Datron PRC-BC4 User manual

PRC-BC4
Multiple Battery Charger
Operator/Technical Manual
Manual Part No. PRC-BC4-MS
Release Date: May 2016
Revision: G

Datron World Communications Inc.
995 Joshua Way, Suite A
Vista, CA 92081, U.S.A.
Phone: [phone] Fax: [phone]
E-Mail: [e-mail]
www.dtwc.com

PRC-BC4-MS i
Revision History
Date of
Revision
Revision
Letter Description of Changes Pages Affected
02/93 D1 Last update. All
09/06 E Convert to FrameMaker and overall update. All
06/11 F Updated the Charger board component locations
diagrams (738100) and parts list (PRC-BC4CHG).
Updated the Display board component locations
diagram (738101) and parts list (PRC-BC4DIS).
4-4, 4-7
4-16, 4-17
05/16 G Update manual format
Update parts lists to latest revisions
All
4-7, 4-11

PRC-BC4-MS iii
Warranty
© 2016 Datron World Communications, Inc. (Datron)
All rights reserved.
Datron World Communications, Inc.
This manual, as well as the software described in it, is furnished
under license and may only be used or copied in accordance
with the terms of such license. The information in this manual is
furnished for informational use only, and is subject to change
without notice. It should not be construed as a commitment by
Datron. Datron assumes no responsibility or liability for any
errors or inaccuracies that may appear in this book.
Except as permitted by such license, no part of this publication
may be reproduced, stored in a retrieval system, or transmitted,
in any form or by any means, electronic, mechanical, recording,
or otherwise without the prior written permission of Datron.
Software License Agreement and Warranty
This software is licensed to the user (licensee) under the
express terms and conditions of Datron’s software licensing
policies and agreement as outlined below. By receiving and
installing this software package the user (licensee) has
indicated acceptance of the terms and conditions of this
agreement presented herewith.
As used in this document, the term “Software” shall refer to the
application or control software in machine readable format and
the hardware protection key, along with any or all supporting
documentation, as well as all updated or enhanced versions of
the program supplied to the user at later date(s). This software
license does not include source code, and therefore, no license
is granted with respect to source code of any kind utilized
directly or indirectly in any Datron or Datron supplied third party
product. Note, in some cases, covered software may be
included in Datron products in RAM or ROM, and/or forms of
machine readable code, not readily accessible to the user or
licensee.
In consideration of the terms and conditions of this agreement,
Datron grants the user a non-exclusive, nontransferable license
to install and operate one copy of the program. Licensee agrees
not to attempt, aid, authorize, or direct any effort, either directly
or indirectly to reverse engineer or reverse compile the
Software. Licensee further agrees they or their agents are not
authorized to make derivative versions or changes to the
Software.
Title to and ownership of the Software shall at all times remain
with Datron and/or its licensors. Further, no license is granted to
copy or reproduce in any form whatsoever the Software
supplied without the express written permission of Datron, prior
to any such contemplated action.
Datron may terminate this agreement and discontinue further
warranty coverage at any time due to failure to comply with the
terms and conditions of this agreement.
In such an event, Datron will provide the user with written notice
of such a “failure-to-comply” and the user will have 10 days to
demonstrate that a remedy has been implemented. If the user
fails to perform, the agreement will be terminated by further
written notice from Datron. Upon termination, the user shall
immediately return all original Software, documentation, and
any copies of each to Datron.
This Software is licensed “AS IS” and Datron provides a
warranty that covers the media upon which the Software is
embedded for a period of 30 days from receipt of the product.
Under this warranty policy Datron’s sole obligation shall be to
replace or repair, at Datron’s discretion, any such media that in
Datron’s opinion proves defective.
The user is obligated to provide Datron with a detailed
description of possible defects along with sample material such
that Datron can reproduce the identified defects.
By receipt and use, user (licensee) acknowledges that certain
software developed or distributed by Datron is controlled by one
or more governmental agencies. The user (licensee) herewith
acknowledges they will take all necessary actions to comply
with applicable regulations concerning the use of licensed
software. Further, Datron is under no obligation to supply source
code or documentation of its software for any reason.
Datron makes no representation, express or implied, with
respect to any Software licensed under this document as to its
fitness for any particular purpose or intended use.
Furthermore, Datron shall have no liability under this agreement
for any incidental, special, or consequential damages arising
out of the use of any supplied software programs. Datron
reserves the right to make periodic changes in it’s software for
any purpose without any obligation to notify users.

