Bassi BDX User manual

[ver 100 Sept 2013] [M2013Oct10V100GR] BASSI-BDX
User's Manua
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DISCHARGER
BDX
USER'S MANUAL
Software Revision ver 100
Sept 2013
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[ver 100 Sept 2013] [M2013Oct10V100GR] BASSI-BDX
User's Manua
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1. SAFETY INSTRUCTIONS AND
WARNINGS
GENERAL
Battery dischargers can cause injury or death, or damage to other equipment or property, if the user
does not strictly observe all safety rules and take precautionary actions.
Safe practices must be learned through study and training before using this equipment.
Only qualified personnel should install, use, or service this battery discharger.
SHOCK PREVENTION
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipments can
fatally shock a person. To protect against shock, have competent electrician verify that the equipment is
adequately grounded and learn hat terminals and parts are electrically HOT.
The body’s electrical resistance is decreased hen et, permitting dangerous current to flo through the
body. Do not ork in damp area ithout being extremely careful. Stand on dry rubber mat or dry ood
and use insulating gloves hen dampness or s eat cannot be avoided. Keep clothing dry.
INSTALLATION AND GROUNDING – Electrical equipment must be installed and mantained in
accordance ith all the applicable national and local codes.
A po er disconnect s itch must be located at the equipment. Check the data label for voltage and phase
requirements. If only 3-phase po er is available, connect single-phase equipment to ONLY TWO
WIRES of the 3-phase line.
DO NOT CONNECT the equipment grounding conductor to the third live ire of the 3-phase line as this
makes the equipment frame electrically HOT, hich can cause a fatal shock.
If a grounding conductor is part of the po er supply cable, be sure to connect it to a properly grounded
s itch box or building ground. If not part of the supply cable, use a separate grounding conductor. Don’t
remove a ground prong from any plug. Use correct mating receptacles. Check ground for electrical
continuity before using equipment.
The grounding conductor must be of a size equal to or larger than the size recommended by Code or this
manual.
CHARGING LEADS – Inspect leads often for damage to the insulation. Replace or repair cracked or
orn leads immediately. Use leads having sufficient capacity to carry the operating current ithout
overheating.
BATTERY TERMINALS – Do not touch battery terminals hile equipment is operating.
SERVICE AND MAINTENANCE – Shut OFF all po er at the disconnect s itch or line breaker
BEFORE inspecting, adjusting, or servicing the equipment. Lock s itch OPEN (or remove line fuses) so
that the po er cannot be turned ON accidentally.
Disconnect po er to equipment if it is to be left unattended or out of service.
Disconnect battery from discharger.
Measure voltage on capacitors and, if there is any voltage reading, ait 5 minutes before to proceed.
Keep inside parts clean and dry. Dirt and/or moisture can cause insulation failure. This failure can result
in high voltage at the discharger output.
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[ver 100 Sept 2013] [M2013Oct10V100GR] BASSI-BDX
User's Manua
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BURN AND BODILY INJURY PREVENTION
The battery produces very high currents hen short circuited, and ill burn the skin severely if in
contact ith any metal conductor that is carrying this current.
Do not permit rings on fingers to come in contact ith battery terminals or the cell connectors on top of
the battery.
Battery acid is very corrosive. Al ais ear correct eye and body protection hen near batteries.
FIRE AND EXPLOSION PREVENTION
When batteries are being recharged, they generate hydrogen gas that is explosive in certain
concentrations in air (the flammability or explosive limits are 4.1% to 72% hydrogen in air). The spark-
retarding vents help slo the rate of release of hydrogen, but the escaping hydrogen may form an
explosive atmosphere around the battery if ventilation is poor.
The ventilation system should be designed to provide an adequate amount of fresh air for the number of
batteries being charged. This is essential to prevent an explosion.
