Hotstart BCU User manual

INSTALLATION INSTRUCTIONS
BATTERY CHARGER
BCU MODEL
| page 1
customer service:509.536.8660
[email protected] |www.hotstart.com Read carefully for proper
installation and operation.
Hotstart Manufacturing, Inc. is the owner of
all trademarks and copyrightable material
contained herein; all rights are reserved;
no form of reproduction is authorized
without prior written consent from Hotstart
Manufacturing, Inc.
installation instructions
bcu battery charger
Original Instructions216372-000 rev0
IOM216372-000 rev0
Corporate & Manufacturing
Headquarters
5723 E. Alki Ave.
Spokane, WA 99212 USA
509.536.8660
[email protected]
Oil & Gas Ofce
21732 Provincial Blvd.
Suite 170
Katy, TX 77450 USA
281.600.3700
[email protected]
Railroad Ofce
8915 Broadway
Merrillville, IN 46410 USA
219.648.2448
[email protected]
Europe Ofce
HOTSTART Europe GmbH
Hansestraße 79
51149 Köln, Germany
+49.2203.98137.30
[email protected]
Asia Pacic Ofce
HOTSTART Asia Pacic Ltd.
2-27-15-4F Honkomagome
Bunkyo-ku, Tokyo
113-0021, Japan
+81.3.6902.0551
[email protected]
BEFORE YOU INSTALL
HOTSTART’s BCU battery charging unit provides oat charging to batteries, allowing
them to maintain their available voltage. The BCU is designed for use in locomotives,
heavy equipment, mobile applications and other battery installations.
DANGER
!
Hazardous voltage: Before wiring or servicing the charging system, turn off the power and follow
your organization’s lockout and tagout procedure. Failure to do so could allow others to turn on the
power unexpectedly, resulting in harmful or fatal electrical shock.
CAUTION
!
Electrical hazard: Power source must be properly grounded and in accordance with national and
local electrical codes.
NOTICE
Read instructions carefully: The HOTSTART warranty does not cover any damage that a
charging system may sustain from improper installation, improper operation, improper specification
or corrosion. Before installing, be sure you have the right charging system for your application.
Carefully read all instructions before installing and energizing your system. The safety of any system
incorporating this charging unit is the responsibility of the assembler. The safe and proper use of
this charging unit is dependent upon the installer following sound engineering practices. If the
equipment is used in a manner not specified by the manufacturer, the protection provided by the
equipment may be impaired. All applicable electrical safety standards defined by local jurisdictions
must be followed. (Reference EU directive 2006/95/EC in EU countries.)
INSTALLING THE CHARGER
INSTALL CHARGER
CAUTION
!
Proper lifting: Use proper lifting equipment and rigging to move this equipment. Create a plan
before attempting to move. Proper lifting locations are identified with labels on each system; use
these locations when lifting and mounting the system.
Improper mounting hazard: Reference charging system component drawings before mounting
the system. Unless mounted properly, the charging system will be unstable.
C
A
D
B
E
I
E
H
F
G
A. Battery charger
B. Battery charger
interface
C. Identication plate
D.Power in wiring
entrance
E. Lift points × 2
F. Program connector
(factory use only)
G.Battery charging
connector
H. Power in wiring
entrance
I. Mounting slots × 8
(0.41 × 0.75")
J. Battery charging
connector for battery
wire (shipped loose)
J

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installation instructions
bcu battery charger
1. Mount the unit in a vertical orientation with charger directly
above control box. Reference drawings for mounting
position. When installing the charging system, HOTSTART
recommends a minimum total front-to-back clearance of
26.5 inches (67.2 cm) to account for door swing.
2. Fasten charger in place using foot mounting slots
(0.41 × 0.75”).
CONNECT BATTERY
1. Ensure BCU is not connected to battery or power source.
2. Locate supplied battery charging connector in control box.
NOTE: Battery charging connector will accept wire sizes of
16 –6 AWG
3. Strip battery positive and negative wires to 0.56"(14 mm).
Slide positive and negative wires into connectors. NOTICE!
Ensure correct position and orientation of connectors
to avoid wire twisting.
4. Using appropriate crimping tool, crimp positive wire
connector and negative wire connector.
5. Noting correct polarity, insert connectors into housing until
connector snaps over spring.
6. Tighten cable strain relief.
7. Connect other end of cable to battery. Connect battery
connector to BCU connector.
CONNECT POWER SOURCE
1. Ensure power is disconnected.
2. Route power source wiring through either wiring entrance
(0.875").
