Larson Electronics EXP-BCHR-120V-2X0.75-26A-4X User manual

EXP-BCHR-120V-2X0.75-26A-4X
Explosion Proof Battery Charger
C1D1 - 120V AC Input, 12/24V DC Output - 26A - (2) 3/4" Hubs - N4X
Instruction Manual
WARNING
TO AVOID THE RISK OF FIRE, EXPLOSION OR ELECTRIC SHOCK, THIS PRODUCT SHOULD BE INSTALLED,
INSPECTED AND MAINTAINED BY A QUALIFIED ELECTRICIAN ONLY, IN ACCORDANCE WITH ALL APPLICABLE
ELECTRICAL CODES.
TO AVOID ELECTRIC SHOCK:
•BE CERTAIN ELECTRICAL POWER IS OFF BEFORE AND DURING INSTALLATION AND MAINTENANCE.
•PRODUCT MUST BE CONNECTEDTOA WIRING SYSTEM WITHAN EQUIPMENT-GROUNDING
CONDUCTOR.
TO AVOID EXPLOSION:
•MAKE SURE THE SUPPLY VOLTAGE IS WITHIN THE VOLTAGE RATING.
•ENSURE THE MARKED T RATING IS LESS THAN THE IGNITION TEMPERATURE OF THE HAZARDOUS
ATMOSPHERE.
•DO NOT OPERATE IN AMBIENT TEMPERATURES ABOVE THOSE INDICATED ON THE PRODUCT
NAMEPLATE.
•DO NOT OPERATE IF THE LENS, CORD, SEALS, HOUSING, RECEPTACLES, ETC. IS CRACKED OR
DAMAGED. IF SO, DISCONTINUE USE AND CONTACT MANUFACTURER FOR REPLACEMENT PARTS.
•ALL FASTENERS SHOULD BE PROPERLY SEATED.
The Larson Electronics EXP-BCHR-120V-2X0.75-26A-4X Explosion Proof Battery Charger is designed for battery repair,
charging, restoration and maintenance in Class I, Division 1 and Class II, Division 1 environments. The NEMA 4X-rated
unit accepts 120V AC @ 50-60 Hz input and provides 12-24V DC output. Constructed of cast aluminum, operators can
access terminal strips for completing connections to a 120V power source (input) and a customer-provided battery (output).
Mounting
The Larson Electronics EXP-BCHR-120V-2X0.75-26A-4X Explosion Proof
Battery Charger has a mounting bracket on each corner of the back of the unit,
allowing it to be mounted to any sturdy, flat surface capable of supporting the
load of the unit. Unit is a bit heavy and may require two people to install. Hold
the unit to the desired mounting place to mark the locations for mount holes.
Pre-drill holes for mounting hardware, then secure the unit in place using
suitable hardware. Hardware is not included, but may be purchased from
Larson Electronics if needed.
Wiring
The Larson Electronics EXP-BCHR-120V-2X0.75-26A-4X is equipped with
terminal strips for connecting the 120V supply power to the charger (input), and
another for connecting customer provided batteries for charging (output) to the
12-24V output power. Feed wiring into the case via NPT hubs, and complete
electrical connections as needed. Follow all applicable local and national code
when making connections, and use cable glands rated for use in the hazardous
area to seal hubs and maintain ratings and safety standards.
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Battery Charging Modes
The EXP-BCHR-120V-2X0.75-26A-4X has eleven (11) modes: Standby, 12V NORM, 12V COLD/AGM, 24V NORM, 24V
COLD/AGM, 12V LITHIUM, 12V AGM+,16V AGM, 16V LITHIUM, 13.6V SUPPLY and 12V REPAIR, plus JumpCharge for
engine starting. Some charge modes must be pressed and held for three (3) seconds to enter the mode. These “Press and
Hold” modes are advanced charging modes that require your full attention before selecting. “Press and Hold” are indicated
on the charger by a red line. It is important to understand the differences and purpose of each charge mode. Do not
operate the charger until you confirm the appropriate charge mode for your battery. Below is a brief description:

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Mode Explanation
12V
NORM
Standby
12V
COLD/
AGM
14.8V | 26A | 50-500Ah Batteries
24V
NORM
29V | 13A | 25-250Ah Batteries
29.6V | 13A | 25-250Ah Batteries
No Power
14.5V | 26A | 50-500Ah Batteries
24V
COLD/
AGM
In Standby mode, the charger is not
charging or providing any power to
the battery. Energy Save is activated
during this mode, drawing microscopic
power from the electrical outlet. When
selected, an orange LED will illuminate.