Al ays keep sparks, flames, burning cigarettes, and other sources of ignition a ay from the battery
recharging area. Do not break "live" circuits at the terminals of batteries. Do not lay tools or anything
that is metallic on top of any battery.
To prevent arcing and burning of the connector contacts, be sure the discharger is OFF before
connecting or disconnecting the battery. The digital display must be completely OFF.
MEDICAL AND FIRST AID TREATMENT
First aid facilities and a qualified first aid person should be available for each shift for immediate
treatment of electrical shock victims.
EMERGENCY FIRST AID: Call phisician and ambulance immediately and use First Aid techniques
recommended by the American Red Cross.
DANGER: ELECTRICAL SHOCK CAN BE FATAL.
If person is unconscious and electric shock is suspected, do not touch person if he or she is in contact
ith charging equipment, battery, charging leads, or other live electrical parts. Disconnect po er at all
s itch and then use First Aid.
Dry ood, ooden broom, and other insulating material can be used to move cables, if necessary, a ay
from person.
IF BREATHING IS DIFFICULT, give oxygen.
IF NOT BREATHING, BEGIN ARTIFICIAL BREATHING, such as mouth-to-mouth.
IF PULSE IS ABSENT, BEGIN ARTIFICIAL CIRCULATION, such as external heart massage.
In case of acid in the eyes, flush very ell ith clean ater and obtain professional medical attention
immediately.
EQUIPMENT WARNING LABELS
Inspect all precautionary labels on the equipment.
Order and replace all labels that cannot be easily read.
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User's Manua
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2. DESCRIPTION
The BDX battery discharger/ana yzers have been designed to test the efficiency of batteries of
any type, vo tage and capacity.
These instruments perform a contro ed discharge of the battery, whi e the current is kept
constant by a high frequency DC/DC converter, based on MOSFET techno ogy for sma er
units and IGBT techno ogy for bigger units.
The operation of the BDX is comp ete y automatic: it's sufficient to connect the battery, to set
the stop vo tage, the maximum time and the discharge current.
A the test is made automatica y, whi e the digita disp ay shows the partia resu ts.
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[ver 100 Sept 2013] [M2013Oct10V100GR] BASSI-BDX
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RECOMMENDED DISCHARGE CURRENT
BATTERY
CAPACITY
DISCHARGE CURRENT
C5 (Ah) AMPS (A)
50 10
60 12
80 16
100 20
120 24
180 36
200 40
240 48
300 60
360 72
380 76
400 80
420 84
480 96
500 100
540 108
600 120
700 140
750 150
800 160
900 180
1000 200
RECOMMENDED STOP VOLTAGE
NOMINAL VOLTAGE STOP VOLTAGE
V V
6 5,1
12 10,2
24 20,4
36 30,6
48 40,8
72 61,2
80 68,0
96 81,6
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TEST VALUE
Whi e the test is in progress, it's a ways possib e to visua ize on the disp ay a the partia
resu ts of the test, by pressing the button “SET”:
PARAMETER UNITS
CURRENT (AMPS)
CAPACITY DISCHARGED (AMPS*HOURS)
TIME (HOURS.MINUTE DECADES)
BATTERY VOLTAGE (VOLTS)
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3. INSTALLATION OF DISCHARGER
Conditions of use:
•Operating /Storage temperature: 5°C to 45°C
•Relative humidity: less than 75%
A
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WARNING !
The discharger can be installed by qualified personnel only!
To avoid the risk of injuries, the user is not allo ed to open the cabinet.
Al ays refer to qualified electricians for installation and service operations.
WARNING !
To prevent fire or shock hazard, do not expose the discharger to rain or moisture.
Do not use the e discharger in presence of flammable gas, because it can generate sparks!
Do not install the discharger near flammable materials.
CAUTION !
Before to install the discharger:
Check that the discharger input voltage (V) is identical to your AC po er supply voltage.
Check that the discharger max input po er (KVA) is available from your AC po er supply.
WARNING !
To reduce the risk of fire, the discharger must be installed on a
floor of non-combustible material.
If this is not possible, a floor plate of at least 1,6mm steel extended
at least 150mm beyond the discharger on all sides must be installed.