NOTE: Power in wiring entrance may be knocked out to a
larger diameter size if necessary.
3. Secure power source wiring using appropriate cable grip or
cable strain relief (not supplied).
4. Connect power to the BCU circuit breaker CB1 terminals
CB1:L1 (A) and CB1:L2 (B). Connect main power ground
wire to the ground block terminal (C).
NOTE: Do not connect to terminal L3. If connecting a
three-phase power supply, connect two legs only.
12.2 in.
14.5 in.
14.3 in.
24.5 in.
A
AA
AB
AC
AA AB
AC
Figure 1. BCU dimensions. HOTSTART recommends a minimum front-to-
back clearance of 26.5 inches (67.2 cm) to account for door swing.
Figure 2. BCU underside, showing foot mounting slots (A).
Figure 3. Battery connector, showing connectors (A), strain relief (B), and
housing (C).
Figure 4. Connecting battery connector to battery charging connector.
Figure 5.
Connecting power
source wiring to
circuit breaker
CB1:L1 (A), CB1:L2
(B) and ground
terminal (C).

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installation instructions
bcu battery charger
CHARGING OPERATION
1. Connect battery charger to battery. Energize battery
charger. For charging status, refer to BCU interface.
•Ammeter
The BCU is not congured for output scaling during bulk
charging phase. Ammeter lights may not apply to BCU
charging operation.
•Bulk Charge Indicator
Displays solid when batteries have reached 80% charged
status.
•AC Indicator
Displays when AC power is present. If ashing, low AC
voltage is present.
•Charge Completion
Batteries have reached 100% charge status. BCU will
now apply charging as needed.
•Fault Indicator
A charger error is present. Battery charging may not
occur normally.
TROUBLESHOOTING
AC Indicator
Off
Problem No AC power connected
Possible
Cause
hMissing/loose connection
hTripped circuit breaker
AC Indicator
Flashing
Problem Low AC voltage present
Possible
Cause
hLow AC voltage power source
hIncorrectly congured for
source voltage
Fault
Indicator
Problem Charger error
Possible
Cause
hIncorrectly connected battery
hIncorrectly connected power
source
hInternal short circuit
Disconnect power source prior to opening control box
or performing further troubleshooting/repairs. Ensure all
electrical connections are secure. Check connections for
correct polarity. Verify circuit breakers are not tripped.
Verify power source voltage is correct and matches BCU
transformer (if applicable) and circuit breaker settings.
Reconnect power and check for AC Indicator and Fault
Indicator lights for proper BCU operation.
CHARGER SOURCE VOLTAGE
WARNING
!
Electrical hazard: All electrical work must be done by qualified personnel
in accordance with national, state and local codes.
System labeling: HOTSTART recommends relabeling BCU if modified
from original factory shipped labeling to prevent connecting to incorrect
power source voltage.
1. Ensure your BCU model can accept the power source. BCU
models without transformers may accept 120, 208 or 240
volt power sources. Models with transformers may accept
460, 480, 575 or 600 volt power sources. CAUTION! Do
not attempt to congure BCU for a voltage source
that is not listed as an available power source for your
model. Contact HOTSTART for additional voltage
conguration options, as conversion may require
additional or replacement parts.
BCU MODELS WITHOUT TRANSFORMERS
BCU Model Primary Voltage Available Voltages (w/o parts)
120 V 208 V, 240 V
208 V 120 V, 240 V
240 V 120 V, 208 V
BCU MODELS WITH TRANSFORMERS
BCU Model Primary Voltage Available Voltages (w/o parts)
480 V 460 V, 575 V, 600 V
575 V 460 V, 480 V, 600 V
2. Disconnect BCU from power source. Open control box
lid. Locate circuit breaker CB1. Adjust CB1 setting to
amperage setting listed on following page. CAUTION! Do
not adjust CB2 amperage setting (if applicable).
3. Locate transformer T1 (if applicable). Disconnect and
reconnect transformer jumpers to terminals positions listed
on following page. Reference part drawings for specic
model information.
Ammeter
Displays scale of
output during
bulk charge
phase.
(BCU is not
congured for
bulk charging.)
Fault Indicator
Charger error.
AC Indicator
Solid
AC power is
present.
Flashing
Low AC voltage.
Bulk Charge Indicator
Bulk charge phase
complete (80%
charged); in
absorption phase.
Charge Completion
Solid
Charging complete
and maintenance
mode is active.
