Analytic Systems BCD315MW User manual

INSTALLATION &

OPERATION MANUAL

101-8128 River Way, Delta B.C. V4G 1K5 Canada T. 604.946.9981 F. 604.946.9983 TF. 800.668.3884 (US/CANADA)

www.analyticsystems.com

An ISO9001:2015 Registered Company Battery Chargers •Inverters •Power Supplies •Voltage Converters

BCD315MW &

BCD315MY

DC-SOURCE

BATTERY CHARGER

SAVE THESE INSTRUCTIONS — This manual contains important safety and operating

instructions for the battery charger.

BATTERY CHARGER PRECAUTIONS

1. Do not expose the battery charger to rain or snow unless it is a sealed model.

2. Use of an attachment not recommended or sold by the battery charger manufacturer may

result in a risk of re, electric shock, or injury to persons.

3. Do not disassemble the battery charger; return it to the manufacturer or an authorized

service center when service or repair is required. Incorrect reassembly may result in a risk

of electric shock or re. Voltages in excess of 350 volts are present inside the charger any

time it is plugged into a power source, even if it is switched off.

4. To reduce risk of electric shock, unplug the battery charger from the power source before

attempting any maintenance or cleaning. Turning off controls will not reduce this risk.

5. Never place battery charger directly above battery; gases from battery will corrode and

damage battery charger.

6. Never allow battery acid to drip on to the battery charger.

1. WARNING — RISK OF EXPLOSIVE GASES

i. WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES

GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS

REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE SERVICING

EQUIPMENT IN THE VICINITY OF THE BATTERY, YOU READ THIS USER GUIDE AND

FOLLOW THE INSTRUCTIONS EXACTLY.

ii. To reduce risk of battery explosion, follow these instructions and those published by

the battery manufacturer and manufacturer of any equipment you intend to use in

vicinity of battery. Review the cautionary marking on these products.

2. PERSONAL PRECAUTIONS

i. Someone should be within range of your voice or close enough to come to your aid

when you work near a battery.

ii. Have plenty of fresh water and soap nearby in case battery acid contacts skin,

clothing, or eyes.

iii. Wear complete eye protection and clothing protection. Avoid touching eyes while

working near battery.

DC SOURCE BATTERY CHARGER

IMPORTANT SAFETY INSTRUCTIONS

BATTERY SAFETY

MEDICAL EQUIPMENT NOTICE

Analytic Systems does not recommend the use of their products in life support

applications where failure or malfunction of the product can be reasonably

expected to cause failure of the life support device or to signicantly affect its

safety or effectiveness. Analytic Systems does not recommend the use of any of

its products in direct patient care.

Examples of devices considered to be life support devices are neonatal oxygen

analyzers, nerve stimulators (whether used for anesthesia, pain relief, or other

purposes), auto-transfusion devices, blood pumps, debrillators, arrhythmia

detectors and alarms, pacemakers, hemodialysis systems, peritoneal dialysis

systems, neonatal ventilator incubators, ventilators for both adults and infants,

anesthesia ventilators, and infusion pumps as well as any other devices

designated as “critical” by the U.S. FDA.

iv. If battery acid contacts skin or clothing, wash immediately with soap and water. If

acid enters eye, immediately ood eye with running cold water for at least 10

v. NEVER smoke or allow a spark or ame in the vicinity of a battery.

vi. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark

or short-circuit the battery or other electrical part that may cause a re or explosion.

vii. Remove personal metal items such as rings, bracelets, necklaces, and watches

when working with a lead-acid battery. A lead-acid battery can produce a short-

circuit current high enough to melt metal, causing a severe burn.

viii. NEVER charge a frozen battery.

ix. If it is necessary to remove a battery from service, always remove grounded terminal

from battery rst. Make sure all accessories connected to the battery are off, to

prevent an arc when reconnecting the new battery.

x. Be sure area around battery is well ventilated.