[ver 100 Sept 2013] [M2013Oct10V100GR] BASSI-BDX
User's Manua
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GROUNDING AND LINE CONNECTION
If the discharger is to be connected to the AC po er supply ith a flexible jacketed cable, one having a
separate grounding conductor should be used.
If, for any reason, an input cable hich does not include a grounding conductor is used, the equipment
must be grounded ith separate conductor. Minimum size and color coding requirements must be in
accordance ith any applicable national or local code.
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WARNING !
The cabinet of the battery discharger must be properly grounded to protect
personnel against hazard of electrical shock in case of fault on the discharger!
The grounding conductor must have a current carrying capacity equal or
higher than the current carrying capacity of the AC-input ires.
CAUTION !
Allo adequate air circulation to prevent internal heat buildup.
Do not place the unit near materials that may block the ventilation slots.
Do not install the unit near heat sources such as radiators or air ducts, or in a place subject to
direct sunlight, excessive dust, mechanical vibration or shock.

[ver 100 Sept 2013] [M2013Oct10V100GR] BASSI-BDX
User's Manua
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LOCATION - Choose your insta ation ocation to:
· Avoid tempe atu e and humidity ext emes.
· Minimize moistu e and dust.
· P ovide adequate ai ci culation to p event the buildup of fumes.
· Install on a cement pad minimum 7” above su ounding cu bing o walkways fo wate flood
cont ol,
· Maintain a minimum of 32” (80 cm) of clea ance on the sides of the unit fo p ope
ventilation.
· Maintain 18” (45 cm) minimum clea ance on F ont and Back fo se vicing as equi ed by
local codes.
· Do not install unit whe e it will be exposed to di ect sunlight.
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[ver 100 Sept 2013] [M2013Oct10V100GR] BASSI-BDX
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4. HOW TO USE THE DISCHARGER
PRELIMINARY CHECKS
•Inspect the discharger completey for loose scre s, electrical connections or other damages;
•Check that all the ventilation slots are not obstructed to assure proper air flo ;
•Make sure that the discharger is installed as instructed in this manual and in accordance ith any
applicable national or local Code.
PROGRAMMATION
Turn on the discharger by moving the main s itch to position “1”.
The discharger ill perform an automatic test of the control circuits, and ill ait for a random delay
on start.
The display ill visualize the follo ing messages.
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BASSI - BATTERY
BDX - DISCHARGER

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BDX DISCHARGER
MAX xxx V – xxx A
SYSTEM CHECK
PLEASE WAIT ...
SYSTEM READY
DATE TIME

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User's Manua
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USER PROGRAMMING MODE
HOW TO ACTIVATE USER PROGRAMMING MODE
•Press the button DOWN and keep it pressed for 3 seconds
The display ill sho the message:
•Enter the Programming Pass ord.
The display ill sho the message:
HOW TO MODIFY A VALUE
•Scroll bet een the programmable values using the UP/DOWN buttons.
•In order to modify a value, press ENTER and keep it pressed for 2 seconds, until the cursor ill
start blinking over the value that can be modified.
•Modify the value using the UP/DOWN buttons.
•Confirm the modified value by pressing ENTER for 2 seconds, until the cursor ill disappear. At
this point the ne value ill be saved.
HOW TO RETURN TO NORMAL MODE
•Press the buttons UP and DOWN simultaneously.
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EDIT PASSWORD
MOD. SETTING

[ver 100 Sept 2013] [M2013Oct10V100GR] BASSI-BDX
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PARAMETER 1 DATE and TIME
Programmab e va ues: Month/Day/Yea , Hou /Minutes
Defau t va ue: Easte n Time (GMT-5)
NOTES:
It's fundamental to keep the Real Time lock set to the correct date and time, in order to use all the time base
functions.The Discharger calculates the Day of the Week automatically, however it's necessary to adjust the
Clock manually in Daylight saving time periods.
PARAMETER 2 START TIME WINDOW
Programmab e va ues: F om 00.00 to 23:59
Defau t va ue: F om 00.00 to 23:59
NOTES:
This parameter sets a time indo during the day in hich the discharger is allo ed to start a ne
discharge cycle. If a battery is connected outside of this time indo , the discharger ill remain in
stand-by mode until the programmed Start time ill be reached.
Once the discharge cycle has begun, this time indo is not considered anymore.
PARAMETER 3 MAX TEMPERATURE
Programmab e va ues: f om (45 to 70 °C) 115 to 160 °F, o DISABLED
Defau t va ue: (60 °C) 140 °F
NOTES:This pa amete sets a maximum limit fo the batte y tempe atu e. If this limit is
eached, the cha ge is te minated and a specific e o message is given. This
functionality equi es the connection of an optional tempe atu e p obe.
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START BEG<->END
00:00 2 .59
TEMPERATURE
TOO HIGH

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(SPECIAL PARAMETERS FOR REGENERATIVE SYSTEM
CHARGER + DISCHARGER)
PARAMETER 4 CONSECUTIVE CYCLE
Programmab e va ues: f om 1 to 20 , o DISABLED
Defau t va ue: DISABLED
NOTES:
The discharger can apply a recursive number of discharging cycle at the same battery,
This function is very useful in case of regenerative test charger (MVD) and discharger (BDX)
PARAMETER 5 TIME WAIT CHARGE
Programmab e va ues: f om 1 to 99 Hou o DISABLED
Defau t va ue: DISABLED
NOTES:
In case of egene ation mode (Cha ge MVD + discha ge BDX), this pa amete define the
maximum time of cha ging, du ing this time, the discha ge will check voltage, but it cannot
esta t in automatic mode.
In standa d application no mally the use will conside the maximum time of cha ging and he
will add 2 hou s in o de to wait a cooling of the batte y, befo e to launch a new discha ging
cycle
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5. OPERATION
CONNECTION OF THE BATTERY AND AUTOMATIC RECOGNITION
Connect the Battery to the discharger, using a connector of adequate size.
When the battery is correctly connected, the discharger visualizes the follo ing message:
The display ill sho :
The discha ge shows the value used in the p evious discha ging cycle.
The use need to set the value of cu ent (Amps) in acco ding with the capacity/time/size of
the batte y to test.
(change this setting with button ENTER 3 'secs' and p ess button UP/DW to set the value,
confi m the change with button ENTER 3 secs)
-----P ess Button DW to sc oll next pa amete
In left side the use eads a eal voltage of the batte y, in ight side the use eads the ta get
final voltage. This final voltage will define the END of the Discha ging cycle.
The use need to set the value of final voltage (V) in acco ding with the capacity/time/size of
the batte y to test.
(change this setting with button ENTER 3 'secs' and p ess button UP/DW to set the value,
confi m the change with button ENTER 3 secs)
-----Press Button DW to scroll next parameter
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AMPERE DISCHARG.
100 A
BATTERY
CONNECTED
DISCHARGING VOLT
22.6 V → 19.4 V