iv PRC-BC4-MS
One Year Limited Warranty and Remedies
Datron warrants that its equipment is free from defects in
design, materials, and workmanship for a period of 12 months
from the date of installation of the equipment, but in no event
later than 15 months from the date of shipment. If the
equipment does not provide satisfactory service due to defects
covered by this warranty, Datron will, at its option, replace or
repair the equipment free of charge.
Should it be impractical to return the equipment for repair,
Datron will provide replacements for defective parts contained in
the equipment for a period of 12 months from the date of
installation of the equipment, but in no event later than 15
months from the date of shipment.
This warranty is limited to the original purchaser and is not
transferable. Repair service performed by Datron is warranted
for the balance of the original warranty or 90 days, whichever is
longer.
Exclusive Warranty
There are no other warranties beyond the warranty as
contained herein. No agent, employee, or representative of
Datron has any authority to bind Datron to any affirmation,
representation, or warranty concerning the equipment or its
parts that is not in conformity with the warranties contained
herein.
EXCEPT AS EXPRESSLY SET FORTH ABOVE, NO OTHER
WARRANTIES, EITHER EXPRESSED OR IMPLIED, ARE
MADE WITH RESPECT TO THE EQUIPMENT OR THE
PARTS CONTAINED THEREIN, INCLUDING BUT NOT
LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, AND DATRON EXPRESSLY DISCLAIMS ALL
WARRANTIES NOT STATED HEREIN.
Limitations of Warranty
This warranty does not cover: Physical damage to the
equipment or its parts that does not involve defects in design,
material, or workmanship, including the following:
- Damage by impact, liquids, temperature, or gases.
- Damage to the equipment or its parts caused by
lightning, static discharge, voltage transients, or
application of incorrect supply voltages.
- Defects or failures caused by unauthorized attempts to
repair or modify the equipment.
- Defects or failures caused by Buyer abuse or misuse.
Return of Equipment - Domestic
To obtain performance of any obligation under this warranty, the
equipment must be returned freight prepaid to:
Technical Support Services
Datron World Communications Inc.
3055 Enterprise Court
Vista, California 92081
The equipment must be packed securely. Datron shall not be
responsible for any damage incurred in transit. A letter
containing the following information must be included with the
equipment:
a. Model, serial number, and date of installation.
b. Name of dealer or supplier of the equipment.
c. Detailed explanation of problem.
d. Return shipping instructions.
e. Telephone or fax number where Buyer may be contacted.
Datron will return the equipment prepaid by United Parcel
Service, Parcel Post, or truck. If alternate shipping is specified
by Buyer, freight charges will be made collect.
Return of Equipment - International
Contact Datron or your local Representative for specific
instructions. Do not return equipment without authorization. It is
usually not possible to clear equipment through U.S. Customs
without the correct documentation. If equipment is returned
without authorization, Buyer is responsible for all taxes,
customs duties, clearance charges, and other associated costs.
Parts Replacement
The following instructions for the supply of replacement parts
must be followed:
a. Return the parts prepaid to:
“Customer Service”
Datron World Communications Inc.
3055 Enterprise Court
Vista, California 92081; and
b. Include a letter with the following information:
1. Part number
2. Serial number and model of equipment
3. Date of installation
Parts returned without this information will not be replaced. In
the event of a dispute over the age of the replacement part,
components date-coded over 24 months previously will be
considered out of warranty.
Remedies
Buyer’s sole remedies and the entire liability of Datron are set
forth above. In no event will Datron be liable to Buyer or any
other person for any damages, including any incidental or
consequential damages, expenses, lost profits, lost savings, or
other damages arising out of use of, or inability to use the
equipment.

