Analytic Systems BCD305 Series User manual

INSTALLATION &
OPERATION MANUAL
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 Registered Company Battery Chargers •Inverters •Power Supplies •Voltage Converters
BCD305 SERIES DC
SOURCE BATTERY
CHARGER

Copyright (2005-2019) Analytic Systems Ware (1993) Ltd.
Revised - June 20, 2019

3
SAVE THESE INSTRUCTIONS — This manual contains important safety instructions for
operating the battery charger.
BATTERY CHARGER PRECAUTIONS
1. Do not expose the battery charger to rain or snow unless it is a sealed model.
2. Do not use any attachments with the battery charger unless recommended or sold by the
manufacturer, this may result in a risk of re, electric shock, or injury to persons.
3. Do not disassemble the battery charger; if service or repair is required, return it to the
manufacturer or an authorized service center. Incorrect reassembly may result in a risk of
re, electric shock, or injury to persons. Voltages in excess of 350 volts are present inside
the charger any time it is plugged into an AC outlet, even if switched off.
4. To reduce risk of electric shock, unplug the battery charger from the AC power before
attempting any maintenance or cleaning. Turning off controls will not reduce this risk.
5. Do not place battery charger directly above battery; gases generated by battery will cor-
rode and damage battery charger.
6. Do not allow battery acid to drip on the battery charger.
BATTERY SAFETY
1. WARNING — RISK OF EXPLOSIVE GASES
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
iii. When working near a battery there should be another person within range of your
voice, who is close enough to come to your aid if needed.
iv. Be sure that the area you are working in is well ventilated.
v. Clean the battery terminals regularly to keep them free of corrosion.
vi. Wear complete eye protection and protective clothing. Avoid touching your eyes while
working near a battery.
vii. Have plenty of fresh water and soap nearby and ready in case battery acid contacts
your clothing, skin or eyes.
viii.If battery acid contacts your skin or clothing, immediately wash it off with soap and
water. If battery acid enters your eye, immediately ood eye with running cold water
for at least 10 minutes and seek medical attention immediately.
DC SOURCE BATTERY CHARGER
IMPORTANT SAFETY INSTRUCTIONS

4
MEDICAL EQUIPMENT NOTICE
Analytic Systems does not recommend the use of their products 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), 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
i. Never work on a lead-acid battery in the vicinity of sparks or open ames. Never
smoke while working on a battery.
ii. Never charge a frozen battery.
iii. Never drop a metal tool onto a battery. This may generate sparks or short-circuit the
battery or other electrical part causing to re or explosion.
iv. Remove all metallic personal 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 severe burns.
v. When removing a battery from service, always disconnect the grounded (negative)
battery terminal rst.
vi. When connecting a new battery to the battery charger, make sure all accessories
connected to the battery are off, to prevent an arc from forming.
vii. Study all of the battery manufacturer’s specic precautions before charging a battery
such as removing or not removing cell caps and recommended rates of charge.

4
Copyright (2005-2019) Analytic Systems Ware (1993) Ltd.
Revised - June 20, 2019
TABLE OF CONTENTS
•Front Cover, Product Photo and Title
•Product Warnings and Advisories
•Table of Contents
•Introduction
•Box Contents
•Main Parts
•Operation Instructions
•Charging Proles
•Installation Instructions
•Remote Control Accessory
•Troubleshooting
•Specications
•Warranty