xi. Clean the battery terminals. Be careful to keep corrosion from coming in contact

with eyes.

xii. Study all the battery manufacturer’s specic precautions such as removing or not

removing cell caps while charging and recommended rates of charge

TABLE OF CONTENTS

• Front Cover, Product Photo and Title

• Product warnings and advisories

• Table of Contents

• Introduction/Box Contents

• Main Parts

• Operation/Operational Indicators

• Charging Proles

• Connections

• Installation

• Battery Temperature Sensor/Equalize Cycle

• Troubleshooting

• Specications

• Special Services and Options

• Warranty

Revised - Aug 9, 2023

Introduction

The BCD315MW is a C.O.T.S DC-source battery charger designed to provide up to 300 watts

of precision charging power to a one or two bank battery system at 12, 24, 32, 36, or, 48 VDC.

The batteries must share a common ground.

The updated single board design incorporates state-of-the-art switch- mode technology for

unmatched efciency and ultra-quiet operation. In the absence of a battery, this unit can also

be used as a DC-DC voltage converter up to the continuous current rating.

The BCD315MW features expanded operating temperature, MIL-spec connectors, and

military-grade shock and vibration protection. Additionally, this unit is sealed to meet the IP66

rating (IP67 certication is available as an option for this product line)

Safety features include over-temperature shutdown, current limiting, short circuit protection

with automatic recovery, input under voltage shutdown, output over-voltage protection and

battery reverse connection protection. Extra features include visual indicators for low input

voltage, charging and overtemperature, dry contact output fail output and remote control

connection.

Box Contents

The box you have received should contain the following:

• One BCD315MW or BCD315MY DC-DC Battery Charger

• One Waterproof Battery Temperature Sensor (BTEMP-W)

• This Manual

• One Warranty Card

If anything is missing or damaged please contact your dealer or Analytic Systems for a replacement

6 7

Main Parts

1. Indicator LEDs

2. Battery Temperature Sensor Connection

3. Output Fuse

4. DC Output Connection

5. Output Voltage Adjust

6. Equalize Cycle Start Button

7. Charging Prole select switch

8. Power Switch

9. Input Fuse

10. DC Input Connection

FRONT PANEL

6 7

Operation

This battery charger is designed for simple operation. Before operating, the unit must be

properly installed and connected. See Installation for more information regarding mounting

and connections.

TO CHARGE A BATTERY

1. Choose which type of charging prole will be used during charging by moving the Stage

Select switch. See Charging Proles for more information about two-stage and three-

stage charging.

2. Move the power switch to ON. The alarm buzzer will sound and the LOW VOLTAGE

OUTPUT LED will glow red briey, then the POWER LED will glow green. This is normal.

3. The CHARGING LED will glow green indicating normal operation. The unit will

automatically charge the connected battery until it is fully charged. This may take several

hours.

4. When the battery is fully charged, the CHARGING LED will turn off. The unit will maintain

the battery at full charge for as long as it is connected.

TO ADJUST THE CHARGING (FLOAT) VOLTAGE

1. Disconnect the battery temperature sensor(s) from the unit, if in use.

2. Locate the Output Voltage Adjustment potentiometer on the front panel. On some units,

this is covered by a protective cap to prevent accidental operation.

3. Rotate the knob to adjust the charging voltage. The charging (oat) voltage can be

adjusted over a range of ±1.0 volts.

4. Rotate the potentiometer clockwise to increase the charging voltage; counterclockwise

to decrease the voltage.

5. Using a multimeter, read the charging voltage at the battery terminal. On units with the

optionall digital multimeter, that can be used to read the voltage instead.

6. When satised with the new voltage reading, return the protective cap in place and

reconnect the battery temperature sensor(s) if needed.

TO END OPERATION

1. Move the power switch to OFF.

2. Wait for all the Indicator LEDs stop glowing.

3. It is now safe to disconnect the unit from the power source and battery. The unit is now

ready for storage or service.

