Analytic Systems BCD1000 Series User manual

INSTALLATION &
OPERATION MANUAL
BCD1000 SERIES
Battery Charger
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 and AS9100 Registered Company Battery Chargers •Inverters •Power Supplies •Voltage Converters

Copyright (2005-2016) Analytic Systems Ware (1993) Ltd.
Revised - May 19, 2016

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IMPORTANT & SAFETY INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS — This manual contains important safety and operating
instructions for battery charger
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.
5. To reduce risk of electric shock, unplug battery charger from outlet before attempting any
maintenance or cleaning. Turning off controls will not reduce this risk.
6. Never place battery charger directly above battery; gases from battery will corrode and
damage battery charger.
7. Never allow battery acid to drip on battery charger when reading gravity or lling battery.
8. O/P CONNECTION PRECAUTIONS
Connect and disconnect DC output connections only after setting the I/P power switch to
off position.
ALL BATTERY CHARGERS
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 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,
clothing, 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.

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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-circuit
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 in the vessels are off, 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. This helps purge excessive gas from cells. Do not overll. For a battery
without cell caps, carefully follow manufacturer’s recharging instructions.
Analytic Systems does not recommend the use of the BCD1000 Series Battery Chargers in life
support applications where failure or malfunction of this 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), autotransfusion
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.

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Introduction
All new Current Mode switching design offers increased power and reliability in a compact
package. Extra input and output ltering reduce EMI to extremely low levels. Reliability
features include an input fuse, thermal shutdown, current limiting, reverse battery hookup
protection and output short circuit shutdown with automatic recovery. The output voltage is
easily adjusted 1.0 volts above or below the standard output voltage. The model BCD 1000
Battery Charger supplies either 12, 24, 32 or 48 VDC from a 72, 110, 250 or 300 VDC power
source. High quality digital meters can be added (factory option) to allow monitoring of
charging current and charging voltage.
Specications
Input Voltages
Nominal (ip) 110 250 300
Actual (Vdc) 100 - 140 230 - 280 280 - 360
Input Amps (max) 14.8 6.5 5.3
Input Fuse (slow blow) MDA-15 MDA-7 MDA-6
Output Voltages
Nominal (op) 12 24 32 48
Float (Vdc) 13.6 ± 0.05 27.2 ± 0.05 36.3 ± 0.05 54.4 ± 0.05
Absorption Voltage (Vdc) 14.4 28.8 38.4 57.6
Charging Amps 60 40 30 20
Absorption to Float 9 Amps 6 Amps 4.5 Amps 3 Amps
Battery Size (Amp Hour)* 240 – 360 160 – 240 120 – 180 80 - 120
Output Fuse (ATC) 40 x 2 40 x 2 40 x 2 25 x 2
Battery Banks 1 or 2 1 or 2 1 or 2 1 or 2
Output Adjust ± 1.0 Volts
Output Crowbar 16.0 ± 0.5 V 32.0 ± 1.0 V 43.7 ± 1.3 V 63.9 ± 2.0 V
Equalize Voltage (Vdc) 15.5 31 41.3 62
Temperature Compensation Coefcient -30mV / oC -60mV / oC -80mV / oC -120mV / oC

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* This is Analytic Systems’ suggested range. Please consult your battery manufacturer for their recommendations.
* Specications subjects to change without notice.
Installation
MOUNTING
Mount the unit in a DRY location. Allow at least 4 inches of clearance around the heat sink
ns for adequate cooling.
POWER CONNECTION
The unit is supplied with power leads about 3 feet long. This should normally be adequate to
connect to a source of power. If you must extend the power leads, be sure to use at least a
good quality (typeTEW) AWG8 wire. The wire colours are:
All connections should be made inside an appropriate junction box. Refer to the specications
table for the correct sizing of the circuit breaker in the distribution panel.
Red - Positive Black- Negative
Designed and manufactured by: ANALYTIC SYSTEMS WARE (1993) LTD.
8128 River Way
Delta, BC V4G 1K5 Canada
p. 604.946.9981 f. 604.946.9983
tf. 800.668.3884 US/Canada
www.analyticsystems.com [email protected]
General
Efciency > 80 % @ maximum output
Stages 2 or 3
Temp. Range -25 to +40o C @ maximum output
Isolation Input-Output & Input-Case 1500 Vdc
Output-Case 500 VDC (1500Vdc @ 48 V Out)
Length 14.5 in / 36.8 cm
Width 9.9 in / 25.1 cm
Height 5.5 in / 14.0 cm
Clearance 1 Inch (2.5 cm) all around
Material Marine Grade Aluminum
Finish Black Anodize / Black Powder Epoxy
Fastenings 18-8 Stainless
Weight 12 lb / 5.5 kg