6
Introduction
Box Contents
The box you have received should contain the following:
• One BCD305 DC Battery Charger
• This manual
• One Warranty Card
If there is anything is damaged or missing, please contact your dealer or Analytic Systems for a
replacement.
The BCD305 DC-DC battery charger provides up to 300 watts of precision charging power to
charge a 12 or 24 volt battery system from a 12 or 24 VDC source. For maximum versatility in
operation, this unit features two-stage charging capability with adjustable output voltage.
In absence of a battery, the unit can also be used as a DC-DC voltage converter up to its
continuous current rating The unit is Non-Isolated and Common Negative meaning that there
is a direct connection between the Input Negative and Output Negative.
Internally, the recently updated single board design features time-tested switch-mode
technology for unmatched efciency and ultra-quiet operation. Multiple stages of ltering
reduce radiated or conducted noise to very low levels.
Safety features include over-temperature shutdown with automatic recovery, current limiting,
short circuit protection with automatic recovery, input undervoltage shutdown, output
overvoltage protection, and both input and battery reverse connection protection. Additional
features include a dry contact alarm relay output, and remote panel monitoring with On/Off
control.

6 7
4
Main Parts
2
5
5
3
2
4
1
3
1. DC Input Negative Connection:
1-ft (0.3m) #12AWG Black Input Lead
2. DC Input Positive Connection:
1-ft (0.3m) #12AWG Red Input Lead
3. Input Fuses: 2x AGC-20
Input Side
4. Chassis Grounding Stud
5. Output Fuses: 2x AGC-30
1
1. Battery Output Connection: Molex
4-pin BEAU Terminal Strip
2. Output Voltage Adjust Potentiometer
(under Cover Plate)
3. Indicator LEDs
Output Side
4. Remote Control Port
5. Power Switch

8 9
Operation
This unit is designed for simple and intuitive operation. Before operating, make sure that this
unit is properly installed and connected. See Installation for more information.
TO CHARGE A BATTERY
1. Move the Power Switch to ON. The alarm buzzer will sound and the LOW OUTPUT LED
will glow red briey, then the POWER LED will glow green. This is normal.
2. The CHARGING LED will start glowing green indicating normal operation. The unit will
automatically charge the battery until it is fully charged. This may take several hours.
3. Once 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. Move the Power Switch to ON. The alarm buzzer will sound and the LOW OUTPUT LED
will glow red briey, then the POWER LED will glow green. This is normal.
2. Loosen the two screws holding the cover plate to the top panel and remove the plate to
access the output voltage adjust potentiometer.
3. Using a small at-blade screwdriver, rotate the potentiometer.
4. The charging (oat) voltage can be adjusted over a range of ±1.0 volts. Rotate the
potentiometer clockwise to increase the voltage; counterclockwise to decrease the voltage.
5. Using the digital voltmeter/ammeter, monitor the charging voltage.
6. When satised with the new voltage, return the cover plate to its original position,
TO END OPERATION
1. Move the Power Switch to OFF.
2. Wait for all the LEDs stop glowing.
3. Once all of the LEDs are off, it is safe to disconnect the unit from the power source and
battery. The unit is now ready for storage or service.

8 9
Charging Proles
This unit charges connected batteries using a two-stage charging prole. Below is a detailed
explanation of how this charging cycle works.
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Maintenance
(Constant Volts)
Time
Two Stage Charger
Volts
Amps
TWO-STAGE CHARGING
A two-stage charging prole occurs in two stages.
• During the Bulk stage, the unit charges the battery with a constant current (13 A) until the
battery voltage reaches the unit’s pre-programmed oat voltage (27.2 VDC). The oat volt-
age is higher than the battery’s rated voltage to compensate for the characteristic discharge
of idle batteries.
• During the Float stage, the current reduces as necessary to maintain the battery at the oat
voltage. When the current drops below 2 Amps, the charging cycle is complete. The battery
can be left connected to the charger, which will keep it at full charge.
Two-stage charging is recommended in more instances over three-stage since it is more ver-
satile. The battery is subjected to lower voltage and current than in three-stage charging and
therefore is less stressed. In addition, the battery can be used to power a load without altering
the battery charger’s ability to keep the battery at full charge.

