Analytic Systems BCD605 User manual

Installation &

Operation Manual

BCD605

DC Battery Charger

8128 River Way, Delta B.C. V4G 1K5 Canada T. 604.946.9981 F. 604.946.9983 TF. 1.800.668.3884 (US/CANADA)

www.analyticsystems.com

IMPORTANT & SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS — is manual contains important safety and operating instructions for the

battery charger.

ALL BATTERY CHARGERS

1) CAUTION — To reduce risk of injury, charge only lead acid or sealed gel cell type rechargeable

batteries. Other types of batteries may burst causing personal injury and damage.

2) Do not expose battery charger to rain or snow.

3) 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.

4) Do not disassemble battery charger; take it to a qualied serviceman when service or repair is

required. Incorrect reassembly may result in a risk of electric shock or re.

6) To reduce risk of electric shock, disconnect battery charger from batteries and AC supply

before attempting any maintenance or cleaning. Turning o controls will not reduce this risk.

DC BATTERY CHARGERS

1) WARNING — RISK OF EXPLOSIVE GASES.

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

TERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERA-

TION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH

TIME BEFORE SERVICING EQUIPMENT IN THE VICINITY OF THE BATTERY,

YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.

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

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

vicinity of battery. Review cautionary marking on these products and on engine.

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 lead-acid battery.

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

ing, or eyes.

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

working near battery.

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 minutes

and get medical attention immediately.

v) NEVER smoke or allow a spark or ame in vicinity of battery or engine.

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

spark or short-circuit battery or other electrical part that may cause 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-cir-

cuit current high enough to weld a ring or the like to metal, causing a severe burn.

viii) NEVER charge a frozen battery.

ix) If necessary to remove battery from service, always remove grounded terminal

from battery rst. Make sure all accessories are o, so as not to cause an arc.

x) Be sure area around battery is well ventilated.

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

eyes.

xii) Study all battery manufacturer’s specic precautions such as removing or not

removing cell caps while charging and recommended rates of charge.

xiii) Add distilled water in each cell until battery acid reaches level specied by battery

manufacturer. is helps purge excessive gas from cells. Do not overll. For a battery

without cell caps, carefully follow manufacturer’s recharging instructions.

3) BATTERY CHARGER LOCATION

i) Never place battery charger directly above battery; gases from battery will corrode

and damage converter.

ii) Never allow battery acid to drip on battery charger when reading gravity or lling

battery.

4) DC CONNECTION PRECAUTIONS

i) Connect and disconnect all DC connections only aer setting battery

charger switch to o position.

Analytic Systems does not recommend the use of the BCD605 Series Battery Chargers in life support ap-

plications where failure or malfunction of this product can be reasonably expected to cause failure of the life

support device or to signicantly aect its safety or eectiveness. 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), autotransfusion devices, blood pumps, debrilla-

tors, arrhythmia detectors and alarms, pacemakers, hemodialysis systems, peritoneal dialysis systems, neona-

tal 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.

Introduction

is all new single board design incorporates state of the art switchmode technology for unmatched

eciency and ultra-quiet operation. Multiple stages of ltering reduce radiated or conducted noise to very

low levels. Extra features include adjustable output voltage, audible and visual indicators for low input

voltage, low output voltage and over temperature. Safety features include reverse input protection, over-

temperature shutdown, current limiting, short circuit protection with automatic recovery, input undervoltage

shutdown, reverse battery protection and output overvoltage crowbar. Optional features include a dry

contact alarm relay output, and remote panel monitoring with On/O control.

We are condent that you will get many years of reliable service from this DC Battery Charger.

Designed and manufactured by: ANALYTIC SYSTEMS WARE (1993) LTD.

8128 River Way, Delta, B.C., V4G 1K5, Canada

phone (604) 946-9981 fax (604) 946-9983 toll free 800-668-3884 US/Canada

email: analyticinfo@analyticsystems.com web site: www.analyticsystems.com Revised May 2005

* Specications subjects to change without notice.

* is is Analytic Systems’ suggested range. Please consult your battery manufacturer for their recommendations.