PRC-BC4-MS v
Safety Considerations
This product and manual must be thoroughly understood before
attempting installation and operation. To do so without proper
knowledge can result in equipment failure and bodily injury.
Caution: Before applying AC power, be sure that the
equipment has been properly configured for the
available line voltage. Attempted operation at
the wrong voltage can result in damage and
voids the warranty. See the manuals section on
installation. DO NOT operate equipment with
cover removed.
Earth Ground
All Datron products are supplied with a standard, 3-wire,
grounded AC plug. DO NOT attempt to disable the ground
terminal by using 2-wire adapters of any type. Any
disconnection of the equipment ground causes a potential
shock hazard that could result in personal injury. DO NOT
operate any equipment until a suitable ground has been
established. Consult the manual section on grounding.
Servicing
Only trained personnel should perform product repair. To avoid
electric shock, DO NOT open the case unless qualified to do so.
Various measurements and adjustments described in this
manual are performed with AC power applied and the protective
covers removed. Capacitors (particularly the large power supply
electrolytic type) can remain charged for a considerable time
after the unit has been shut off. Use particular care when
working around them, as a short circuit can release sufficient
energy to cause damage to the equipment and possible injury.
To protect against fire hazard, always replace line fuses with
ones of the same current rating and type (normal delay,
slow blow, etc.). DO NOT use higher value replacements in an
attempt to prevent fuse failure. If fuses are failing repeatedly this
indicates a probable defect in the equipment that needs
attention.
Use only genuine Datron factory parts for full performance and
safety of this product.
Made in the USA

PRC-BC4-MS vii
Contents
Chapter 1: Introduction
1.1 PRC-BC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Chapter 2: Installation
2.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-1 Captive and Chassis Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Figure 2-2 Power Transformer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Figure 2-3 DC Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Chapter 3: Operation
Figure 3-1 PRC-BC4 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Table 3-1 Status LED Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Figure 3-2 Charging Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Chapter 4: Technical Description
4.1 Input Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Component Locations, Schematic, and Parts List . . . . . . . . . . . . . . . 4-3
Figure 4-1 Charger Board Component Locations (738100 Rev. F) . . . . . . . . . . . .4-4
Figure 4-2 Charger Board Schematic Diagram (994003 Rev. E). . . . . . . . . . . . . .4-5
Table 4-1 Charger Board Parts List (PRC-BC4CHG Rev. T) . . . . . . . . . . . . . . . .4-7
4.5 Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Figure 4-3 Display Board Component Locations (738101 Rev. D) . . . . . . . . . . .4-10
Table 4-2 Display Board Parts List (PRC-BC4DIS Rev. F). . . . . . . . . . . . . . . . .4-11

viii PRC-BC4-MS
Chapter 5: Maintenance
5.1 Functional Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Figure 5-1 Charger Output Check Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Figure 5-2 DC Current Check Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Table 5-1 Troubleshooting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

PRC-BC4-MS 1-1
Chapter 1: Introduction
1.1 PRC-BC4
The PRC-BC4 is a multiple battery charger designed to charge up to four
BB-LA6 lead-calcium batteries simultaneously. The PRC-BC4 can use a 110 or
220 VAC power source (50 or 60 Hz); it can also use a 20 to 30V DC power
source.
The PRC-BC4 includes the following features:
• Up to four battery charging capacity
• 3-level charging circuitry
• AC or DC power source
• Front panel status LEDs for each charging station
• Front panel reset button for each charging station