10
MOUNTING
Mount the unit in a DRY and WELL
VENTILATED location with at least 1 inch
of clearance around the unit for adequate
cooling.
The best mounting conguration is to mount
the unit on a horizontal surface using #10
screws of the appropriate type for the
mounting surface to securely mount the unit.
There is 1500 volts of isolation between the
input and output, and the input and case. There is 500 volts (1500V for 48V Output) of isolation
between the output and case. Therefore, the unit may be mounted on any surface without fear
of electrolysis or ground fault.
A ground stud is provided to bond the chassis to local ground to reduce or eliminate EMI.
Installation
Red Input Lead - Positive DC Terminal
Black Input Lead - Negative DC Terminal
INPUT POWER CONNECTION
The unit is equipped with two 3-foot/1 meter Type D Stranded AWG12 wire leads to serve as
a DC Input Connection. Connect these leads to the DC power source in the polarity indicated.
IMPORTANT: To reduce the risk of high voltage electrical shock, always
make the power switch is OFF Before making or breaking any connections.
Normally these leads should be adequate to connect to the DC power source, however, if you
must extend the leads, be sure to:
• Use the smallest extension length possible.
• Use a good quality (typeTEW) wire
• Use no less than 12 gauge conductors.
• Splice and solder the joints and protect the joints with heat shrink tubing.

11
IMPORTANT: If multiple batteries are connected to the output, they must
share a common ground!
OUTPUT POWER CONNECTION
The unit is equipped with a 4-pin Molex BEAU Terminal strip to serve as a DC Output Connection.
This connection can support up to two connected loads, the wiring for this connection can be found
on the unit’s label.
Max. Output Current 24.00 A 15.00 A 9.30 A 5.90 A 3.70 A
American Wire Gauge #8AWG #10AWG #12AWG #14AWG #16AWG
Max. Output Current 2.30 A 1.50 A 0.92 A 0.58 A 0.23 A
American Wire Gauge #18AWG #20AWG #22AWG #24AWG #28AWG
TIP: If you are only
powering a single load,
connect it to the unit in the
conguration shown.
By connecting the load to both
of the battery charger’s positive
output terminals, you reduce
the strain on each individual
connection.
Connect the load to the terminals using an appropriate gauge of wire for the Output Current. See
Specications for the unit’s Output Current and the table below for the necessary gauge of wire.
CAUTION: Do not connect the battery in the reverse polarity!
This will activate the reverse connection protection which will blow the output fuses in order to
protect the device. The unit will be inoperable until these fuses have been replaced.

12 13
Remote Control Accessory
Pin Number Function
1 Dry Contact Relay (Closed for fault)
6 Dry Contact Relay (Closed for fault)
2 Remote Off (Short to 5 to turn unit OFF)
7 OverTemp (Low for fault)
3 UnderVolt In (Low for fault)
8 OverLoad (Low for fault)
4 UnderVolt Out (Low for fault)
9 +12 Volts
5 Common
The remote control panel and 9-pin D-connector are an optional feature for this product line.
The remote control panel allows the unit to be operated remotely and duplicates all the
diagnostic LED indicators with audible alarm. A built-in dimmer switch allows you to control
the brightness of the remote control LEDs.
CAUTION: Do not turn on the battery charger until the remote is connected!
To prevent the possibility of high voltage electrical shock, the charger must be OFF while
connecting the remote control. Do not remove the dust-cover on the remote control connector
if it is not being used.
CAUTION: Do not connect this port to a computer!
This will cause serious damage to the battery charger and computer. This damage is not be
covered under warranty.
IMPORTANT: This remote is to be used
only on Battery Chargers manufactured
by Analytic Systems.
DRY CONTACT RELAY
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, you must take the cover off the
unit and move the jumper to the other position on J11 on the circuit board. J11 is located next
to the relay.

