Cofko LLC. BC-9000 User manual

BC-9000
BATTERY CHARGER
Operations Manual
COFKO ELECTRONICS LLC
COPYRIGHT © 2020
P/N 4169-20

Page 1
Unpacking
As you unpack your new BC-9000 battery charger, inspect the BC-9000 for signs of shipping damage. If shipping damage
is present, stop and contact the shipping company for damage claims information. The box should contain the following
items:
One (1) each-Part no. 4169 BC-9000 Battery Charger/ DC Power Supply
One (1) each-Part no. 4169-20, BC-9000 Instruction Manual
One (1) each-Part no. 4169-50, BC-9000 DC Output Cable
One (1) each-Part no. 4161-60, Battery Adaptor Cable with 5/16 (7.9mm) Ring Terminal connectors
One (1) each-Part no. 4161-70, Battery Adaptor Cable, Quick Disconnect Assembly 1
1 Note: 4161-70 Assembly consists of Part no. 4161-60 and MS3349-2 connector.
P/N 4169 P/N 4169-20 P/N 4169-50
P/N 4161-60 P/N 4161-70
IMPORTANT: Save the shipping box and packaging material. They should be used to repack the BC-9000 if it needs to
be shipped back for warranty or service.

Page 2
Introduction
Congratulations and thank you for purchasing your BC-9000 battery charger. The BC-9000 has been designed to provide
the operator with accurate battery charging and ease of operation.
The BC-9000 features:
- Universal AC power input 100-264VAC 1 PH (47 to 63Hz)
- NEMA 5-15P AC Plug
- Adjustable Charge Output Voltage from 3.0 to 36.0 Vdc. (0.1-volt steps)
- Adjustable Output Amperes from 0.05 to 25 Adc.
- Constant Voltage Charge.
- Constant Current Charge.
- Adjustable Charge Time from 1 to 999 minutes.
- Single or Two Step Charge Routine.
- Deep Discharge Recovery (D.D.R.). Charge Routine Mode.
- 16x4 Character LCD Display.
- 10mv Voltage Resolution.
- Over Temperature Protection
- DC Power Supply Mode.
- Forced Air Cooling.
- Beeper Audio Warning.
- 1-year warranty
Before operating your new BC-9000 familiarize yourself with this operation manual and the BC-9000.
Questions?
PH: [phone] or [email protected]
Thank you,
COFKO Electronics LLC

Page 3
Table of Contents
Unpacking 1
Introduction 2
Table of Contents 3
History of Revisions 4
Battery Handling and BC-9000 Operations Precautions 4,5,6
BC-9000 Operation 6
Battery Charging 7,8
AGM Lead Acid Battery Deep Discharge Recovery Mode 8,9
Power Supply Mode 9,10
BC-9000 Care 10
BC-9000 Technical Data 10,11
BC-9000 Limited Warranty 11
BC-9000 Notes 12

Page 4
History of Revisions
Revision # Effective Date Description of Change Approval by
A 12/20/2011 Initial Issue M.C.
B 10/23/2012 Increase Maximum Operation Altitude from 6000’ to 6500’ Page 11 M.C.
B 10/23/2012 Change Description of Box Contents Page 2 M.C.
C 04/05/2013 Minimum and Maximum Charger Operation Temperature Page 11 M.C.
D 01/03/2014 Update Safety Information Page 7 Line 9 M.C.
E 04/05/2014 Added Power Supply Mode Page 9 G.K.
F 04/28/2015 Add Box Content Part Numbers Page 2 M.C.
G 02/12/2016 Deep Discharge Recovery Mode Page 9 M.C.
H 02/12/2016 BC-9000 Configuration Page 6 M.C.
I 05/14/2020 Revised Issue Released M.C.
Battery Handling and BC-9000 Operations Precautions
Your new BC-9000 battery charger has been designed with operator safety as a function of its design, construction, and
operation. Understanding how to safely operate the BC-9000 is important. Failure to follow the operation and safety
guidelines when using the BC-9000 can result in personal injury to the operator and damage to the BC-9000. Always
review the battery manufacturer’s battery charging guidelines before recharging batteries.