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Operation
Prior to turning on the unit, you must decide on which charging prole, 2 or 3 stage charging,
to use. To help you decide, please see the following section entitled 2 or 3 Stage Charging to
determine the charging prole.
Once you have decided on the charging prole you must set the switch to the correct position.
To access the switch remove the cover plate (secured by 2 screws). Set the switch to the
correct position as shown on the label. When you are done, replace the cover plate and
securely tighten the screws.
To turn the unit on, simply move the power switch to the ON position. The alarm buzzer will
sound and the Low Output LED will come on briey, and then the green OUTPUT ON LED will
illuminate.
When the unit is rst turned on, it will charge the batteries at a constant current and the
charging light will be on. After a period of time, which may be minutes to hours, the batteries
will reach the oat voltage at which time the charging light will go off, and the charging
current will reduce as necessary to maintain the batteries at that voltage. You may check this
OUTPUT CONNECTIONS
Two Positive output terminals and two Negative output terminals are provided. Connect only
one wire to each terminal. Ensure that the total average load connected does not exceed the
continuous current rating of the unit.
To ensure spark free connections the power switch must be in the OFF position prior to making
the connections to the battery bank(s).
The unit may be hooked to 1 or 2 battery banks. Hook up the battery bank(s) as shown below.
If you are hooking up 2 battery banks keep in mind that they MUST share a common ground!
If you are going to hook up one battery to a 12Vdc charger, you must hook up the outputs in
parallel as shown below in the left hand drawing!
OUTPUT 1 OUTPUT 1
OUTPUT 2 OUTPUT 2
BATTERY
BANK #1
BATTERY
BANK #1
BATTERY
BANK #2
High quality digital meters can be added to the charger (factory installed only). Both outputs
can be monitored for current and voltage.
Meters

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This charger features user selectable 2 or 3 stage charging. The charging prole is selected by
moving the slide switch on the front panel up to 3 stage or down for 2 stage charging.
A two-stage charger provides a constant current until the battery reaches its rated capacity
and then switches to a “oat” voltage. The current then reduces as necessary to maintain
the battery at the oat voltage. The charger can be connected to the battery indenitely and
will provide the appropriate prole. A two-stage charger is recommended in most instances
since it is the most versatile and can be permanently connected to attenuate the characteristic
discharge of unused batteries. A load can be put on the battery or batteries without altering
its ability to keep the battery at optimal charge.
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Float
(Constant Volts)
Time
Two Stage Charge
Volts
Amps
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Absorption
(Constant Volts)
Float
(Constant Volts)
Time
Three Stage Charge
Volts
Amps
2 or 3 Stage Charging
voltage at the output terminals of the unit with a good digital voltmeter. As shipped from the
factory, the unit is preset to 13.6, 27.2, 36.3 or 54.4 VDC, which is generally recommended for
lead-acid batteries. If you wish to adjust the charging voltage, remove the cover plate (secured
by 2 screws) to expose the output adjust potentiometer. Reach in with a very small at blade
screwdriver to rotate the potentiometer. Please note that this adjusts both the oat and
absorption voltages at the same time. Clockwise increases the output voltage, and counter
clockwise decreases it. When you are done, replace the cover plate and securely tighten
the screws. It is advisable to check with the battery manufacturer before changing the oat
voltage.