8 9

POWER ON

This LED glows green when the unit is connected to an AC power source and turned ON.

CHARGING

This LED glows green when the unit is charging a battery. This LED turns off when the

connected battery is fully charged. The charger will maintain the battery at full charge for as

long as it is connected.

OVERTEMP

This LED glows red if the unit’s internal temperature is above the safe limit, the unit will then

turn off its output as a precaution. If the internal temperature returns to the safe operating

range, the unit will automatically resume operation.

UNDERVOLTAGE OUTPUT

This LED glows red if the unit detects the output voltage is too low for proper operation, the

unit will then shut off its output as a precaution. If the unit detects the output voltage return

to normal operating range, it will automatically resume operation.

UNDERVOLTAGE INPUT

This LED glows red if the unit detects the the input voltage is too low for proper operation, the

unit will then shut off its output as a precaution. If the unit detects the input voltage return the

normal operating range, it will automatically resume operation.

EQUALIZE

BATTERY TEMPERATURE SENSOR MUST BE INSTALLED TO USE THIS FUNCTION.

This LED glows red when the unit is performing an equalize cycle. This LED blinks red when

the unit is waiting for a battery to nish charging before performing an equalize cycle.

BATTERY OVERTEMP

BATTERY TEMPERATURE SENSOR MUST BE INSTALLED TO USE THIS FUNCTION.

This LED glows red when the battery’s temperature is above the safe limit, the unit will then

turn off its outputs as precaution. If the battery temperature returns to the safe operating

range, the unit will automatically resume operation.

Operational Indicators

This unit’s top panel features seven indicator LEDs on its front panel to display the unit’s

operating condition. The meanings of these LEDs are detailed below. For more information

regarding the malfunctions these LEDs can indicate and how to correct them, see

Troubleshooting.

8 9

Charging Proles

This unit has both two-stage and three-stage charging capability. You can choose which type

of charging is used during operation by using the Stage Select switch located on the front

panel. Below are explanations of the two charging proles:

1. The battery is charged at constant

current until the battery’s voltage

reaches the oat voltage.

2. The charging current diminishes as

necessary to maintain the battery at

that voltage.

TWO-STAGE CHARGING

Two-stage charging eliminates any risk of

overcharging the battery if it is connected to

a load while being charged.

THREE-STAGE CHARGING

1. The battery is charged at constant

current until the battery voltage

reaches the absorption voltage.

2. Then the charging current diminishes

as necessary to maintain the battery

at that voltage.

3. Once the charging current drops

below 10% of the rated output,

the charging cycle is complete. The

charger then switches to the oat

voltage to maintain the battery at

full charge.

Three-stage charging is more complete than two-stage, but the charging current must drop

below 10% of the rated output current of the charger for the Absorption Mode to terminate.

For that reason, three-stage charging is not recommended for charging loaded batteries

because the unit cannot differentiate between current going to a load connected to the

battery and current being absorbed by the battery, which may cause overcharging.

10 11

Connections

INPUT CONNECTION

The DC Input connection is intended for connection to the DC power source that is powering

the battery charger.

This unit is equipped with an Amphenol Industrial Circular MIL-spec GTS02R16-11P connector

to serve as a DC input connection. This connector’s pin-out is as follows:

Pin Function

A Positive 1

B Negative

C Negative

D Positive 2

OUTPUT CONNECTION

The DC Output connection is intended for connection to the batteries being charged. This unit

is equipped a Amphenol Industrial Circular MIL-spec GTS02R-14S-2S (027) connector to serve

as a DC Output connection. This connector’s pin-out is as follows

The charger may be used to charge to either one or two battery banks simultaneously. If

charging two battery banks keep in mind that they MUST share a common ground! If charging

only a single bank, it is recommended you connect it to both outputs in parallel to reduce

stress on the output isolation diodes inside the charger.

Pin Function

A Positive

B Negative

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