Analytic Systems BCD315-12-24 User manual

INSTALLATION &
OPERATION MANUAL
BCD315
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 (2005-2014) Analytic Systems Ware (1993) Ltd.

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IMPORTANT & SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS — This manual contains important safety and operat-
ing 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 DC supply
before attempting any maintenance or cleaning. Turning off controls will not reduce this
risk.
6. WARNING — RISK OF EXPLOSIVE GASES.
a. 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 FOL-
LOW THE INSTRUCTIONS EXACTLY.
b. 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.
7. PERSONAL PRECAUTIONS
a. Someone should be within range of your voice or close enough to come to your aid
when you work near a lead-acid battery.
b. Have plenty of fresh water and soap nearby in case battery acid contacts skin, cloth-
ing, or eyes.
c. Wear complete eye protection and clothing protection. Avoid touching eyes while
working near battery.
d. 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.
e. NEVER smoke or allow a spark or ame in vicinity of battery or engine.
f. 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.

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g. 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 cur-
rent high enough to weld a ring or the like to metal, causing a severe burn.
h. NEVER charge a frozen battery.
i. 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.
j. Be sure area around battery is well ventilated.
k. Clean battery terminals. Be careful to keep corrosion from coming in contact with
eyes.
l. Study all battery manufacturer’s specic precautions such as removing or not remov-
ing cell caps while charging and recommended rates of charge.
m. 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.
8. BATTERY CHARGER LOCATION
a. Never place battery charger directly above battery; gases from battery will corrode
and damage converter.
b. Never allow battery acid to drip on battery charger when reading gravity or lling
battery.
9. O/P CONNECTION PRECAUTIONS
a. Connect and disconnect DC output connections only after setting battery charger
switch to off position.
Analytic Systems does not recommend the use of the BCD315 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), autotransfu-
sion 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 and a dry
contact alarm relay output.
Safety features include reverse input protection, over-temperature protection, current limiting,
and short circuit protection with automatic recovery, input undervoltage shutdown, reverse
battery protection and output overvoltage crowbar.
Optional features include a high quality digital volt/ammeter (factory install only), and remote
panel monitoring with On/Off control.
Specications
Input Voltages
Nominal (ip) 24 36 48 72
Actual (Vdc) 20 - 35 30-45 40 – 60 65 – 90
Input Amps (max) 18.7 12.5 9.4 5.7
Input Fuse (slow blow) MDA-25 MDA-20 MDA-15 MDA-10
Output Voltages
Nominal (op) 12 36 24 48
Float (Vdc) 13.6 ± 0.05 40.8 27.2 ± 0.05 54.4 ± 0.05
Absorption Voltage (Vdc) 14.4 43.2 28.8 57.6
Charging Amps 20 6.7 10 5
Absorption to Float 3.0 Amps 1 Amp 1.5 Amps 0.75 Amps
Battery Banks 1 or 2
Battery Size (Amp Hours)* 80 – 120 50-80 40 – 60 20 – 30
Output Adjust ± 1.0 volts
Output Fuses AGC 25 AGC 10 AGC 15 AGC 7
Output Crowbar 16.0 ± 0.5 V 48 ± 2.0 V 32.0 ± 1.0 V 64.0 ± 2.0 V
Temperature Compensation Coefcient -30mV / °C -45mV / °C -60mV / C -120mV / °C

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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
Allow at least 1 inch of clearance all around the case for cooling. The best mounting congu-
ration is to mount the unit on a vertical surface oriented as shown. Use #10 screws of the
appropriate type for the mounting surface to securely mount the unit.
There is 1500 volts (500V for 24V Input) 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.
General
Efciency > 80 % @ maximum output
Stages 2 or 3
Temp. Range -25 to +40oC @ maximum output
Isolation Input-Output & Input-Case 1500 Vdc (500 Vdc @ 24 V In),
Output-Case 500 VDC (1500Vdc @ 48 V Out)
Length 9.6 in / 24.4 cm
Width 8.2 in / 20.8 cm
Height 3.5 in / 6.4 cm
Clearance 1 Inch (2.5 cm) all around
Material Marine Grade Aluminum
Finish Black Powder Epoxy
Fastenings 18-8 Stainless
Weight 7.0 lb / 3.2 kg
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] Revised July 2014
INPUT
FUSE
TO
REMOTE
OUTPUT TERMINAL
ON/OFF
INPUT POWER
OUTPUT
FUSE

