Analytic Systems BCD605 User manual

Installation &
Operation Manual
BCD605
DC Battery Charger
8128 River Way, Delta B.C. V4G 1K5 Canada T. 604.946.9981 F. 604.946.9983 TF. 1.800.668.3884 (US/CANADA)
www.analyticsystems.com

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Copyright (2005-2013) Analytic Systems Ware (1993) Ltd.

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IMPORTANT & SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS — is 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.
6) To reduce risk of electric shock, disconnect battery charger from batteries and AC supply
before attempting any maintenance or cleaning. Turning o 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. BAT-
TERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERA-
TION. 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 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, cloth-
ing, 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.
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.

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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-cir-
cuit 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 o, 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. is 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) DC CONNECTION PRECAUTIONS
i) Connect and disconnect all DC connections only aer setting battery
charger switch to o position.
Analytic Systems does not recommend the use of the BCD605 Series Battery Chargers in life support ap-
plications where failure or malfunction of this product can be reasonably expected to cause failure of the life
support device or to signicantly aect its safety or eectiveness. 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brilla-
tors, arrhythmia detectors and alarms, pacemakers, hemodialysis systems, peritoneal dialysis systems, neona-
tal 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
is all new single board design incorporates state of the art switchmode technology for unmatched
eciency and ultra-quiet 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/O control.
We are condent that you will get many years of reliable service from this DC Battery Charger.

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Designed and manufactured by: ANALYTIC SYSTEMS WARE (1993) LTD.
8128 River Way, Delta, B.C., V4G 1K5, Canada
phone [phone] fax [phone] toll free 800-668-3884 US/Canada
email: [e-mail] web site: www.analyticsystems.com Revised May 2005
* Specications subjects to change without notice.
* is is Analytic Systems’ suggested range. Please consult your battery manufacturer for their recommendations.
◆ e 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 40
For example, at 10.5VDC in and 13.6VDC out, the charging current = 10.5/13.6 x 40 = 30.8 amps
Specications
Model BCD605-12-12 BCD605-12-24
Input Volts (DC) 10.5 - 14 10.5 - 28
Input Amps (max) 50
Output Volts (DC) 13.6 ± 0.5 V 27.2 ± 0.5 V
Charging Amps ◆ 42 ◆ 21
Output Crowbar Output Volts x (1.3 ± 1%)
Input Fuses AGC 30 x 2 Amp
Output Fuses AGC 25 x 2 Amp
Low Input Voltage Alarm 10.5 VDC
Low Output Voltage Alarm Output Voltage minus 2.5 VDC
Battey Banks 1 2 (Only if the input voltage < 15 Vdc)
Stages 2
Battery Size (Amp Hours)* 168 - 252 84 - 126
Transient Response < 1V for 15A Surge
Eciency > 85 % @ maximum output
Temperature 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 4.3 in / 10.8 cm
Clearance 1 Inch (2.5 cm) all around
Material Marine Grade Aluminum
Finish Black Powder Epoxy
Fastenings 18-8 Stainless
Weight 6.0 lb / 2.7 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 three foot power input leads. 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
◆OUTPUT CONNECTIONS
Two positive output terminals and two negative output terminals are provided. Connect only one wire to
each terminal. A jumper externally connects the positive terminals of the BCD605-12-24. This jumper may
be removed and the BCD605-12-24 used as a dual bank charger if and only if the input voltage is less than 15
volts.
Note that the current specifications 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 40
For example:
11 VDC in and 27 VDC out, the max output current = 11/27 x 40 = 16.3 Amps.
20 VDC in and 27 VDC out, the max output current = 20/27 x 40 = 29.6 Amps
Each output terminal can supply up to 25 Amps, therefore do not connect more than 25 amps of load to
either output terminal. If the load exceeds 25 Amps but not the continuous rated output of the unit, do the
following: The output terminals must be connected to the load in parallel ensuring that the wiring used has
sufficient capacity to handle the current.
Please NOTE:
e BCD605-12-12 is a single bank charger ONLY and must be hooked up as shown in the drawing above!
e BCD605-12-24 may be used as a dual bank charger if the input voltage is less than 15 volts! If the input is
greater than 15 volts the unit must be hooked up as shown in the drawing above!

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Operation
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 moni-
tor the voltage. Next, remove the cover plate (secured by 2 screws) to expose the output adjust potentiom-
eter. 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.
• 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. Aer 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.
Troubleshooting
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 8 in the remote connector diagram.
e 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 o 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 o and disconnect the unit from both the power and
batteries. Next, turn the unit on for 30 seconds to discharge the capacitors, then turn it o again. Turn the
unit upside down and remove the four screws. 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. e remote control panel and D connector are part of the remote control option.
e remote control panel allows the unit to be operated remotely as well as duplicating all the diagnostic
indicators and audible alarm.
REMOTE CONNECTOR
is 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: is remote is to be used only on Battery Chargers manufactured by Analytic Systems.

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Limited Warranty
1. e equipment manufactured by Analytic Systems Ware (1993) Ltd. (the “Warrantor”) is war-
ranted to be free from defects in workmanship and materials under normal use and service.
2. is warranty is in eect for:
a. 3 Years from date of purchase by the end user for standard products oered 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. e date of shipment by Analytic Systems, or
b. e 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 Purchas-
ers 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 dierent 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. e defect is the result of misuse, neglect, improper installation, environmental condi-
tions, non-authorized 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 aer having a reasonable number of opportunities to do so.
8128 River Way, Delta B.C. V4G 1K5 Canada T. 604.946.9981 F. 604.946.9983 TF. 1.800.668.3884 (US/CANADA)

8. Only the Warrantor shall perform warranty service. Any attempt to remedy the defect by anyone
else shall render this warranty void.
9. ere 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. is 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. ere shall be no responsibility or liability whatsoever on the part of the Warrantor or its em-
ployees and representatives 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. e Warrantor assumes no liability for incidental or consequential damages of any kind.
8128 River Way, Delta B.C. V4G 1K5 Canada T. 604.946.9981 F. 604.946.9983 TF. 1.800.668.3884 (US/CANADA)
www.analyticsystems.com