1: Introduction
1-2 PRC-BC4-MS
1.2 Specifications
PRC-BC4 Specifications
Note: All specifications subject to change without notice or obligation.
Characteristic Description
General
Input voltage 110/220 VAC or 20 to 30 VDC
Input current 1A (max.) at 110 VAC
0.5A (max.) at 220 VAC
5A (max.) at 20 to 30 VDC
Input protection Fully protected on DC input and battery outputs
Electrical
Bulk charging rate 1.1A (C/5)
Bulk to overcharge
transition voltage
14.0 VDC
Overcharge terminate
current
110 mA (c/50)
Float charge voltage 13.3 VDC
Float to bulk transition
voltage
12.0 VDC
Temperature coefficient
on voltage levels
-12 mV/°C
Current drain on battery
with power off
5µA(max.)
Nominal charge time with
80% discharged battery
6 hrs
Mechanical
Weight 4.3 kg (9.5 lbs.)
Size (HWD) 4.0 in. x 9.5 in. x 11.0 in.
(10 cm x 24 cm x 28 cm.)
Panel indicators POWER ON and FAULT, CHARGING, and READY
for each charger circuit
Operating controls POWER switch, RESET button for each charger
circuit

1: Introduction
PRC-BC4-MS 1-3
BB-LA6 Battery Specifications
CY-2562 Battery Box Specifications
Environmental
Temperature
Operating 0° to +60°C (ambient)
Characteristic Description
Characteristic Description
Electrical
Nominal capacity 6 Ah
Nominal voltage 12 VDC
Max. instantaneous
output current
30A at 20°C
Max. continuous output
current
7A at 20°C
Internal resistance 0.02 ohm max. (fully charged)
Percent of original
capacity versus storage
time
90% after 3 months
80% after 6 months
60% after 12 months
Mechanical
Weight 5.5 lbs. (2.5 kg)
Size (HWD) 3.7 in. x 9.5 in. x 2.3 in.
(9.4 cm x 24.2 cm x 5.8 cm.)
Characteristic Description
Mechanical
Weight 0.5 lbs. (0.23 kg)
Size 3.0 in. x 4.0 in. x 11.0 in.
(7.5 cm x 10 cm x 28 cm.)

PRC-BC4-MS 2-1
Chapter 2: Installation
2.1 Unpacking
The PRC-BC4 is shipped in a heavy-duty corrugated cardboard carton. Do not
discard the cartons and packing materials in case the equipment needs to be
reshipped.
Inspect the PRC-BC4 for possible damage during shipment. Check all
accessories against the packing list. The packing list should include the
following items:
• PRC-BC4 multiple battery charger
•ACpowercord
•DCpowercord
• Four battery charging cables
• CY-2562 battery box
2.2 Power Configuration
2.2.1 AC Input Power
The PRC-BC4 can be configured for 110 or 220 VAC by opening the case and
changing the connections on the power transformer. A label on the case
indicates to what input voltage the transformer is set, however it is prudent to
visually inspect the power transformer to verify what input voltage it is
configured to accept (refer to Figure 2-2 on page 2-3).
CAUTION: Always remember to remove the AC power cable before
opening the PRC-BC4 case. If the charger is energized,
the technician is exposed to dangerous voltages that
can cause personal injury or death from electrical
shock.
To access the power transformer:
1. Make sure the PRC-BC4 is turned off and disconnected from any power
source (see CAUTION above).

2: Installation
2-2 PRC-BC4-MS
2. Place the PRC-BC4 so the front panel is faced away from you. Locate
and remove the four captive screws that hold the front panel to the case
(refer to Figure 2-1 below).
3. Place the PRC-BC4 so the bottom side is facing you. Remove the four
screws that hold the inside chassis to the case.
4. Slide the chassis out of the case.
5. Note the connections on the power transformer behind the regulator
circuit board.
To configure the PRC-BC4 for a 220 VAC power source:
1. Desolder terminals 3, 4, 5 and 6
2. Remove the jumper wires between terminal 3 and terminal 4, and the
jumper between terminal 5 and terminal 6 (refer to Figure 2-2 on page
2-3).
3. Install one of the jumpers between terminal 4 and terminal 5.
4. Resolder terminals 3, 4, 5, 6.
5. Reverse steps 2 through 4 in the previous procedure to reassemble the
PRC-BC4.
Figure 2-1 Captive and Chassis Screws
BOTTOM VIEW
FRONT PANEL
CASE

