Analytic Systems BCDi320 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
BCDi320
Intelligent DC
Battery Charger

Copyright (2005-2019) Analytic Systems Ware (1993) Ltd.
Revised - May 29, 2019

3
DC SOURCE BATTERY CHARGER
IMPORTANT SAFETY INSTRUCTIONS
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
anytime it is plugged into an AC outlet, even if it is switched off.
4. To reduce risk of electric shock, unplug the battery charger from the AC outlet before at-
tempting 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 the battery charger.
BATTERY SAFETY
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.

4
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 minutes and
get medical attention immediately
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 another electrical part and 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 the area around battery is well ventilated.
xi. Clean the battery terminals regularly. 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.

54
Introduction
The BCDi320 series Intelligent DC-source Battery Charger works any standard DC voltage to
deliver up to 300 watts of precision charging power to charge your 12, 24, 32, or 48 volt battery
systems (The batteries must share a common ground).
This unit uses advanced Power Factor Correction circuitry on the input to use the electricity in the
most effective and efcient way. Inside, LLC Resonant Converter technology allows Zero Voltage/
Zero Current switching on the primary or high voltage side of the main power transformer. On
the secondary or low voltage side, active rectication ensures maximum efciency and minimum
electromagnetic interference (EMI) for operation near sensitive radio frequency communication
equipment.
On the front panel, eight dual color LEDs to clearly indicate charging levels and operating condi-
tion. Two sets of easy-to-use color coded battery connection terminals. Two battery temperature
sensor ports are available for connection with the supplied battery temperature sensor (a second
sensor can be added for monitoring two bank systems).
The charger is pre-programmed with the charging proles for three standard types of Lead Acid
batteries; Flooded (traditional Lead Acid), AGM (Absorbed Glass Mat Lead Acid) and Gel or VRLA
(Valve Regulated Lead Acid). A fourth prole pre-set for a typical Lithium Ion battery is also avail-
able. These proles can be further customized by choosing 2 or 3 stage charging using the stage
select switch on the front panel.
Any of the charging proles can adjusted to suit any specic make and model of battery using the
free-to-download PowerWizard software from www.AnalyticSystems.com. PowerWizard adds
advanced algorithm reprogramming, charger monitoring and graphing function all accessible
through the front panel USB port.
The charger uses the temperature data to compensate the output voltage for optimal charging
as well as for monitoring purposes to prevent the battery from overheating during charging and
equalize cycles. Other safety features include charger over temperature shutdown, current limit-
ing, short circuit protection, input under voltage shutdown and output over voltage protection all
with automatic recovery.
Package Contents
The box you’ve received should contain:
• One BCDi320 Intelligent Battery Charger
• One Battery Temperature Sensor
• One USB cable
• This user guide (a .pdf copy can be downloaded from www.analyticsystems.com)
• One Warranty Registration Card
If anything is damaged or missing, please contact us by emailing [email protected]

6
Main Parts
1. Power Button
2. USB Communications Port
3. Indicator LED Display
4. Battery Temperature Sensor
Connection Ports
5. Program Button
Front Panel
Rear Panel
10
2
3
4
6. End-of-Charge Switch
7. Equalize Start Button
8. Stage Select Switch
9. Battery Output Connection: 2x
Phoenix VDFK Terminal Block Connetions
(Red: Positive, Black Negative)
10. Chassis Grounding Stud
1. DC Power Input Connection:
2x Type-D #14AWG Input Leads
(Red: Positive, Black Negative)
5
6
8
7
1
9
2. DC Input Fuse: (Ceramic 6.3A 400
VDC
1
2

