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

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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.

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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

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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.

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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.