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Look for this symbol to identify Safety and Danger precautions. Be Alert- Your safety is
involved! Personal injury or equipment damage can occur if guidelines are not followed.
Precautions
1. CAUTION: Aircraft batteries are certified to have a certain minimum capacity for emergency operations in the
event of an electrical generator system failure. Never “jump start” an aircraft that has a discharged or “dead”
battery.
2. WARNING: ELECTRIC SHOCK HAZARD. Do not touch un-insulated portions of the connector or the battery
terminals. A possibility of serious electrical shock exists. Do not lay tools or other metal objects on the battery
as arcing or explosion can occur. Remove conductive jewelry before working around battery, charger, or test
equipment.
3. CAUTION: ELECTRIC BURN HAZARD. Do not wear conductive rings, belt buckles, or other jewelry when working
with batteries, chargers, or test equipment. Do not lay tools or other metal objects on the battery as arcing and
severe burns could occur.
4. WARNING: Batteries on charge or discharge produce hydrogen gas, which can explode if ignited. Do not
smoke, use an open flame, or cause sparking near a battery. Charge, service or test a battery only in a well-
ventilated area. The use of exhaust fans may reduce the risk of explosion.
5. WARNING: Batteries contain sulfuric acid which will cause burns. DO NOT TOUCH EYES AFTER TOUCHING
BATTERY. Do not get acid in your eyes, or on your skin, or clothing. In the event of acid in the eyes, flush
thoroughly with clean cool water for several minutes. Get professional medical attention. Refer to battery MSDS
for additional information.
6. WARNING: Wear proper eye, face and hand protection always when working with batteries. Know the location
and use of emergency eyewash and shower nearest the battery charging area.
7. CAUTION: To prevent damage to the connector, arc burns, or explosion, batteries should never be connected,
or disconnected while being charged or discharged. Batteries must be connected or disconnected only when the
circuit is open. Ensure the aircraft battery switch, external power source, or the charger is in the “OFF” position
before connecting or disconnecting the battery. Battery terminal protectors should be installed whenever the
battery is not connected in the aircraft or to the test equipment.
8. CAUTION: Batteries contain hazardous materials. Know the location and proper use of emergency response
materials. Refer to battery Material Safety Data Sheet (MSDS) for additional information.
9. CAUTION / WARNING: Before charging or capacity testing a battery always REVIEW, UNDERSTAND, and
FOLLOW all fire and safety codes for your location. Always REVIEW, UNDERSTAND, and FOLLOW the battery
manufacturer’s battery charging and testing guidelines. Always REVIEW, UNDERSTAND, and FOLLOW the
equipment manufacturer’s battery charging and testing guidelines. If the battery is installed in equipment that
is sensitive to over voltage conditions, (i.e. Aircraft) NEVER charge using a constant current (CI) method. Only
charge using a constant voltage (CV) method. There can be a serious risk of injury to personal and or damage to
equipment (i.e. Aircraft) due to high voltage and generation of explosive gases when charging constant current
(CI).
10. DANGER: Never disconnect the AC power cord with recharge current applied to the battery. If you wish to
terminate a recharge cycle, press the NEXT button first to stop the battery recharge cycle. Now place the
POWER switch to the off position. The AC power cord can now be safely removed from the power source.

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11. DANGER: Never recharge batteries without first inspecting all battery wires and connections for condition and
tightness. Replace all defective wires and bad connections before charging batteries. Defective wiring and bad
connections can cause overheating during charging.
12. DANGER: Never connect the BC-9000 to batteries with voltage or recharge charge currents outside the ratings
of the charger. Any questions that arise about the battery or charger ratings, call [phone].
13. DANGER: Never obstruct the BC-9000 air intake or hot air exhaust openings. Obstructing either opening can
cause the BC-9000 to overheat.
BC-9000 Operation
NOTE: Before recharging a battery, review all recharging procedures as required by the battery
manufacturer. Failure to do so can result in permanent damage to the battery or the BC-9000.
DANGER: Never attempt to connect the BC-9000 charger to a battery using anything but the proper
connector. Doing so can damage the BC-9000, battery, or cause injury to the operator.
Warning: Contact the Cofko technical support before charging Lithium Ion batteries with the BC-9000.
Configure
1. Set the BC-9000 battery charger on a stable suitable surface. Plug the AC cord located at the rear of the BC-9000
into an AC power outlet (Note: The BC-9000 comes with a NEMA 5 -15 connector). Set the BC-9000 power
switch to the ON position.
2. Using the UP or DOWN button, select the CONFIGURE mode. Press the NEXT button.
3. To turn off the end of charge Beeper warning, press the NEXT button.
4. Using the UP or DOWN button, change the End Beep ? Y to N.
5. Press NEXT button to accept change.
6. Press UP or DOWN button to display the EXIT option.
7. Press NEXT button to exit the configure mode. The BC-9000 will reboot the display and beep signaling the
changes.
8. Use the UP or DOWN button the select other modes.