2: Installation
PRC-BC4-MS 2-3
The PRC-BC4 is shipped with a molded AC power cable with a 3-wire plug
and jack. It may be necessary to modify the plug to fit non-standard US AC
receptacles. The following table provides the color codes for the conductors in
the AC power cable.
2.2.2 DC Input Power
The PRC-BC4 also ships with a 2-wire (14 AWG) DC power cable. One end
of the cable is unterminated so the appropriate connector can be added to
connect to a DC power source. The power source must provide 20 to 30 VDC
and be capable of supplying 5A. A vehicle battery is a typical DC power
source.
The front panel DC INPUT connector is wired according to Figure 2-3 below.
Figure 2-2 Power Transformer Connections
110
3
VAC
AC
FUSE : A
220
1.5
VAC
AC
FUSE : A
1
2
3
4
5
6
7
8
SWITCH AC PLUG
123456
SWITCH AC PLUG
123456
Wire Type US Standard Color
Code
International Color Code
Phase Black Brown
Neutral White Blue
Ground Green Green/yellow stripe
Figure 2-3 DC Power Connection
AB
(+) 12 V DC
(–) GROUND
B
=
A =
FRONT PANEL
JACK DC
INPUT
CABLE
PLUG
C
CHARGING
CABLE
991610
A
A
B
B

2: Installation
2-4 PRC-BC4-MS
CAUTION: Do not operate the PRC-BC4 when connected to both
an AC and DC power source.
The PRC-BC4 does not require any alignment or adjustment for normal
operation.
2.2.3 Output Power
The PRC-BC4 provides 12 VDC to up to four BB-LA6 lead-calcium batteries.

PRC-BC4-MS 3-1
Chapter 3: Operation
The PRC-BC4 interface consists of four BB-LA6 battery external charging
stations: three accessed from the front panel and a fourth from the rear of the
chassis (refer to Figure 3-2 on page 3-2).
CAUTION: Use the PRC-BC4 to charge BB-LA6 lead-calcium
batteries only. Attempting to recharge lithium,
magnesium or other battery types may result in
explosion or release of toxic material.
To set up the PRC-BC4 for charging operation:
1. Make sure the power transformer is configured correctly for the
intended power source (refer to Figure 2-2 on page 2-3).
2. Do one of the following:
• Connect the AC power cable to the front panel AC INPUT
connector and an AC (110 or 220 VAC) power source.
• Connect the DC power cable (C991609) to the front panel DC
INPUT connector and a DC (20 to 30 VDC) power source.
Figure 3-1 PRC-BC4 Front Panel
BATT. 1
CHARGING
READY
FAULT
RESET
BATT. 2
CHARGING
READY
FAULT
RESET
BATT. 3
CHARGING
READY
FAULT
RESET
INTERNAL
CHARGING
READY
FAULT
RESET
POWER
ON
OFF
DC FUSE
AC FUSE
DC INPUT
AC INPUT

3: Operation
3-2 PRC-BC4-MS
3. Connect up to three DC charging cables (C991610) from the front
panel charging station connectors to BB-LA6 batteries.
4. Install an additional BB-LA6 battery to the rear of the PRC-BC4.
To charge BB-LA6 batteries:
1. Turn the front panel POWER switch to ON.
2. Push the front panel RESET button to start charging for each charging
station.
3. Observe the front panel status LEDs for the charging stations in use.
The yellow CHARGING LED should be lit. Table 3-1 below provides
additional LED indications.
Table 3-1 Status LED Indications
LED Meaning Required Action
FAULT Battery fuse is blown or battery
voltage is below 4 VDC.
Note: It is normal for the
FAULT LED to go on
if you press RESET
when a battery is not
installed.
Check battery fuse. If the
battery fuse is okay, the
battery is faulty. Discard the
battery.
CHARGING Battery is charging normally. None.
READY Battery is fully charged. Remove battery.
The battery may be left
connected to the charger.
Figure 3-2 Charging Configuration
BATT. 1
AC
INPUT
DC
INPUT
PRC-BC4
BB-LA6
to
115/230 Vac
source
to
24 Vdc
source
C991609
C991610
C991610
C991610
BB-LA6BB-LA6BB-LA6
BATT. 2
BATT. 3
BATT. 4