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A three-stage charger is the fastest charger. It charges the battery at a constant current
until the battery voltage reaches a slightly elevated level. The battery is maintained at
this voltage while the charging current diminishes to a low value, and then the battery is
switched to the oat voltage where it can be maintained indenitely. However, the charger
cannot differentiate between a current going to a load on the battery, or being absorbed by
the battery, so it can overcharge a battery supplying current to a load. A two-stage charger
is preferred for “loaded” batteries and a three-stage for idle or unloaded batteries during
recharging.
All of Analytic Systems’ chargers include adjustable output voltage for charging standard or
deep cycle lead-acid, VLRA or gel type batteries.
Troubleshooting
This unit provides LED indicators and a buzzer to help diagnose any problems. The unit should
sound the buzzer to alert you prior to shutting itself down. You should immediately check the
indicators to determine the cause of the shutdown.
CHARGING Indicates that the battery charger is charging the batteries:
If the LED is not on, the batteries may be fully charged and the charger is
supplying a oat voltage to the batteries to keep them fully charged.
LOW OUTPUT Indicates that the output voltage is below normal because:
The current demanded by the devices connected to the unit exceeds the
maximum output current rating, causing the output voltage to drop to
maintain the current at the maximum level,
The input voltage is not high enough for unit to operate,
LOW INPUT Indicates that the input voltage is below normal because:
The input voltage is not in the correct range for proper operation of the unit.
OVER HEAT Indicates that the Battery Charger is running too hot because:
Too much power is being drawn, turn off or unplug some devices.
The Battery Charger is located in a poorly ventilated area.
If the load exceeds the continuous rating for too long a period, the temperature sensor inside
the unit will turn off the outputs. After the unit cools sufciently, it will automatically come
back on. If this happens frequently, remount the unit for increased airow so it cools better.

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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 10 in the remote connector diagram.
The 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 off the unit and move the jumper to the other
position on J22. J22 is located next to the relay.
To change the position of the jumper, rst turn the unit off 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 off again. Remove the eight screws holding on the cover. Turn the unit upside
down, remove the cover and locate J22. 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 eight screws. Reconnect the unit to the power and
batteries.
BATTERY TEMPERATURE SENSORS
Up to 2 battery temperature sensors can be connected to the charger to allow temperature
compensation of the battery charging voltage (1 is supplied with the unit). If only the 1 sensor
is used, it MUST be plugged into the ‘BATT 1’ connection on the side of the unit. If no sensor
is used, the charger will default to standard output voltage.
For installation instructions of the temperature sensor, please see the section entitled
Remote Battery Temperature Sensor Installation.
Dry Contact Relay

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Remote Control Option
A remote control panel may be connected to the battery charger using a 9-pin D-connector,
which attaches to the side of the battery charger. The remote control panel and D connector
are part of the remote control option. The remote control panel allows the unit to be operated
remotely as well as duplicating all the diagnostic indicators and audible alarm.
REMOTE CONNECTOR
This 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: This remote is to be used
only on Battery Chargers manufactured by
Analytic Systems.