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Battery Charging
DANGER: The BC-9000 battery charger is a fully adjustable battery charger. The BC-9000 will follow
the operator settings during the battery charge cycle. Always consult the battery manufacturer’s CMM guidelines
before starting a charge cycle. If the battery is subjected to improper charge settings, serious damage or injury can
occur to the operator and the BC-9000. Critical settings, such as maximum charge voltage, maximum charge
amperes, and charge time must follow the battery manufacturer’s CMM guidelines. Always remove the battery from
the equipment before starting a charge cycle. SAFETY FIRST!
1. Set the BC-9000 on a stable suitable surface.
2. Plug the AC cord located at the rear of the BC-9000 into an AC power outlet. Connect the DC cord (4169-50) to the
BC-9000. (Note: The BC-9000 comes with a NEMA 5 -15P connector).
3. Using the UP or DOWN button, select charge steps. The BC-9000 will charge the battery using a single step or two
step charge mode. Single step charging is used to charge lead-acid and Lithium Ion batteries using constant
potential charging. Two step charging is used in constant current charging of nickel cadmium batteries. Press
NEXT.
a. If single step was selected above, enter the battery recharge time using the UP or Down buttons to
increase or decrease charge time. Charge time is in minutes with 60 minutes equaling 1-hour charge
time. Tip: Holding down the UP or DOWN buttons will rapidly advance the number selection. Press NEXT.
b. The BC-9000 display will now ask for a CHARGE VOLTS? selection. Single step charging requires only one
charge voltage selection. Charging voltage can be adjusted from 3.0 to 36.0 volts. Use the UP or DOWN
button to set the charging voltage. This voltage is the maximum voltage the BC-9000 will output to the
battery. Consult with the battery manufacturer for proper recharge voltage settings. Note: The charge
voltage selection must always be greater than the batteries rated voltage. Press NEXT.
c. The BC-9000 will now ask for CHARGE AMPS? selection. The BC-9000 recharge current can be adjusted
from 0.05 to 25 amperes. Consult the battery manufacturer recharge guidelines for proper settings.
Never set the recharge amperes to a value outside the battery recharge specifications. Press NEXT.
d. The BC-9000 will display the message START CHARGING? Press NEXT. Pressing the next button will start
the battery charging cycle. With the charger running, the BC-9000 display will show all the entered
settings under the CHARGING heading on the left side of the display. The arrow displayed will point to
the setting that is active at that moment of the charge cycle. On the right side of the display all the
charging readings are displayed under the ACTUAL heading. Upon completion of the charge cycle the
audio buzzer will beep, signaling the charge is done.
Note: The charge cycle can be stopped at any time by pressing the NEXT button.
4. If two step charge was entered above the BC-9000 will display CHARGE Step 1 Time?