For charging 12-volt Wet Cell, Gel Cell,
Enhanced Flooded, Maintenance-Free
and Calcium batteries. When selected,
a white LED will illuminate.
For charging 12-volt batteries in cold
temperatures below 50ºF (10ºC) or
AGM batteries. When selected, a blue
LED will illuminate.
For charging 24-volt Wet Cell, Gel Cell,
Enhanced Flooded, Maintenance-Free
and Calcium batteries. When selected,
a white LED will illuminate.
For charging 24-volt batteries in cold
temperatures below 50ºF (10ºC) or
AGM batteries. When selected, a blue
LED will illuminate.
Mode Explanation
12V
AGM+
16V
AGM
12V
LITHIUM
15.5V | 26A | 50-500Ah Batteries
13.6V | 5A | Max 6A
19.45V | 20A | 25-250Ah Batteries
14.2V | 26A | 50-500Ah Batteries
16.5V | 1.5A | Any Capacity
19.6V | 20A | 25-250Ah Batteries
12V
REPAIR
16V
LITHIUM
For charging 12-volt advanced AGM
batteries, which requires a higher
than normal charging voltage. When
selected, a blue LED will illuminate.
For charging 16-volt AGM batteries,
which are commonly used in racing
vehicles. When selected, a blue LED
will illuminate.
For charging 12-volt lithium-ion
batteries, including lithium iron
phosphate. When selected, a blue
LED will illuminate.
An advanced battery recovery mode
for repairing and storing, old, idle,
damaged, stratied or sulfated
batteries. When selected, a red LED
will illuminate and ash
For charging 16-volt lithium-ion
batteries, including lithium iron
phosphate, which are commonly used
in racing vehicles. When selected, a
blue LED will illuminate.
13.6V
SUPPLY
Converts to a DC power supply for
powering any 12VDC device, like a tire
inator, oil changer, or as a memory
retainer when replacing a battery. When
selected, a red LED will illuminate.
Press & Hold
Press & Hold
Press & Hold
Press & Hold
Press & Hold
Press & Hold
Using 12V Lithium. [Press & Hold]
12V Lithium charge mode is designed for 12-volt
lithium-ion batteries only, including lithium iron
phosphate.
CAUTION: USE THIS MODE WITH CARE. THIS
MODE IS FOR 12-VOLT LITHIUM BATTERIES
ONLY. LITHIUM-ION BATTERIES ARE MADE AND
CONSTRUCTED IN DIFFERENT WAYS AND SOME
MAY OR MAY NOT CONTAIN A BATTERY
MANAGEMENT SYSTEM (BMS). CONSULT THE
LITHIUM BATTERY MANUFACTURER BEFORE
CHARGING AND ASK FOR RECOMMENDED
CHARGING RATES AND VOLTAGES. SOME
LITHIUM-ION BATTERIES MAY BE UNSTABLE AND
UNSUITABLE FOR CHARGING.
Using 12V AGM+. [Press & Hold]
12V AGM+ charge mode is designed for 12-volt
advanced AGM batteries only. Advanced AGM
batteries are a new battery technology typically found
in start-stop micro-hybrid vehicles. These batteries
accept a higher than normal charging voltage around
15.5-volts. 12V AGM+ charge mode is NOT suitable
for traditional AGM batteries. Consult the battery
manufacturer before using this mode.