Flashing
Absorption phase
complete, in nishing
phase.
AA
AB
Figure 6. BCU charger interface.
Figure 7.
Adjusting CB1
amperage
(A) and
reconnecting
transformer
jumper (B).

| page 4
installation instructions
bcu battery charger
BCU Voltage CB1 Setting (72 V) Jumper Conguration
120 12 A –
208 10 A –
240 9 A –
460 5.6 A 32-36
480 5.4 A 33-36
575 4.5 A 33-35
600 4.4 A 34-35
4. Close control box lid.
5. Unplug charger input cable. Reconnect power source.
Using an appropriately rated multimeter, test charger input
cable for transformer output voltage (if applicable).
NOTE: Charger will accept voltages between 108 V and
265 V. All transformer-equipped BCU models must
have a transformer output voltage of 230 V ± 10
volts.
6. Reconnect charger input cable. Ensure BCU is
connected to power source to resume battery
charging. WARNING! HOTSTART recommends
relabeling BCU for new power source conguration to
prevent connecting to incorrect power source voltage.
BC1
72VDC
OUTPUT
AC
POWER IN
BATTERY
CHARGER
L1 T1
L2 T2
T3
L3
CB1
NOTES:
4.
FOR THREE-PHASE POWER, LAND ANY TWO LEGS.
4
PRIMARY VOLTAGE CB1 SETTING
120 12A
208 10A
240 9A
D
C
B
A
A
B
C
D
SCALE
SIZE
DWG. NO.
B
SHEET
REV.
A-9330-0S
DATE
APPROVALS
DRAWN BY
APPROVED BY
DO NOT SCALE DRAWING
1
2
3
4
5
6
7
8
8
7
6
5
4
3 2
1
THIRD ANGLE
PROJECTION
TOLERANCES
ANGULAR
.XX
.XXX
(Except as noted)
HOTSTART, INC.
SPOKANE, WA.
PROPRIETARY INFORMATION
This drawing and the information shown on it are property of Hotstart, Inc.
and are for the sole purpose of doing business with us. Any copying or transmittal to others
of this information is strictly prohibited without prior written consent from Hotstart.
UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN INCHES [mm]
ORIGIN
3 OF 3
KP
11-14-19
CO9738
1:8
11-14-19
JTB
N/A N/A
N/A
01
TITLE
72V BATTERY CHARGER
BC1
72VDC
OUTPUT
AC
POWER IN
BATTERY
CHARGER
T1
T1:3X
JUMPER
0
0
115V
115V
(230V)
T1:1
T1:2
T1:3X
L1 T1
L2 T2
T3
L3
CB1 CB2
NOTES:
4.
NOT ALL TERMINALS ARE SHOWN IN THE
TRANSFORMER SCHEMATIC.
5.
FOR THREE-PHASE POWER, LAND ANY TWO LEGS.
4
T3
T2
T1
L3
L2
L1
5
PRIMARY VOLTAGE JUMPER CONFIGURATION CB1 SETTING
460 32-36 5.6A
480 33-36 5.4A
575 33-35 4.5A
600 34-35 4.4A
D
C
B
A
A
B
C
D
SCALE
SIZE
DWG. NO.
B
SHEET
REV.
A-9297-0S
DATE
APPROVALS
DRAWN BY
APPROVED BY
DO NOT SCALE DRAWING
1
2
3
4
5
6
7
8
8
7
6
5
4
3 2
1
THIRD ANGLE
PROJECTION
TOLERANCES
ANGULAR
.XX
.XXX
(Except as noted)
HOTSTART, INC.
SPOKANE, WA.
PROPRIETARY INFORMATION
This drawing and the information shown on it are property of Hotstart, Inc.
and are for the sole purpose of doing business with us. Any copying or transmittal to others
of this information is strictly prohibited without prior written consent from Hotstart.
UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN INCHES [mm]
ORIGIN
3 OF 3
KP
10-04-19
CO9738
1:8
10-04-19
JTB
N/A N/A
N/A
1
TITLE
72V BATTERY CHARGER WITH TRANSFORMER
A
Figure 8. Testing BCU charger input cable for voltage (A).
Figure 9. Example BCU
wiring schematic for models
without transformer (left)
and wiring schematic for
models with transformer
(below). Reference electrical
schematic drawing for proper
wiring locations; illustrations
are typical wiring schematics.
Table 1. BCU circuit breaker amperage settings and transformer jumper
congurations.