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The purpose of the Equalize Option is to deliberately overcharge the battery at a low rate of
current to ensure that all cells are fully charged and to reduce the chance of sulfation of the
battery. During the Equalize cycle, the cells, which are fully charged, will produce Hydrogen
gas, and the cells, which are undercharged, will be brought up to full charge. An Equalize
cycle should be done once every 2-3 months, or whenever battery capacity appears to be
diminished. The Equalize Option also includes a battery temperature sensor to compensate the
charging voltage for battery temperature, as well as to shut the charger down if the battery
should become overheated. A 2nd temperature sensor can be added to allow monitoring of
both batteries if the charger is connected to 2 banks of batteries.
An Equalize cycle can be initiated at any time by simply pressing the equalize start button
located next to the ON/OFF switch. This button is deliberately recessed to prevent accidental
operation. It is most easily pressed by using a ballpoint pen. If the charger is in the middle
of charging the battery (the Charging LED is on), the Equalize LED will ash. Once the main
charging cycle is complete, the Equalize cycle will begin and the Equalize LED will stay on all
the time. If the Charging LED is off when the button is pressed, the Equalize cycle will begin
immediately.
The charger will charge the battery at approximately 10% of its normal rate (i.e. 4 amps for
a 40 amp charger) until the battery reaches equalize voltage and then the current reduces as
necessary to maintain the battery at that voltage. Three hours after the Equalize cycle begins,
the charger will return to the oat mode where the battery can be maintained indenitely. If
the battery temperature reaches 120 degrees F (50 degrees C) the equalize cycle will end and
the charger output reduced to a very low voltage until the battery cools, and then the charger
will return to the oat mode.
Remote Battery Temperature Sensor Installation
The remote battery temperature sensor allows the monitoring of the battery bank so that
the charging prole can be adjusted to optimally charge the battery bank depending on the
temperature of the battery bank. NOTE: The temperature sensor must be used during an
equalize cycle or damage to the battery may occur.
The battery temperature sensor may be installed in many different ways, so long as the sensor
stays in contact with the battery. The preferred method is as follows:
The batteries to be charged will be placed on a platform made of wood. Prior to placing the
batteries on the wooden platform a cavity is hollowed out such that the sensor will t inside
the cavity and be ush with the battery. Place the sensor inside the cavity facing the proper
way (this is shown on the sensor). Next connect the sensor wiring to the telephone jack
marked “Batt 1” on the side of the unit. Note: If there is only one temperature sensor, it gets
Equalize Option

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plugged into “Batt 1”. If there is a second temperature sensor, it should be plugged into to the
phone jack labeled “Batt 2”.
If a battery blanket is used the sensor may be tucked inside the blanket with the proper side of
the sensor facing the battery. The sensor may be placed on top of the battery but it should be
secured to the battery so as to prevent it from losing contact with the battery.
Battery Charger Temperature Compensation
The charger is calibrated with the sensor input preset to 77 degrees (25 degrees C). For
example, for a 12V battery, this voltage is 13.6 volts, and 27.2 volts for a 24V battery. See the
specications for the temperature compensation coefcient.

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Limited Warranty
1. The equipment manufactured by Analytic Systems Ware (1993) Ltd. (the “Warrantor”) is warranted to be free
from defects in workmanship and materials under normal use and service.
2. This warranty is in effect for:
a. 3 Years from date of purchase by the end user for standard products offered 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. The date of shipment by Analytic Systems, or
b. The 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 Purchasers 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 different 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. The defect is the result of misuse, neglect, improper installation, environmental conditions, non-autho-
rized 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 after having a reasonable number of opportunities to do so.
8. Only the Warrantor shall perform warranty service. Any attempt to remedy the defect by anyone else shall
render this warranty void.
9. There shall be no warranty for defects or damages caused by faulty installation or hook-up, abuse or misuse of
the equipment including exposure to excessive heat, salt or fresh water spray, or water immersion except for
equipment specically stated to be waterproof.
10. No other express warranty is hereby given and there are no warranties that extend beyond those described
herein. This warranty is expressly in lieu of any other expressed or implied warranties, including any implied
warranty of merchantability, tness for the ordinary purposes for which such goods are used, or tness for a
particular purpose, or any other obligations on the part of the Warrantor or its employees and representatives.
11. There shall be no responsibility or liability whatsoever on the part of the Warrantor or its employees and rep-
resentatives for injury to any person or persons, or damage to property, or loss of income or prot, or any other
consequential or resulting damage which may be claimed to have been incurred through the use or sale of the
equipment, including any possible failure of malfunction of the equipment, or part thereof.
12. The Warrantor assumes no liability for incidental or consequential damages of any kind

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 and AS9100 Registered Company Battery Chargers •Inverters •Power Supplies •Voltage Converters