◆ e Actual charging rate depends upon the input/output voltage ratio. To obtain the charging capacity at any given input

voltage, use the following formula:

Charging Current = Input Volts/Output Volts x 40

For example, at 10.5VDC in and 13.6VDC out, the charging current = 10.5/13.6 x 40 = 30.8 amps

Specications

Model BCD605-12-12 BCD605-12-24

Input Volts (DC) 10.5 - 14 10.5 - 28

Input Amps (max) 50

Output Volts (DC) 13.6 ± 0.5 V 27.2 ± 0.5 V

Charging Amps ◆ 42 ◆ 21

Output Crowbar Output Volts x (1.3 ± 1%)

Input Fuses AGC 30 x 2 Amp

Output Fuses AGC 25 x 2 Amp

Low Input Voltage Alarm 10.5 VDC

Low Output Voltage Alarm Output Voltage minus 2.5 VDC

Battey Banks 1 2 (Only if the input voltage < 15 Vdc)

Stages 2

Battery Size (Amp Hours)* 168 - 252 84 - 126

Transient Response < 1V for 15A Surge

Eciency > 85 % @ maximum output

Temperature Range -25 to +40 deg° C @ maximum output

Isolation Any Input or Output to Case 500VDC

Input to Output Common Negative

Length 9.1 in / 23.1 cm

Width 7.8 in / 19.8 cm

Height 4.3 in / 10.8 cm

Clearance 1 Inch (2.5 cm) all around

Material Marine Grade Aluminum

Finish Black Powder Epoxy

Fastenings 18-8 Stainless

Weight 6.0 lb / 2.7 kg.

Installation

◆ MOUNTING

Mount the unit in a DRY location. Allow at least 1 inch of clearance for adequate cooling.

◆ POWER CONNECTION

The unit is supplied with three foot power input leads. This should normally be adequate to connect to a

source of power. If you must extend the cable:

• Usethesmallestextensionlengthpossible.

• Usenolessthan10gaugeconductors.

• Spliceandsolderthejoints.

• Protectthejointswithheatshrinktubing.

Connect the wires as follows:

• RedtoPositive

• BlacktoNegative

◆OUTPUT CONNECTIONS

Two positive output terminals and two negative output terminals are provided. Connect only one wire to

each terminal. A jumper externally connects the positive terminals of the BCD605-12-24. This jumper may

be removed and the BCD605-12-24 used as a dual bank charger if and only if the input voltage is less than 15

volts.

Note that the current specifications are for input current. To obtain the maximum output current capability

at any given input voltage, use the following formula:

Output Current = Input Volts / Output Volts x 40

For example:

11 VDC in and 27 VDC out, the max output current = 11/27 x 40 = 16.3 Amps.

20 VDC in and 27 VDC out, the max output current = 20/27 x 40 = 29.6 Amps

Each output terminal can supply up to 25 Amps, therefore do not connect more than 25 amps of load to

either output terminal. If the load exceeds 25 Amps but not the continuous rated output of the unit, do the

following: The output terminals must be connected to the load in parallel ensuring that the wiring used has

sufficient capacity to handle the current.

Please NOTE:

e BCD605-12-12 is a single bank charger ONLY and must be hooked up as shown in the drawing above!

e BCD605-12-24 may be used as a dual bank charger if the input voltage is less than 15 volts! If the input is

greater than 15 volts the unit must be hooked up as shown in the drawing above!

Operation

Turn the power switch on the front of the unit on to energize the outputs.

If you wish to adjust the output voltage, rst attach a good digital voltmeter to the output terminals to moni-

tor the voltage. Next, remove the cover plate (secured by 2 screws) to expose the output adjust potentiom-

eter. Reach in with a very small at blade screwdriver to rotate the potentiometer. Clockwise increases the

output voltage, and counter clockwise decreases it. When you are done, replace the cover plate and securely

tighten the screws. Remove the voltmeter from the output terminals.

• If the load exceeds the continuous rating for too long a period, the internal temperature sensor will

cause the unit to stop boosting the input voltage until the unit has cooled down. Aer the unit has

cooled down, normal operation will resume.

• If the input voltage drops below the specied minimum input, the unit will sound the alarm.