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OUTPUT 1
OUTPUT 2
BATT
BANK #2
BATT
BANK #1
NEGATIVE
NEGATIVE
Red - Positive Black- Negative
POWER CONNECTION
The unit is supplied with power leads 1 meter 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) AWG12 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.
A ground stud is provided to bond the chassis to local ground to reduce or eliminate EMI.
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. If you are hooking up 2 battery banks keep in
mind that they MUST share a common ground!
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 posi-
tion. The switch is located to the right of the output terminal on the front panel. Set the
switch to the correct position as shown on the label.
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 maximum current and the
charging light will be on. After a period of time which may be minutes to hours, the batteries
will reach the absorption voltage (3-stage) or oat voltage (2-stage), and the charging current
will reduce as necessary to maintain the batteries at that voltage. Once the charging current
has dropped to a low level (about 10% of the charging current rating), the charging light will
go off, and if set to 3-stage charging the voltage will drop to the oat level. You may check

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2 or 3 Stage Charging
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Float
(Constant Volts)
Time
Two Stage Charge
Volts
Amps
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)
Absorption
(Constant Volts)
Maintenance
(Constant Volts)
Time
Three Stage Charger
Volts
Amps
this voltage at the output terminals of the unit with a good digital voltmeter. As shipped from
the factory, the unit is preset for a oat voltage of 13.6, 27.2 or 36.3 VDC, which is generally
recommended for lead-acid batteries. The output adjust potentiometer is located to the right
of the 2 stage / 3 stage select switch. If you wish to adjust this voltage, 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. 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 differenti-
ate 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.
Meters
A high quality digital meter can be added to the voltage converter (factory installed only). The
meter shows simultaneous voltage and current on either of the two output terminals. A toggle
switch permits selection between the output terminals. The meter features bright red LED
readouts to permit easy monitoring from many feet or meters away.
Special Services & Options
Conformal Coating INCLUDED ON ALL UNITS UNLESS REQUESTED NOT TO as of April 1, 2014
Option “c” Ruggedization Package (EXTRA Conformal Coating and RTV Compound)
Option “v” Marine / Industrial Pkg (EXTRA Conformal dipping and RTV Compound)
Option “MS” Military Pkg
(incl. Wide Temp Components, Conformal Dipping and RTV Compound)
Option “w” Wide Temperature Operation (-40 to +55 C, incl)
Option “SM” High Voltage Protection on the DC Input Side
Option “d” Paralleling Diodes
Option “FI” Forklift Modications
Option “F” Open Frame - No chassis just heat sink bars (not for all products)
Special Input There is no charge for nominal output voltages (ie. 12.0, 24.0, 48.0), but this
must be noted at the time of order (Contact Factory for details)
Special Output
Water tight options IP66, IPS67, IPS68

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Troubleshooting
If the red OVERTEMP LED and the audible alarm come on, the unit has overheated, and it
will shut down until it cools off sufciently. You may not have allowed sufcient space around
the unit for cooling, or there may be too many devices connected to the output of the unit.
Either reduce the number of devices connected to the unit, or reposition the unit for better
cooling. If necessary, direct a stream of moving air over the unit.
If the yellow LOW INPUT LED and the audible alarm comes on, the input voltage has
dropped to below a usable level.
If the LOW OUTPUT LED and the audible alarm come on, and the green OUTPUT ON LED
is completely off, the output of the unit has been shorted out, or there has been an internal
failure. Turn the unit off, disconnect all the loads connected to it, and turn it back on again. If
it comes on normally, turn it off again, reconnect one load, and turn it back on. Continue recon-
necting loads until the short circuit condition returns. Turn the unit off, disconnect the faulty
load, and reconnect it only after the fault is found and rectied. If the condition still exists
even after all the loads have been disconnected, the unit is defective, and must be returned to
the factory or an authorized service center for repair.
If the unit will not turn on at all, check the input fuse. To do this, rst turn off the unit and
disconnect the power cord. Next, remove the negative battery lead and cover the end with non
conductive material such as tape. Repeat this with the other battery lead. This will prevent an
accidental discharge from the battery. Remove the fuse and check it with an ohmmeter. If it is
blown, replace it with a new one. If that fuse blows as well or the unit still will not turn on, it
is defective, and must be returned to the factory or an authorized service center for repair.
If the batteries are hooked up backwards the output fuses will blow. To change them follow
the same procedure as for the input fuse.
If both the input and output fuses are good and the unit still does not function it must be
returned to the factory for servicing.