CAUTION: USE THIS MODE WITH CARE. THIS
MODE IS FOR 12-VOLT LEAD-ACID ADVANCED
AGM BATTERIES ONLY. THIS MODE USES A HIGH
CHARGING VOLTAGE AND MAY CAUSE SOME
WATER LOSS IN WET (FLOODED) CELL
BATTERIES OR OVERCHARGE IN SOME
BATTERIES.
Mode Explanation
Delivers 30A for five (5) minutes to
jumpstart your dead vehicle battery.
When selected, a white LED will
illuminate. (Red Manual Mode)
5Min | 30A | 50-400Ah Batteries
Jump
CHARGE
Using 16V Lithium. [Press & Hold]
16V Lithium charge mode is for 16V lithium-ion batteries only, including lithium iron phosphate batteries. 16-volt lithium-ion batteries
are commonly found in racing vehicles, where the alternator might be removed, or used to improve the performance of the injector or
fuel pump.
CAUTION: THIS MODE IS FOR 16-VOLT LITHIUM BATTERIES ONLY. LITHIUM-ION BATTERIES ARE MADE AND
CONSTRUCTED IN DIFFERENT WAYS AND SOME MAY OR MAY NOT CONTAIN A BATTERY MANAGEMENT SYSTEM (BMS).
CONSULT THE LITHIUM BATTERY MANUFACTURER BEFORE CHARGING AND ASK FOR RECOMMENDED CHARGING RATES
AND VOLTAGES. SOME LITHIUM-ION BATTERIES MAY BE UNSTABLE AND UNSUITABLE FOR CHARGING.
Using 16V AGM. [Press & Hold]
16V AGM charge mode is for 16V AGM batteries only. 16-volt AGM batteries are commonly found in racing vehicles, where the
alternator might be removed, or used to improve the performance of the injector or fuel pump.
CAUTION: USE THIS MODE WITH CARE. THIS MODE IS FOR 16-VOLT AGM BATTERIES ONLY. DO NOT USE ON A 12-VOLT
BATTERY. CONSULT THE BATTERY MANUFACTURER BEFORE CHARGING AND ASK FOR RECOMMENDED CHARGING
RATES AND VOLTAGES.
Using 13.6V Supply. [Press & Hold]
13.6V Supply converts the charger to a constant current, constant voltage DC power supply. It can be used to power 12VDC devices,
including; tire inflators, oil changers, coffee pots, seat heaters and more. As a power supply, it can also be used to retain a vehicle’s
on-board computer settings during battery repair or replacement. 13.6V Supply provides 13.6-volts at 5A with overload protection at 6A
(Max).
CAUTION: THIS MODE IS FOR 12-VOLT LEAD-ACID BATTERIES ONLY. PRIOR TO USE, READ YOUR 12VDC DEVICE MANUAL
TO DETERMINE IF IT IS SUITABLE FOR USE WITH THIS MODE. BOTH THE SPARK PROOF AND REVERSE POLARITY SAFETY
FEATURES ARE DISABLED IN THIS MODE. DO NOT ALLOW THE POSITIVE AND NEGATIVE BATTERY CLAMP OR EYELET
TERMINAL CONNECTORS TO TOUCH OR CONNECT TO EACH OTHER AS THE CHARGER COULD GENERATE SPARKS.
CHECK THE POLARITY OF THE BATTERY TERMINALS BEFORE USING THIS MODE.
Battery Charging Modes

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Using 12V Repair. [Press & Hold]
12V Repair is an advanced battery recovery mode for repairing and storing, old, idle, damaged, stratified or sulfated batteries. Not all
batteries can be recovered. Batteries tend to become damaged if kept at a low charge and/or never given the opportunity to receive
a full charge. The most common battery problems are battery sulfation and stratification. Both battery sulfation and stratification will
artificially raise the open circuit voltage of the battery, causing the battery to appear fully charged, while providing low capacity. Use
12V Repair in attempt to reverse these problems. For optimal results, take the 12-volt battery through a full charge cycle, bringing the
battery to full charge, before using this mode. 12V Repair can take up to four (4) hours to complete the recovery process and will
return to Standby when completed.
