Analytic Systems BCD315MW User manual

INSTALLATION &
OPERATION MANUAL
101-8128 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 ISO9001:2015 Registered Company Battery Chargers •Inverters •Power Supplies •Voltage Converters
BCD315MW &
BCD315MY
DC-SOURCE
BATTERY CHARGER

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SAVE THESE INSTRUCTIONS — This manual contains important safety and operating
instructions for the battery charger.
BATTERY CHARGER PRECAUTIONS
1. Do not expose the battery charger to rain or snow unless it is a sealed model.
2. 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.
3. Do not disassemble the battery charger; return it to the manufacturer or an authorized
service center when service or repair is required. Incorrect reassembly may result in a risk
of electric shock or re. Voltages in excess of 350 volts are present inside the charger any
time it is plugged into a power source, even if it is switched off.
4. To reduce risk of electric shock, unplug the battery charger from the power source before
attempting any maintenance or cleaning. Turning off controls will not reduce this risk.
5. Never place battery charger directly above battery; gases from battery will corrode and
damage battery charger.
6. Never allow battery acid to drip on to the battery charger.
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 USER GUIDE AND
FOLLOW THE INSTRUCTIONS EXACTLY.
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
i. Someone should be within range of your voice or close enough to come to your aid
when you work near a 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.
DC SOURCE BATTERY CHARGER
IMPORTANT SAFETY INSTRUCTIONS
BATTERY SAFETY

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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 the 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.
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
v. NEVER smoke or allow a spark or ame in the vicinity of a battery.
vi. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark
or short-circuit the battery or other electrical part that may cause a re or 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 melt metal, causing a severe burn.
viii. NEVER charge a frozen battery.
ix. If it is necessary to remove a battery from service, always remove grounded terminal
from battery rst. Make sure all accessories connected to the battery are off, to
prevent an arc when reconnecting the new battery.
x. Be sure area around battery is well ventilated.
xi. Clean the battery terminals. Be careful to keep corrosion from coming in contact
with eyes.
xii. Study all the battery manufacturer’s specic precautions such as removing or not
removing cell caps while charging and recommended rates of charge

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TABLE OF CONTENTS
• Front Cover, Product Photo and Title
• Product warnings and advisories
• Table of Contents
• Introduction/Box Contents
• Main Parts
• Operation/Operational Indicators
• Charging Proles
• Connections
• Installation
• Battery Temperature Sensor/Equalize Cycle
• Troubleshooting
• Specications
• Special Services and Options
• Warranty
Revised - Aug 9, 2023
Copyright (2005-2022) Analytic Systems Ware (1993) Ltd.

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Introduction
The BCD315MW is a C.O.T.S DC-source battery charger designed to provide up to 300 watts
of precision charging power to a one or two bank battery system at 12, 24, 32, 36, or, 48 VDC.
The batteries must share a common ground.
The updated single board design incorporates state-of-the-art switch- mode technology for
unmatched efciency and ultra-quiet operation. In the absence of a battery, this unit can also
be used as a DC-DC voltage converter up to the continuous current rating.
The BCD315MW features expanded operating temperature, MIL-spec connectors, and
military-grade shock and vibration protection. Additionally, this unit is sealed to meet the IP66
rating (IP67 certication is available as an option for this product line)
Safety features include over-temperature shutdown, current limiting, short circuit protection
with automatic recovery, input under voltage shutdown, output over-voltage protection and
battery reverse connection protection. Extra features include visual indicators for low input
voltage, charging and overtemperature, dry contact output fail output and remote control
connection.
Box Contents
The box you have received should contain the following:
• One BCD315MW or BCD315MY DC-DC Battery Charger
• One Waterproof Battery Temperature Sensor (BTEMP-W)
• This Manual
• One Warranty Card
If anything is missing or damaged please contact your dealer or Analytic Systems for a replacement

6 7
Main Parts
1. Indicator LEDs
2. Battery Temperature Sensor Connection
3. Output Fuse
4. DC Output Connection
5. Output Voltage Adjust
6. Equalize Cycle Start Button
7. Charging Prole select switch
8. Power Switch
9. Input Fuse
10. DC Input Connection
FRONT PANEL
1
5
1
9
4
8
37
10
2
6