76
Operation
1. Connect the unit to the DC power source and batteries being charged.
2. Press the Power Button on the unit’s front panel.
3. The battery charger will go through its startup sequence. All 6 microprocessor-controlled
LEDs ash red and then green. When the Power Button starts glowing, the sequence is
complete.
4. The charger will automatically begin charging the connected batteries according to the
settings selected during setup. See Conguration Mode for more information.
The BCDi320 battery charger is designed for simple and intuitive operation. It is intended to
operate fully unattended and will attempt to recover from any fault, including Charger Over-
Temperature, Battery Over-Temperature, Low Input Voltage, Input Power Failure and more.
In addition to being a battery charger, the BCDi320 is also capable of functioning as a power
supply. While in Power Supply Mode, the unit’s functionality is changed in the following
ways:
• The DC (Battery) Outputs will be live regardless of whether or not a battery is detected.
• The End-of-Charge Switch and Stage Select Switch have no function.
• The Equalize Start button has no function.
• The Power Supply’s output voltage is same value as the Battery Charger’s oat voltage.
This value can be changed using PowerWizard. See the PowerWizard manual, for more
information.
BATTERY CHARGER MODE
In Charger mode, the LED indicators show the amount of current being supplied to the
battery. This current drops and the battery voltage rises as charging nishes.
75
BLINKING
CHARGING CURRENT
60-84%
I/P
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CHARGING COMPLETE
I/P
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CHARGING CURRENT
1-10%
I/P
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CHARGING CURRENT
40-59%
I/P
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CHARGING CURRENT
>85%
I/P
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CHARGING CURRENT
11-39%
I/P
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS

8
1. Connect the unit to the DC power source and batteries being charged.
2. Press the Power Button on the unit’s front panel.
3. The battery charger will go through its startup sequence. All 6 microprocessor-controlled
LEDs ash red and then green. When the Power Button starts glowing, the sequence is
complete.
4. Press and hold the Power Button until you hear two beeps,indicating the unit is in Power
Supply mode. The unit will remain in Power Supply mode until switched back to Charger
mode, even if it is turned off.
5. To change the unit back to Battery Charger mode, press and hold the Power Button until
you hear one beep.
POWER SUPPLY MODE
In Power Supply mode, the LED indicators show show the amount of current being
drawn by the load(s).
75
BLINKING
CURRENT > 11-39%
I/P
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CURRENT = 100%
I/P
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CURRENT >85%
I/P
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CURRENT > 40-59%
I/P
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CURRENT < 10%
I/P
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CURRENT > 60-84%
I/P
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS

9
Installation
MOUNTING
When mounting your unit, take the
following into consideration:
• The indicator LEDs and front panel
controls should be easy to read and
access.
• There are at least 2 inches of
clearance all around the charger for
adequate air circulation and heat
dissipation.
• The battery should be close to the
charger to easy connection and to
prevent trampling of the wiring.
• If there is possibility of water drippage, such as if the charger is in a marine environment,
install the optional drip shield above the unit.
Red Input Lead - Positive DC Terminal
Black Input Lead - Negative DC Terminal
Normally these leads should be adequate to connect to the DC power source, however, if you
must extend the leads, be sure to:
• Use the smallest extension length possible.
• Use a good quality (typeTEW) wire
• Use no less than 14 gauge conductors.
• Splice and solder the joints and protect the joints with heat shrink tubing.
INPUT POWER CONNECTION
The unit is equipped with two 3-foot/1 meter Type D Stranded AWG14 wire leads to serve as
a DC Input Connection. Connect these leads to the DC power source in the polarity indicated.
DANGER: Do not connect or disconnect anything to the unit while it is powered.
To reduce the risk of high voltage electric shock, never connect or disconnect anything to the
BCDi320 while it is ON.

10
DC OUTPUT CONNECTION
This unit is equipped with a pair of Phoenix VDFK Terminal block connectors to serve as a DC Output
connection for connection to battery banks. The connection can support up to two connected battery
banks. The polarity for these connections can be found on the unit’s front panel label.
CAUTION: If you are charging two banks of batteries, they MUST share a common ground!
Connector Color Polarity
Red Battery Positive Output
Black Battery Negative Output
CAUTION: Do not connect the battery in the reverse polarity!!
This will activate the reverse connection protection which will blow the output fuses inside the unit
in order to protect the device.The unit will be inoperable until these fuses have been replaced.
Max. Output Current 24.00 A 15.00 A 9.30 A 5.90 A 3.70 A
American Wire Gauge #8AWG #10AWG #12AWG #14AWG #16AWG
Max. Output Current 2.30 A 1.50 A 0.92 A 0.58 A 0.23 A
American Wire Gauge #18AWG #20AWG #22AWG #24AWG #28AWG
IMPORTANT: Make sure the wiring used to make the output connection is appropriately
rated for the expected Output Current. See specications or your unit’s label for the maximum
output current and the table below for usable wire gauges.