CAUTION: USE THIS MODE WITH CARE. THIS MODE IS FOR 12-VOLT LEAD-ACID BATTERIES ONLY. THIS MODE USES A
HIGH CHARGING VOLTAGE AND MAY CAUSE SOME WATER LOSS IN WET (FLOODED) CELL BATTERIES. BE ADVISED,
SOME BATTERIES AND ELECTRONICS MAY BE SENSITIVE TO HIGH CHARGING VOLTAGES. TO MINIMIZE RISKS TO
ELECTRONICS, DISCONNECT THE BATTERY BEFORE USING THIS MODE.
Using JumpCharge
JumpCharge is an innovative new feature for jumpstarting low-voltage or dead vehicle batteries. The JumpCharge process is much
different than your traditional battery charger with an “engine start” feature. JumpCharge uses precision charge control to avoid
overloading the battery that shortens the life of your battery. To operate JumpCharge, the charger must be connected to a 12-volt
battery with the Battery Clamp Connectors connected. Press the JumpCharge button to begin jumpstarting your vehicle. Once
initiated, the Charge LEDs will begin showing the progress of the JumpCharge from 25% to 100%.When using this mode, the Charge
LEDs do not display the battery’s state-of-charge (SOC), only the JumpCharge progress. Once the 100% green LED is illuminated
solid, and the 25%, 50% and 75% Charge LEDs are “off”, the JumpCharge process is completed and your are ready to start your
vehicle. For optimal results, allow JumpCharge to complete its five (5) minute charge.
If unsuccessful when starting your vehicle, let the battery rest for fifteen (15) minutes and try JumpCharge again. Most vehicles will
start with one (1) JumpCharge, but larger vehicles with dual battery systems, may require an additional JumpCharge. If when
pressing the JumpCharge button, an Error Condition (Error LED and Standby LED flashing) illuminates, the battery is below 2-volts.
To JumpCharge a battery below 2-volts, press and hold the JumpCharge button for three (3) seconds, and JumpCharge will begin
jumpstarting your battery.
CAUTION. USE THIS MODE WITH CARE. THIS MODE IS FOR 12-VOLT LEAD-ACID BATTERIES ONLY. DO NOT USE
JUMPCHARGE MORE THAN TWO (2) TIMES WITHIN A TWENTY-HOUR (24) HOUR PERIOD. IF TWO (2) JUMPCHARGES
CANNOT SUCCESSFULLY START YOUR VEHICLE, HAVE YOUR BATTERY EVALUATED BY A LOCAL BATTERY STORE.
Connecting the Battery
Do not connect the supply power until all other connections are made. Identify the correct polarity of the battery
terminals on the battery. The positive battery terminal is typically marked by these letters or symbol (POS,P,+). The
negative battery terminal is typically marked by these letters or symbol (NEG,N,-). Do not make any connections to the
carburetor, fuel lines, or thin, sheet metal parts. The below instructions are for a negative ground system (most
common). If your vehicle is a positive ground system (very uncommon), follow the below instructions in reverse order.
1. Connect the positive (red) battery clamp or eyelet terminal connector to the positive (POS,P,+) battery terminal.
2. Connect the negative (black) battery clamp or eyelet terminal connector to the negative (NEG,N,-) battery terminal
or vehicle or equipment chassis.
3. Connect the battery charger’s power plug into a suitable electrical outlet, or restore power for hardwired units. Do
not face the battery when making this connection.
4. When disconnecting the battery charger, disconnect in the reverse sequence, removing the negative first (or
positive first for positive ground systems).
Begin Charging
1. Verify the voltage and chemistry of the battery.
2. Confirm that you have connected the battery clamps or eyelet terminal connectors properly and the supply power is
connected.
3. The charger will begin in Standby mode, indicated by an orange LED. In Standby, the charger is not providing any
power.
4. Press the mode button to toggle to the appropriate charge mode (press and hold for three seconds to enter an
advanced charge mode) for the voltage and chemistry of your battery.
5. The mode LED will illuminate the selected charge mode and the Charge LEDs will illuminate (depending on the
health of the battery) indicating the charging process has started.
