Analytic Systems BCD305 Series User manual

INSTALLATION &
OPERATION MANUAL
BCD305 SERIES
DC 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
SAVE THESE INSTRUCTIONS — This 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.
5. To reduce risk of electric shock, disconnect battery charger from batteries and AC supply
before attempting any maintenance or cleaning. Turning off 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. 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 the 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.
v. NEVER smoke or allow a spark or ame in vicinity of battery or engine.

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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 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.
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. O/P CONNECTION PRECAUTIONS
Connect and disconnect all DC connections only after setting battery charger switch to off
position.
Analytic Systems does not recommend the use of the BCD305 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
This all new single board design incorporates state of the art switchmode technology for
unmatched efciency and ultra-quite 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/Off control.
We are condent that you will get many years of reliable service from this DC Battery Charger.

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*The 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 26
For example, at 10.5VDC in and 13.6VDC out, the charging current = 10.5/13.6 x 26 = 20.1 amps
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 BCD305-12-12 BCD305-12-24
Input Volts (DC) 10.5 - 14 10.5 - 28
Input Amps (max) 30 30
Output Volts (DC) 13.6 ± 0.5 V 27.2 ± 0.5 V
Charging Amps *26 *13
Output Crowbar Output Volts x (1.3 ± 1%)
Input Fuses AGC-20 x 2
Output Fuse AGC-30 x 2
Low Input Voltage Alarm 10.5 VDC
Low Output Voltage Alarm Output Voltage minus 2.5 VDC
Battery Banks 2
Stages 2
Battery Size (Amp Hours)* 104 – 156 52 - 78
Transient Resp. < 1V for 15A Surge
Efciency > 85 % @ maximum output
Temp. 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 2.5 in / 6.4 cm
Clearance 1 Inch (2.5 cm) all around
Material Marine Grade Aluminum
Finish Black Anodized
Fastenings 18-8 Stainless
Weight 4.0 lb / 1.8 kg.

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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 input power leads 1 meter long. 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
POWER CONNECTION
Two positive output terminals and two negative output terminals are provided. Connect only
one wire to each terminal.
Note that the current specications 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 26
For example:
10 VDC in and 27 VDC out, the max output current = 10/27 x 26 = 9.6 Amps.
20 VDC in and 27 VDC out, the max output current = 20/27 x 26 = 19.3 Amps
It is recommended to parallel the output connections if the unit is used as a single bank battery charger.

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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 monitor the voltage. Next, 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. 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.
Operation
Troubleshooting
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. After 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.

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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 7 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 J11. J11 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, and
then turn it off again. Remove the six screws holding on the cover, turn the unit upside down,
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.

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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. 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.