12 13
Troubleshooting
This unit features several LED indicators and an alarm buzzer to help diagnose any malfunctions.
The voltage converter will sound the buzzer to alert you prior to shutting down. You should
immediately check which LEDs are glowing to determine the cause of the shutdown.
Issue Meaning
LOW INPUT LED is ON
Alarm buzzer sounds
The input voltage is too low for normal operation or there may be
an internal component failure.
Fix: Check that the DC power source is rated for the application. Check
that the input wiring and connections are not corroded or damaged.
If everything is normal, the unit is defective and must be returned to
the factory or an authorized service centre for repair.
OVER TEMP LED is ON
Alarm buzzer sounds
The unit has overheated, its internal temperature is too hot for
normal operation.
Fix: Remount the unit for improved ventilation and cooling or discon-
nect some devices from the output to reduce heat generation.
Check that the unit’s cooling fans are functioning. If they are NOT,
the unit is defective and must be returned to the factory or an
authorized service centre for repair.
Unit will not turn ON The input fuse may have blown or there may be an internal compo-
nent failure.
Fix: Turn the battery charger OFF and disconnect it from the power
source and load. Then remove the input fuse and check if it has
blown using an ohmmeter. Replace the fuse if blown.
If the new fuse blows when the unit is turned ON or the unit still
doesn’t turn ON, the unit is defective and must be returned to the
factory or an authorized service centre for repair.
LOW OUTPUT LED is ON
OUTPUT ON LED is OFF
The output voltage is too low for normal operation. The battery
may be defective, overloaded or there is an internal failure.
Fix: The battery being charged may be defective, or too much load is
connected causing the battery to become severely discharged.
Replace the battery or reduce the load on the system. Check
that the output connection and wires have not been damaged or
corroded.
If the condition persists, then the unit is defective and must be
returned to the factory or an authorized service centre for repair.

14 15
*The actual charging amps depends upon the Input/Output voltage ratio. To obtain the charging amps at any given
Input Voltage value, use the following formula: Charging Amps = Input Voltage/Output Voltage x 26
For example, at 10.5VDC in and 27.2VDC out, the charging amps = 10.5 VDC/27.2 VDC x 26 = 10.0 A.
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]
Specications
Model BCD305-12-24
Input Voltage Range 10.5 - 15 VDC
Input Amps (Max) 30 A
Output Voltage 27.2 ± 0.5 V
Charging Amps *13 A
Overvoltage Crowbar Protection Output Volts x (1.3 ± 1%)
Input Fuses AGC-20 x 2
Output Fuses AGC-30 x 2
Low Input Alarm Threshold 10.5 VDC
Low Output Alarm Threshold Output Voltage minus 2.5 VDC
No. Supported Battery Banks 1 or 2 Battery Banks
Charging Prole 2-Stage
Battery Size 52 - 78 Amp-Hours
Transient Response < 1 V for 15 A Surge
Efciency > 85% @ Maximum Output
Operating Temp. Range -25 °C to +40 °C @ Maximum Output
Humidity 0 - 95% Relative Humidity (non-condensing) with standard conformal coating
Isolation Any Input or Output to Case: 500 VDC
Input to Output: Common Negative
Length 9.1 in / 23.1 cm
Width 7.8 in / 19.8 cm
Height 2.5 in / 6.4 cm
Clearance 1.0 in (2.5 cm) all around
Material and Finish Black Anodized Marine Grade Aluminum
Fastenings 18-8 Stainless
Connections DC Input: 2x 1-ft (0.3m) #12AWG Input Leads (Red: Positive, Black: Negative)
Battery Output: 4-pin Molex BEAU Terminal Strip
Weight 4.0 lb / 1.8 kg
Safety Built to meet CSA 22.2.107.1 & UL458
Warranty 5Years Parts and Labor

14 15
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

Register Products Online | www.AnalyticSystems.com/support/warranty-registration
DESIGNED AND MANUFACTURED BY
800-668-3884
604-946-9983
[email protected]
www.AnalyticSystems.com
8128 River Way
Delta, BC V4G 1K5 | Canada
Battery Chargers •Inverters •Power Supplies •Voltage Converters