Analytic Systems BCD805W-24-24 User manual

INSTALLATION &
OPERATION MANUAL
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
BCD805W-24-24
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 as high as 350 volts may be present inside the charger
any time it is connected to 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 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), 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 Warnings and Advisories
• Table of Contents
• Introduction
• Box Contents
• Main Parts
• Operation
• Two-Stage Charging
• Installation
• Troubleshooting
• Specications
• Warranty
Revised - Sept 21, 2017
Copyright (2005-2017) Analytic Systems Ware (1993) Ltd.

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Introduction
The BCD805W-24-24 DC-DC battery charger provides up to 600 watts of power to charge a 24
volt battery system from a 24 Volt DC source sharing the same ground. In absence of a battery,
the unit can also be used as a DC-DC voltage converter up to the continuous current rating
of the unit. The unit is Non-Isolated and Common Negative meaning that there is a direct
connection between the Input Negative and Output Negative.
The recently updated single board design features parallel buck-boost mode pulse width
modulated converters for power handling and reliability and has multiple stages of ltering
to reduce radiated or conducted noise to very low levels. The buck-boost architecture allows
the input voltage to be higher or lower than the desired output voltage without affecting
regulation.
The BCD805W-24-24 is constructed to be dust tight and water resistant in accordance to
IP66 standards. The unit is designed to operate under temperature extremes ranging -40°C to
+55°C and is protected against shock and vibration.
Safety features include over-temperature shutdown with automatic recovery, current limiting,
short circuit protection with automatic recovery, input undervoltage shutdown, output
overvoltage protection, and both input and battery reverse connection protection.
Box Contents
The box you have received should contain the following:
• One BCD805W-24-24 DC-DC Battery Charger
• This manual
• One Warranty Card
If anything is missing or damaged please contact your dealer or Analytic Systems for a replacement

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Main Parts
1. Indicator LEDs
Top of Chassis
1. Charger Status Indicator Connector
MS3112E8-4S
2. Output Fuse
3. Output Connection: Marathon Power
Stud Block (ST722B2502UH) c/w
cover
Rear Panel
1
1
2
3
1. Input Breaker Switch 2. Input Connection: Marathon Power Stud
Block (ST722B2502UH) c/w cover
Front Panel
1
2

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The BCD805W is a two-stage charger. A two-stage charger provides a constant current at
100% of rated output until the battery reaches its rated voltage and then switches to a “oat”
voltage. The current then reduces as necessary to complete the charge and then maintain the
battery at the oat voltage.
The charger can be connected to the battery indenitely. 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 batteries without
altering the ability of the charger to maintain them at full charge.
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Float
(Constant Volts)
Time
Two Stage Charge
Volts
Amps
Two-Stage Charging
Operation
To turn the unit on, apply power to the input and then switch the Input Circuit Breaker to the
ON position. The Power LED on the top of the chassis will illuminate. The Charging LED will
then illuminate and the battery will begin charging. When the output current drops to 10% of
the continuous rating the Charging LED will turn off. The unit will continue to provide current
as necessary to maintain the battery at full charge.
To turn the unit off, move the Input Circuit Breaker switch to the OFF position or turn off the
source of power to the unit.

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Mounting
Mount the unit in a location protected from total water immersion. The unit is rated
IP66 for protection from water spray and blowing dust. Allow at least 1 inch of clear-
ance around the unit for adequate cooling.
Input Connection
This unit’s front panel is equipped with a Marathon Block Connector (ST722B2502UH)
for the DC input. The connection is rated for 175A and 300V. The studs on the connec-
tor are sized 1/4 - 20 and intended for two hole compression lugs on .625” centers
The recommended wire gauge is AWG 4. If only one Negative connection is being
used, it should be the Input Negative. The input connections are:
Pin Function
Top left Power In Positive
Top Right Power In Positive
Bottom left Power In Negative
Bottom right Power In Negative
Output Connection
This unit’s rear panel is equipped with a Marathon Block Connector (ST722B2502UH)
for the DC output. The connection is rated for 175A and 300V. The studs on the
connection are sized 1/4 - 20 and intended for two hole compression lugs on .625”
centers. The recommended wire gauge is AWG 8. The output connections are:
Pin Function
Top left Battery Positive
Top Right Battery Positive
Bottom left Battery Negative (connection may not be required)
Bottom right Battery Negative (connection may not be required)
Charger Status Connection
This unit’s rear panel is equipped with an MS3112E8-4S status connector. This output
is designed to run an external status LED. In the event that any one of the following
conditions occur, 5 milli-amps of current will be applied to this connector:
• Power Switch A fault • Pulse Width Modulation Controller Fault
• Power Switch B fault • Low Input Voltage
• Heatsink A Over-Temperature • Low Output Voltage
• Heatsink B Over-Temperature
Installation