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Operation
This battery charger is designed for simple operation. Before operating, the unit must be
properly installed and connected. See Installation for more information regarding mounting
and connections.
TO CHARGE A BATTERY
1. Choose which type of charging prole will be used during charging by moving the Stage
Select switch. See Charging Proles for more information about two-stage and three-
stage charging.
2. Move the power switch to ON. The alarm buzzer will sound and the LOW VOLTAGE
OUTPUT LED will glow red briey, then the POWER LED will glow green. This is normal.
3. The CHARGING LED will glow green indicating normal operation. The unit will
automatically charge the connected battery until it is fully charged. This may take several
hours.
4. When 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. Disconnect the battery temperature sensor(s) from the unit, if in use.
2. Locate the Output Voltage Adjustment potentiometer on the front panel. On some units,
this is covered by a protective cap to prevent accidental operation.
3. Rotate the knob to adjust the charging voltage. The charging (oat) voltage can be
adjusted over a range of ±1.0 volts.
4. Rotate the potentiometer clockwise to increase the charging voltage; counterclockwise
to decrease the voltage.
5. Using a multimeter, read the charging voltage at the battery terminal. On units with the
optionall digital multimeter, that can be used to read the voltage instead.
6. When satised with the new voltage reading, return the protective cap in place and
reconnect the battery temperature sensor(s) if needed.
TO END OPERATION
1. Move the power switch to OFF.
2. Wait for all the Indicator LEDs stop glowing.
3. It is now safe to disconnect the unit from the power source and battery. The unit is now
ready for storage or service.

8 9
POWER ON
This LED glows green when the unit is connected to an AC power source and turned ON.
CHARGING
This LED glows green when the unit is charging a battery. This LED turns off when the
connected battery is fully charged. The charger will maintain the battery at full charge for as
long as it is connected.
OVERTEMP
This LED glows red if the unit’s internal temperature is above the safe limit, the unit will then
turn off its output as a precaution. If the internal temperature returns to the safe operating
range, the unit will automatically resume operation.
UNDERVOLTAGE OUTPUT
This LED glows red if the unit detects the output voltage is too low for proper operation, the
unit will then shut off its output as a precaution. If the unit detects the output voltage return
to normal operating range, it will automatically resume operation.
UNDERVOLTAGE INPUT
This LED glows red if the unit detects the the input voltage is too low for proper operation, the
unit will then shut off its output as a precaution. If the unit detects the input voltage return the
normal operating range, it will automatically resume operation.
EQUALIZE
BATTERY TEMPERATURE SENSOR MUST BE INSTALLED TO USE THIS FUNCTION.
This LED glows red when the unit is performing an equalize cycle. This LED blinks red when
the unit is waiting for a battery to nish charging before performing an equalize cycle.
BATTERY OVERTEMP
BATTERY TEMPERATURE SENSOR MUST BE INSTALLED TO USE THIS FUNCTION.
This LED glows red when the battery’s temperature is above the safe limit, the unit will then
turn off its outputs as precaution. If the battery temperature returns to the safe operating
range, the unit will automatically resume operation.
Operational Indicators
This unit’s top panel features seven indicator LEDs on its front panel to display the unit’s
operating condition. The meanings of these LEDs are detailed below. For more information
regarding the malfunctions these LEDs can indicate and how to correct them, see
Troubleshooting.

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Charging Proles
This unit has both two-stage and three-stage charging capability. You can choose which type
of charging is used during operation by using the Stage Select switch located on the front
panel. Below are explanations of the two charging proles:
1. The battery is charged at constant
current until the battery’s voltage
reaches the oat voltage.
2. The charging current diminishes as
necessary to maintain the battery at
that voltage.
TWO-STAGE CHARGING
Two-stage charging eliminates any risk of
overcharging the battery if it is connected to
a load while being charged.
THREE-STAGE CHARGING
1. The battery is charged at constant
current until the battery voltage
reaches the absorption voltage.
2. Then the charging current diminishes
as necessary to maintain the battery
at that voltage.
3. Once the charging current drops
below 10% of the rated output,
the charging cycle is complete. The
charger then switches to the oat
voltage to maintain the battery at
full charge.
Three-stage charging is more complete than two-stage, but the charging current must drop
below 10% of the rated output current of the charger for the Absorption Mode to terminate.
For that reason, three-stage charging is not recommended for charging loaded batteries
because the unit cannot differentiate between current going to a load connected to the
battery and current being absorbed by the battery, which may cause overcharging.

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Connections
INPUT CONNECTION
The DC Input connection is intended for connection to the DC power source that is powering
the battery charger.
This unit is equipped with an Amphenol Industrial Circular MIL-spec GTS02R16-11P connector
to serve as a DC input connection. This connector’s pin-out is as follows:
Pin Function
A Positive 1
B Negative
C Negative
D Positive 2
OUTPUT CONNECTION
The DC Output connection is intended for connection to the batteries being charged. This unit
is equipped a Amphenol Industrial Circular MIL-spec GTS02R-14S-2S (027) connector to serve
as a DC Output connection. This connector’s pin-out is as follows
The charger may be used to charge to either one or two battery banks simultaneously. If
charging two battery banks keep in mind that they MUST share a common ground! If charging
only a single bank, it is recommended you connect it to both outputs in parallel to reduce
stress on the output isolation diodes inside the charger.
Pin Function
A Positive
B Negative