidirectional Charging: The chargers support reverse charging, allowing the leisure battery to charge the input battery when the output battery voltage exceeds a certain threshold (e.g., >13.5V for 12V systems). This feature can be disabled if not desired.
Engagement Modes:
- Automatic Mode (Default): Activates when input voltage is >13.5V and turns off below 12.8V.
- Ignition Feed Mode: Controlled by a 12V ignition signal (5V-32V live turns unit on, 0V turns off). Recommended for Euro 6 smart alternators. Operates down to 11.0V input.
- Vibration Sense Mode: Activates after detecting two vibration events. Overrides ignition signal, useful for smart alternators without an ignition feed. Monitors input battery voltage to prevent excessive discharge.
Temperature Sensor (TEMP1): Included with the charger. Connects to the negative terminal of the output battery. In Lead or AGM settings, it compensates charge voltage based on temperature. In Lithium settings, it disables charging if the battery temperature is 0°C or lower.
Jump Start Assist: Manually forces reverse charge by pressing the Select button four times.
Fault Indication: A dedicated fault LED illuminates if a problem is detected, guiding users to the troubleshooting section of the manual.
Remote Control (BBR): An optional accessory that provides a display for monitoring charge status, output voltage, and current. It allows users to configure settings such as battery type, EQ mode (desulphation for lead-acid), float on/off (for lithium), ignition mode, backlight timer, and current limits (65%, 85%, or 100%). It also supports user-defined charge profiles (absorption voltage, float voltage, absorption time).
Parallel Operation: Multiple chargers can be combined to increase output capabilities, either by using busbars or wiring them individually.
Voltage Conversion: The manual provides guidance for 24V and 48V systems, instructing users to multiply 12V nominal values by 2 or 4, respectively, for appropriate thresholds.

Maintenance Features:

General Maintenance: The device should be switched off and all cables removed during maintenance. Only original parts should be used for repairs. Connections should be kept clean and tight to prevent humidity and water ingress.
Installation Guidelines: Emphasizes the importance of correct installation, common negative connections, appropriate cable sizing, and fusing to ensure safe and efficient operation.
Troubleshooting Guide: A comprehensive section detailing common problems, possible causes, suggested solutions, and recovery conditions for issues like low output voltage, input voltage problems (especially with Euro 6 vehicles), and fault indications (e.g., over voltage, over temperature, fan fault).
Warranty: Sterling Power products come with at least a 2-year limited factory warranty covering material and workmanship defects. Warranty is voided by unauthorized modifications or negligent repairs.