Analytic Systems BCD615-48-48 User manual

INSTALLATION &
OPERATION MANUAL
BCD615 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 Registered Company Battery Chargers •Inverters •Power Supplies •Voltage Converters

Copyright (2005-2016) Analytic Systems Ware (1993) Ltd.
Revised - May 31, 2017

3
IMPORTANT & SAFETY INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS — This manual contains important safety and operating
instructions for battery charger
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, unplug battery charger from outlet before attempting any
maintenance or cleaning. Turning off controls will not reduce this risk.
6. Never place battery charger directly above battery; gases from battery will corrode and
damage battery charger.
7. Never allow battery acid to drip on battery charger when reading gravity or lling battery.
8. O/P CONNECTION PRECAUTIONS
Connect and disconnect DC output connections only after setting the I/P power switch to
the off position.
ALL 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 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.

4
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.
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 in the vessels 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.
Analytic Systems does not recommend the use of the BCA615 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.

5
Introduction
All new Current Mode switching design offers increased power and reliability in a compact
package. Extra input and output ltering reduce EMI to extremely low levels. Reliability
features include an input fuse, thermal shutdown, current limiting, reverse battery hookup
protection and output short circuit shutdown with automatic recovery. The output voltage is
easily adjusted 1.0 volts above or below the standard output voltage to accommodate special
charging requirements. High quality digital meters can be added (factory option) to allow
monitoring of output current and output voltage.
Specications
Input Voltages
Nominal (ip) 24 48 72
Actual ** 20 – 35 ** 40 – 60 ** 65 – 90
Input Amps (max) 37.9 19.4 12.1
Input Fuse 3 x ATC15 1 x ATC25 1 x ATC20
Output Voltages
Output Nominal (op) 12 24 32 48 72 (rail)
Output Volts (DC) 13.6 ± 0.05 27.2 ± 0.05 36.3 ± 0.05 54.4 ± 0.05 72.6 ± 0.05
Absorption Voltage (Vdc) 14.4 28.8 38.4 57.6 86.4
Charging Amps 40 20 15 10 6.7
Absorption to Float (15%) 6.0 Amps 3.0 Amps 2.25 Amps 1.5 Amps 1.0 Amps
Output Adjustment ± 1.0 V ± 1.0 V ± 1.0 V ± 1.0 V ± 1.0 V
Output Fuses (ATC) ATC 40 x 2 ATC 30 x 2 ATC 20 x 2 ATC 15 x 2 ATC 15 x 2
Battery Banks 1, 2 or 3 Banks
Battery Size (Amp Hrs) 160-240 80-120 60-90 40-60 27-40
Output Crowbar 16.0 ± 0.5V 32.0 ± 1.0V 42.7 ± 1.3V 64.9 ± 2.0V 85.4 ± 4V
Output Ripple & Noise < 100 mV
Regulation (Line & Load) < +/- 0.5%
Temperature Comp. -30 mV/°C -60 mV/°C -80 mV/°C -120 mV/°C -180 mV/°C
Duty Cycle Continuous 100% for 24 hours per day
Efciency > 75% @ Maximum Output
Stages 2 or 3 (user selectable)

6
** Actual startup is at 22, 42, or 67Vdc Input, depending on model
* This is Analytic Systems’ suggested range. Please consult your battery manufacturer for their recommendations.
* Specications subjects to change without notice.
Installation
MOUNTING
Mount the unit in a DRY location. Allow at least 4 inches of clearance around the heat sink
ns for adequate cooling.
POWER CONNECTION
The unit is supplied with power leads about 3 feet 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) AWG 8 gauge wire. The wire colours are:
Red - Positive Black- Negative
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]
General
Battery Banks 1 or 2
Stages 2 or 3
Switching Frequency 60 ± 2 KHz
Idle Power < 10 Watts
Noise on Input < 50 milli-Volts
Noise on Output < 50 milli-Volts
Transient Response < 2V for 50% Surge (Output Amps/2)
Efciency > 75 % @ maximum output
Temp. Range -25 to 40 deg. C @ maximum output
Isolation Input-Output & Input-Case 1500 Vdc (500 Vdc @ 24 V In),
Output-Case 500 VDC (1500Vdc @ 48 V Out)
Dimensions 14.5 x 10 x 4 in / 37 x 25 x 10 cm
Clearance 1 Inch (2.5 cm) all around
Material Marine Grade Aluminum
Finish Black Powder Epoxy
Fastenings 18-8 Stainless
Weight 7.2 lb / 3.3 kg

7
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
position. To access the switch, remove the cover plate (secured by 2 screws). Set the switch
to the correct position as shown on the label. When you are done, replace the cover plate
and securely tighten the screws.
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 15% of the charging current rating), the
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.
OUTPUT CONNECTIONS
Two Positive output terminals and two Negative output terminals are provided. Connect only
one wire to each terminal. Ensure that the total average load connected does not exceed the
continuous current rating of the unit.
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 depending on the model. Hook up the battery
bank(s) as shown below. If you are hooking up 2 battery banks keep in mind that they MUST
share a common ground!
OUTPUT 1 OUTPUT 1
OUTPUT 2 OUTPUT 2
BATTERY
BANK #1
BATTERY
BANK #1
BATTERY
BANK #2

8
charging light will go off, and if set to 3-stage charging the voltage will drop to the oat level.
You may check 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 54.4 VDC,
which is generally recommended for lead-acid batteries. If you wish to adjust this voltage,
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. 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. When you are done, replace the cover
plate and securely tighten the screws. It is advisable to check with the battery manufacturer
before changing the oat voltage.
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.
BATTERY TEMPERATURE SENSORS
Up to 2 battery temperature sensors can be connected to the charger to allow temperature
compensation of the battery charging voltage (1 is supplied with the unit). If only the 1 sensor
is used, it MUST be plugged into the ‘BATT 1’ connection on the side of the unit. If no sensor
is used, the charger will default to standard output voltage.
For installation instructions of the temperature sensor, please see the section entitled
Remote Battery Temperature Sensor Installation

9
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)
Float
(Constant Volts)
Time
Two Stage Charge
Volts
Amps
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Absorption
(Constant Volts)
Float
(Constant Volts)
Time
Three Stage Charge
Volts
Amps
2 or 3 Stage Charging
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 differentiate 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, VRLA or gel type batteries.

10
Troubleshooting
This unit provides LED indicators and a buzzer to help diagnose any problems. The unit should
sound the buzzer to alert you prior to shutting itself down. You should immediately check the
indicators to determine the cause of the shutdown.
CHARGING Indicates that the battery charger is charging the batteries:
If the LED is not on, the batteries may be fully charged and the charger is
supplying a oat voltage to the batteries to keep them fully charged.
LOW OUTPUT Indicates that the output voltage is below normal because:
The current demanded by the devices connected to the unit exceeds the
maximum output current rating, causing the output voltage to drop to
maintain the current at the maximum level,
The input voltage is not high enough for unit to operate,
LOW INPUT Indicates that the input voltage is below normal because:
The input voltage is not in the correct range for proper operation of the unit.
OVERTEMP Indicates that the Battery Charger is running too hot because:
Too much power is being drawn, turn off or unplug some devices.
The Battery Charger is located in a poorly ventilated area.
If the load exceeds the continuous rating for too long a period, the temperature sensor inside
the unit will turn off the outputs. After the unit cools sufciently, it will automatically come
back on. If this happens frequently, remount the unit for increased airow so it cools better.