Cotek BP Series User manual

BP- □□□□ Series
Switch Mode 3 Stage
Battery Charger
User’s Manual

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List of contents
1. Important Safety Instructions……………………..……………………………. 1
1-1 General Safety Precautions………………….…………………………… 2
1-2 Precautions When Working with Batteries……….……………………… 3
2. Features………………………………………………………………….…………. 4
2-1 Battery Charging Curve………………………………..……….…………. 4
2-2 Electrical Performance……………………..……………………………… 5
2-3 Mechanical Drawings……………………………………..……………….. 6
3. Introduction…………………………………..…………………….……………… 7
3-1 Front Panel Operations..………………………………………..………… 7
3-2 Rear Panel Operations .……………………………………………..……. 8
3-3 Troubleshooting………………………..…..………………………………. 9
3-4 Selection of battery type………………..…….…………………………… 9
©Copyright : This manual is the copyright of COTEK Electronic Ind. Co., Ltd. And may not be reproduced or copied
without the express permission of the owner.

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1. Important Safety Instructions
1-1. General Safety Precautions
1-1-1. Do not expose the BP- Battery Charger to rain, snow, spray,
bilge or dust.
To reduce risk of hazard, do not cover or obstruct the ventilation
openings. Do not install the BP- Battery Charger in a
zero-clearance compartment. Overheating may result.
1-1-2. To avoid a risk of fire and electronic shock. Make sure that existing
wiring is in good electrical condition; and that wire size is not
undersized.
Do not operate the BP- Battery Charger with damaged or
substandard wiring.
1-1-3 The Battery terminal not connected to the chassis has to be
connected first. The other connections is to be made to this
chassis, remote from the battery and fuel line. The battery charger
is then to be connected to the supply mains.
1-1-4 After charging, disconnect the battery charger from supply mains.
Then remove the chassis connection and battery connection, in this
order.
1-1-5 Do not charge non-rechargeable batteries.
1-1-6 During charging the battery must be placed in a well ventilated area.
1-1-7 The battery charger must only be plugged-in to an earthed
socked-outlet.
1-1-8 If the power supply cord is damaged, it must be replaced by the
Manufacturer or its service agent or a similar qualified person in
Order to avoid a hazard.
WARNING !
Before you install and use Your BP- Battery Charger,
be to read and save these safety instructions.

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1-2. Precautions When Working with Batteries
1-2-1. If battery acid contacts skin or clothing, wash immediately with soap
and water. If acid enters eye, immediately flood eye with running
cold water for at least 20 minutes and get medical attention
immediately.
1-2-2. Never smoke or allow a spark or flame in vicinity of battery or
Engine.
1-2-3. Do not drop a metal tool on the battery. The resulting spark or
short-circuit on the battery or other electrical part may cause an
explosion.
1-2-4. Remove personal metal items such as rings, bracelets, necklaces,
and watches when working with a lead-acid battery.
A lead-acid battery produces a short-circuit current high enough to
weld a ring or the like to metal, causing a severe burn.

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2. Features
High-performance 3-stage charging effect
Advanced 8 bit microprocessor control circuit
Reverse battery protected by fuse
Ignition protection
Output short circuit protection
Over power protection
Switch mode technology
Easy to read LED’s for system status
Compact size, Light weight
2.1 Battery Charging Curve
CHARGING CURVE
Battery Voltage
Current
BULK ABSORPTION FLOATING
TIME
OUTPUT
IU Charging Characteristic
VA
VB
IA
IB
Model
VA
VB
IA
IB
12V / 5A 12V / 10A 24V / 5A 24V / 3A
28.8V14.4V
13.6V 27.2V
10A5A 5A 2.5A
1.5A0.75A 0.75A 0.38A
14.4V
13.6V
28.8V
27.2V

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2-2. Electrical Performance
Specification Technical Data
Model No BP-1205 BP-1210
Power Watt. 80W 160W
Input Voltage 100-240VAC / 50~60Hz
Power Factor PF: 0.98
Output Voltage 12V DC
Output Current 5A Max. 10A Max.
Safety UL1236 , CE , TUV , Pending
EMC
FCC Class A , EN55022:1994/A1:1995/A5:1997
EN61000-3-2:2000, EN61000-3-3:1995 and EN55024:1998
Dimensions 210 (L) x 85 (W) x 50 (H) mm / 8.26 (L) x 3.34 (W) x 1.96 (H) Inch
Weight 0.9 kgs. / 1.8 Lbs.
Specification Technical Data
Model No BP-2403 BP-2405
Power Watt. 80W 160W
Input Voltage 100-240VAC / 50~60Hz
Power Factor PF: 0.98
Output Voltage 24V DC
Output Current 2.5A Max. 5A Max.
Safety UL1236 , CE , TUV , Pending
EMC
FCC Class A , EN55022:1994/A1:1995/A5:1997
EN61000-3-2:2000, EN61000-3-3:1995 and EN55024:1998
Dimensions 210 (L) x 85 (W) x 50 (H) mm / 8.26 (L) x 3.34 (W) x 1.96 (H) Inch
Weight 0.9 kgs. / 1.8 Lbs.

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2-3. Mechanical Drawings

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3. Introduction
This BP- series is a high frequency switching mode 3-stage battery
Charger and equipped with a micro controller and PFC circuit to perform
Intelligent battery management and to provide highly reliable operation.
Before using the BP-, read all instructions and cautionary marking on
this manual.
3-1. Front Panel Operations:
3-1-1. Front view:
0N
0FF
0
I
AC INPUT
I
00FF
AC INPUT
0N

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3-1-2. ON / OFF switch:
Power ON/OFF switch, leave in the OFF position during installation.
3-1-3. LED Status
Charging Status LED Indication
Fast Charge Blinking Green Fast
Slow Charge Blinking Green Slow
Floating Charge Solid Green
Charging Fault Blinking Red
Bad Battery or Wire Disconnection Blinking Red
3-2. Rear Panel Operations:
STATUS
DC
OUTPUT
PUSH
FUSE
DC
3-2-1. Ventilation window:
Do not obstruct, allow at least 1 inch for air flow.
3-2-2. DC Output terminals:
Connect to 12V / 24V battery.
【＋】is positive,【－】is negative. Reverse polarity connection will
blow internal fuse and may damage BP- permanently.

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3-3. Troubleshooting :
Problems and Symptoms Possible Cause Solutions
“Red” LED Blinking Battery is disconnected Check the Battery
connection.
Battery fault Chang to another
new battery
LED light off No AC power delivering
Polarity Reverse
Thermal Shutdown
Check input power
connection.
Place proper polarity.
Check DC fuse if broken,
and then replace the
same rating fuse.
Make sure ventilation is
not obstructed.
Improve ventilation.
Reduce ambient
temperature.
3-4. Selection of battery types:
Sealed lead acid and open lead acid battery shall be used.
Model No. Battery Capacity ( Min.) Battery Capacity ( Max.)
BP-1205 12V / 15 Ah 12V / 50 Ah
BP-1210 12V / 30 Ah 12V / 100 Ah
BP-2403 24V / 7.5 Ah 24V / 25 Ah
BP-2405 24V / 15 Ah 24V / 50 Ah