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a. Enter the first step charge time using the UP or DOWN button. The time can be adjusted from 1 minute
to 999 minutes. Press the NEXT button to advance the display menu.
b. The BC-9000 will display CHARGE Step 1 Volts? Use the UP or DOWN button to adjust the value from 3.0
to 36.0 volts. Press the NEXT button to advance the display menu.
c. Now enter the first step charge current setting using the UP or DOWN button. The charge current can
be adjusted from 0.05 to 25 amperes. Press the NEXT button to advance the display menu.
d. The BC-9000 will display CHARGE Step 2 Time? Use the UP or DOWN button to adjust the charge time
value from 1 minute to 999 minutes. Press the NEXT button to advance the display menu.
e. The BC-9000 will display CHARGE Step 2 Voltage? Using the UP or DOWN button the step 2 voltage can
be adjusted from 12.5 to 36.0 volts. Press the NEXT button to advance the display menu.
f. Now enter the second step charge current setting using the UP or DOWN button. The charge current
can be adjusted from 0.05 to 25 amperes. Press the NEXT button to advance the display menu.
g. The BC-9000 will display the message START CHARGING? Press NEXT. Pressing the next button will start
the battery charging cycle.
h. With the charger running the BC-9000 display will show all the entered settings under the flashing
CHARGING/Step 1 heading on the left side of the display. The arrow on the far-left points to the limiting
item now. TIME, VOLTS, or AMPS. If a charge time limit was met the arrow will point to TIME. If the unit
is limiting the current to the user’s current limit setting, the arrow will point to AMPS (this is constant
current mode). If the unit is limiting the voltage to the user’s voltage limit setting, the arrow will point to
VOLTS (this is constant potential mode). The arrows will point to only 1 item at a time. If a charge time
limit has not been reached the arrow will point to VOLTS or AMPS to indicate constant voltage or
constant current charge mode respectively. The operating modes constant potential or constant current
are automatically invoked by your VOLTS and AMPS limit settings. The arrow displayed will point to the
setting that is active at that moment of the charge cycle. On the right side of the display all the current
charging readings are displayed under the ACTUAL heading. Upon completion of the charge cycle the
BC-9000 will turn off the charge and turn on the audio beeper to signal the charge cycle is done.
The charge cycle can be stopped at any time by pressing the NEXT button.
AGM Lead Acid Battery Deep Discharge Recovery (D.D.R.) Mode
Deep Discharge Recovery (D.D.R) mode is specifically for Concorde® sealed AGM lead acid batteries. If a battery has
been accidently completely discharged, D.D.R. provides the battery technician with a charge routine that attempts to
recover the battery to working condition. The D.D.R. charge routine utilizes two phases D.D.R.1 and D.D.R.2. D.D.R.1
consist of a 240-minute constant current pre-charge. The maximum charge voltage is set to 36 volts for a 24-volt battery
and 18-volts for a 12-volt battery. The charge current is set to 1/10th the batteries C1 Amp hour rating. A C1 rated
battery of 40-Ahr yields a constant current 4-Amp charge rate.
D.D.R.1 starts with 240 minutes of charge time. After the 240-minute time is reached, the D.D.R.1 program checks the

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on-charge battery voltage. If the battery voltage rises to or greater than the prescribed battery voltage set point (12-volt
battery = 15.5-volts, 24-volt battery = 31-volts) D.D.R.2 is started. If the on-charge voltage is less than the prescribed
voltage, the D.D.R.1 charge is continued up to 1440 minutes. If the prescribed-on charge voltage point is not reached
after 1440 minutes, D.D.R. is terminated.
D.D.R.2 phase will load the charger timer with 240 minutes (4-hours). The D.D.R.2 charge amperage is 1/10th the battery
C1 rating.
For non-Concorde® sealed AGM lead acid batteries, consult your battery manufacturer’s component
maintenance manual (CMM) before using the DDR charge mode.
Never use D.D.R. on Nickle Cadmium or Lithium-Ion batteries.
1. Set the BC-9000 on a stable surface.
2. Connect the AC power cord (4161-10) to the AC power source. Connect the DC cord (4161-50) to the BC-9000
and the battery. Set the AC power switch to the ON position.
3. Press the UP or DOWN buttons to select the Mode? DEEP DIS. RECOVER.
4. Press the NEXT button to select the DEEP DIS. RECOVER option.
5. Press the UP or DOWN buttons to select the battery voltage. 12 or 24-volts.
6. Press the NEXT button to enter the value.
7. Now select the C1 AMPS ? Use the UP or DOWN buttons to select the C1 AHr battery rating. This value can be
found in the battery manufacturer’s model specifications.
8. Press the NEXT button to select the entered value.
9. Press the NEXT button to start the DEEP DIS. RECOVER mode.
10. To stop the DDR charge, routine press the NEXT button.
11. At the completion of the DDR charge, the BC-9000 LCD display will provide a summary of the charge results.
Power Supply Mode
The BC-9000 DC output connector has power applied when the power supply mode is active. Never attach a
load to the DC output with the output energized. Sparks at the DC output connector can occur and damage the BC-
9000.
Never use an improper adaptor connector to attach the BC-9000 to the targeted equipment.