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Troubleshooting
This unit provides LED indicators to help diagnose any problems. The following table lists the
meanings of the LEDs and tips for troubleshooting the issues they indicate.
OVERTEMP Indicates that the battery charger is running too hot. The charger will shut
down until it cools and then resume normal operation.
The ambient temperature is too high or the charger is it located in a poorly
ventilated area.
UNDER VOLTAGE
INPUT
Indicates that the input voltage is not high enough for the charger to operate
normally.
Ensure the power source is supplying the correct voltage. Check that the
input connection and wires have not been damaged or corroded. Ensure the
gauge of the wires is suitable for the input current.
UNDER VOLTAGE
OUTPUT
Indicates that the output voltage has fallen to less than 50% of the regulated
value.
The battery connected to the charger may be defective, or too much load is
connected causing the battery to become severely discharged. REplace the
battery or reduce the load on the system. Check that the output connection
and wires have not been damaged or corroded.
The output connection is detailed as follows:
Pin Function
A LED Anode (positive)
B no connection
C LED Cathode (negative)
D no connection
A bright waterproof status
LED with an 0.5 meter cable
designed for operation with
this connection is available,
part number SASY.100308.

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Specications
Input Specications
Input Voltage Range 20 to 35 VDC
Inrush Current 40 Amps Peak
Input Amps 38A Maximum (at 20.0 VDC In)
Circuit Protection 40 Amp Magnetic Circuit Breaker
Noise on Input < 50mV p-p
Output Specications
Output Volts 27.2 VDC
Output Current 20 Amps Continuous
Output Fuse AGC 30 Amp
Efciency > 85% at 20 Amps Out
Regulation (Line or Load) +/- 1.0% max.
Noise and Ripple < 100mV p-p @ 20A Load
Output Overvoltage Protection 34 VDC Latching (Opens Input Circuit Breaker, manual reset)
Charging Stages 2 - Constant Current to Constant Voltage
Mechanical Specications
Case Material Black Anodized Extruded Aluminum Chassis, Black Anodized sheet
aluminum Front and Rear Panels, with 18-8 Stainless Fasteners
Audible Noise none, 0 db
Connections Input and Output - Marathon ST722B2502UH
Status - MS3112E8-4S
Dimensions 16.0 in / 40.6 cm Long x 8.0 in/ 19.3 cm Wide x 3.8 in / 9.7 cm High
Weight 17.5 lbs / 7.9 kg
Workmanship Manufactured in accordance with IPC-A-610
Isolation 500 VDC Input or Output to Case, Input to Output Common Negative
Environmental Specications
Operating Temperature -40°C to 60°C
Storage Temperature Range -50°C to 85°C
Cooling Convection Cooling via Case, 1 Inch Clearance all around recommended
Vibration Per MIL-STD 810G, Method 514-3, Cat-I Proc I
Shock Per MIL-STD 810G, Method 516-3, Proc 11, IV, VI
Humidity 0 - 95% Non-Condensing
Ingress Protection Designed to meet IP66 for water and dust protection
EMC – conducted emissions Designed to meet MIL-STD-461F: CE102, g CE102-1, 10kHz to 10MHz.
EMC – radiated emissions Designed to meet MIL-STD-461F: RE102, g RE102-4, 2MHz to 1GHz.