• If the output voltage drops below the specied minimum, the unit will sound the alarm.

• If the current demanded by the devices connected to the unit exceed the maximum current rating, the

fuse will blow.

• If the fuse blows with no load connected, check that the power leads are connected to the battery with

the correct polarity; if they are then the unit is damaged and must be returned for repair.

Troubleshooting

Dry Contact Relay

To use your dry contact output fail relay you must connect a 9-pin D connector to the unit. You must use

pins one and six as is indicated on page 8 in the remote connector diagram.

e relay is factory preset to fail in the closed position when the low output LED and buzzer come on. If you

wish to have the relay fail in the open position when the low output LED and buzzer come on, you must take

the cover o the unit and move the jumper to the other position on J11. J11 is located next to the relay.

To change the position of the jumper, rst turn the unit o and disconnect the unit from both the power and

batteries. Next, turn the unit on for 30 seconds to discharge the capacitors, then turn it o again. Turn the

unit upside down and remove the four screws. Remove the cover and locate J11. It will be next to the relay

as is shown in the above diagram. Simply move the jumper to the desired position as is shown in the above

diagram. Replace the cover and re-install the four screws. Reconnect the unit to the power and batteries.

Remote Control Option

A remote control panel may be connected to the converter using a 9-pin D-connector, which attaches to the

side of the battery charger. e remote control panel and D connector are part of the remote control option.

e remote control panel allows the unit to be operated remotely as well as duplicating all the diagnostic

indicators and audible alarm.

REMOTE CONNECTOR

is connector is located on the side of the unit. Important: To prevent the possibility of High Voltage

Electrical Shock, do not power up the battery charger unless all wiring from the unit to the remote is securely

connected. Do not remove the dust cover from the DB-9 connector if the remote is not being used.

IMPORTANT: is remote is to be used only on Battery Chargers manufactured by Analytic Systems.

Limited Warranty

1. e equipment manufactured by Analytic Systems Ware (1993) Ltd. (the “Warrantor”) is war-

ranted to be free from defects in workmanship and materials under normal use and service.

2. is warranty is in eect for:

a. 3 Years from date of purchase by the end user for standard products oered in our

catalog.

b. 2 Years from date of manufacture for non-standard or OEM products

c. 1 Year from date of manufacture for encapsulated products.

3. Analytic Systems will determine eligibility for warranty from the date of purchase shown on the

warranty card when returned within 30 days, or

a. e date of shipment by Analytic Systems, or

b. e date of manufacture coded in the serial number, or

c. From a copy of the original purchase receipt showing the date of purchase by the user.

4. In case any part of the equipment proves to be defective, the Purchaser should do the following:

a. Prepare a written statement of the nature of the defect to the best of the Purchasers

knowledge, and include the date of purchase, the place of purchase, and the Purchas-

ers name, address and telephone number.

b. Call Analytic Systems at 800-668-3884 or 604-946-9981 and request a return material

authorization number (RMA).

c. Return the defective part or unit along with the statement at the Purchasers expense

to the Warrantor; Analytic Systems Ware (1993) Ltd., 8128 River Way, Delta, B.C.,

V4G 1K5, Canada.

5. If upon the Warrantor’s examination the defect proves to be the result of defective material or

workmanship, the equipment will be repaired or replaced at the Warrantor’s option without

charge, and returned to the Purchaser at the Warrantor’s expense by the most economical means.

Requests for a dierent method of return or special handling will incur additional charges and

are the responsibility of the Purchaser.

6. Analytic Systems reserves the right to void the warranty if:

a. Labels, identication marks or serial numbers are removed or altered in any way.

b. Our invoice is unpaid.

c. e defect is the result of misuse, neglect, improper installation, environmental condi-

tions, non-authorized repair, alteration or accident.

7. No refund of the purchase price will be granted to the Purchaser, unless the Warrantor is unable

to remedy the defect aer having a reasonable number of opportunities to do so.

8128 River Way, Delta B.C. V4G 1K5 Canada T. 604.946.9981 F. 604.946.9983 TF. 1.800.668.3884 (US/CANADA)

Table of contents

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