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The discha ge shows the value used in the p evious discha ging cycle.
The use need to set the value of capacity to etu n OFF (Ampe Hou ) in acco ding with the
capacity/time/size of the batte y to test.
This capacity etu ned will define the END of the Discha ging cycle.
(change this setting with button ENTER 3 'secs' and p ess button UP/DW to set the value,
confi m the change with button ENTER 3 secs)
-----Press Button DW to scroll next parameter
The discha ge shows the value used in the p evious discha ging cycle.
The use need to set the value of maximum discha ging time to etu n OFF (HOUR) in
acco ding with the capacity/time/size of the batte y to test.
This maximum time will define the END of the Discha ging cycle.
(change this setting with button ENTER 3 'secs' and p ess button UP/DW to set the value,
confi m the change with button ENTER 3 secs)
-----Press Button together UP+DW at the same time for launch a discharging cycle
Once the discharger has been properly set, the display visualizes the message:
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PREPARING TO
DISCHARGE
AMPEREHOUR DISCH
200Ah
DISCHARGING TIME
4 HH

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ERROR SETTING
In case that the user inserted a bad values, not comaptible in terms of Ampere, AmpereHour, Time,
Final Volt
If this message appears, it's recommended to verify launch ne discharging test, and check all
parameters inserted.
BATTERY VOLTAGE TOO LOW
If the battery voltage is lo er than a minimum threshold, the discharge cycle ill not start and the
display visualizes the message:
If this message appears, it's recommended to verify that the nominal battery voltage.
BATTERY VOLTAGE TOO HIGH
If the battery voltage is higher than a maximum threshold, the discharge cycle ill not start and the
display visualizes the message:
If this message appears, it's recommended to verify that the nominal battery voltage.
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ERROR
PARAMETER
BATTERY VOLTAGE
TOO LOW !!!
BATTERY VOLTAGE
TOO HIGH !!!

[ver 100 Sept 2013] [M2013Oct10V100GR] BASSI-BDX
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BATTERY TEMPERATURE TOO HIGH
If the battery temperature is higher than a maximum threshold, the discharge cycle ill stop and the
display visualizes the message:
If this message appears, it's recommended to verify the temperature of the battery, and even redefine the
Amps settings, because the battery seems sthermal tressed
OUTPUT CURRENT NOT CORRECT
If the discharger have a difficult to manage konstant current fase, the display ill sho
If this message appears, it's recommended to verify that the voltage of the battery is too lo , and at the
same time the current in discharging is too high
FUSE ERROR OR POWER STAGE ERROR
If the discharger is not able to manage output current
If this message appears, it's recommended to ait 30 minutes, in order to reduce the internal
temperature of the discharger, after this time it is possibile launch a ne discharging cycle.
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BATTERY TEMPERATURE
TOO HIGH !!!
EMERGENCY STOP
CURRENT
EMERGENCY STOP
SEE MANUAL

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DISCHARGE CYCLE
When the preliminary controls are complete, the discharge starts and the display visualizes the follo ing
information:
•Batte y Voltage [Volt]
•Discha ging Cu ent [Amps]
•Time of Cha ge [hou s.minutes]
•Capacity Retu ned [Ah]
The Discharger performs an konstant current discharging profile.
While the discharge is in progress, it's al ays possible to scroll bet een different menu pages, using the
buttons UP/DOWN:
•DISCHARGE STATE
◦Identifies the position in the charge curve, ith reference to the picture blo .
•TEMPERATURE
◦Visualizes the temperature of the battery, if the optional probe is connected.
•HISTORY LOG
◦Visualizes the history log of the previous charge cycles. Refer to Paragraph 6 “History Log”
AC INPUT BLACK OUT
If there is a black-out of the AC input, hile the discharge is in progress, the discharger ill shut do n,
When the AC input ill be recovered, the discharger ill ait that the user launch a ne discharging
cycle.
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xx.x V xxx A
xxx Ah x.x t
RESTART AFTER
POWER SUPPLY OFF