6. The charger can now be left connected to the battery at all times to provide maintenance charging.

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Understanding Charge LEDs
The charger has four (4) Charge LEDs per bank -
25%, 50%, 75% and 100%. These Charge LEDs
indicate the connected battery(s) state-of-charge
(SOC). See the explanation below:
LED Explanation
Maintenance
Green LED
25%
Red LED
The 25% Charge LED will slowly
pulse “on” and “off”, when the
battery is less than 25% fully
charged. When the battery is 25%
charged, the red Charge LED will
be solid.
50%
Red LED
During maintenance charging, the
100% Charge LED will pulse “on”
and “off” slowly. When the battery
is topped off and fully charged
again, the 100% Charge LED will
turn solid green. The charger can
be left connected to the battery
indenitely.
75%
Orange LED
The 50% Charge LED will slowly
pulse “on” and “off”, when the
battery is less than 50% fully
charged. When the battery is 50%
charged, the red Charge LED will
be solid.
The 75% Charge LED will slowly
pulse “on” and “off”, when the
battery is less than 75% fully
charged. When the battery is 75%
charged, the orange Charge LED
will be solid.
The 100% Charge LED will slowly
pulse “on” and “off”, when the
battery is less than 100% fully
charged. When the battery is fully
charged, the green LED will be solid,
and the 25%, 50% and 75% Charge
LEDs will turn “off”.
100%
Green LED
25% 50% 75% 100%
25% 50% 75% 100%
25% 50% 75% 100%
25% 50% 75% 100%
25% 50% 75% 100%
Understanding Advanced Diagnostics
Advanced Diagnostics is used when displaying Error Conditions.
It will display a series of blink sequences that help you identify
the cause of the error and potential solutions.
All Error Conditions are displayed with the Error LED and
Standby LED flashing back and forth. The number of flashes
between each pulse denotes a potential Error Condition (except
reverse polarity and low-voltage battery).
Error Reason/Solution
Single
Flash
Battery will not hold a
charge. Have battery
checked by a professional.
Possible battery short.
Have battery checked by a
professional.
Battery voltage is too high
for the selected charge
mode. Check the battery
and charge mode.
Error LED
Solid Red
Reverse polarity. Reverse
the battery connections.
Battery voltage is too
low for charge to detect
or charger is in supply.
Jumpstart the battery to
raise the battery voltage.
Double
Flash
Triple
Flash
Standby
Solid Orange
Charging Steps
1 2 3 4 5 6 7 8
Step
Voltage (V)
itialize
Analyze
Diag
Rec
nose
Mainte
zation
In
overy
Bulk
Optimi
Absorption
nance
Step 1 & 2: Analyze & Diagnose
Checks the battery’s initial condition, including voltage, state-of-charge and health, to determine if the battery is stable
before charging.
Step 3: Recovery
Initializes the Recovery desulfation process (if needed) for deeply discharged or sulfated batteries by pulsing small
amounts of current.
Step 4: Initialize
Starts the charging process with a gentle (soft) charge.
Step 5: Bulk
Begins the Bulk charging process based on the condition of the battery and returns 80% of the battery’s capacity.
Step 6: Absorption
Brings the charge level to 90% by delivering small amounts of current to provide a safe, efficient charge. This limits battery
gassing and is essential to prolonging battery life.
Step 7: Optimization
Finalizes the charging process and brings the battery to maximum capacity. In this step, the charger utilizes multi-layered
charging profiles to fully recapture capacity and optimize the specific gravity of the battery for increased run time and
performance. The charger will switch to Maintenance if the battery tells the charger that more current is needed.

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Step 8: Maintenance
Continuously monitors the battery to determine when a maintenance charge should be initiated. If the battery voltage
falls below its target threshold, the charger will restart the Maintenance cycle until voltage reaches its optimal state and
then discontinues the charge cycle. The cycle between Optimization and Maintenance is repeated indefinitely to keep
the battery at full charge. The battery charger can be safely left connected indefinitely without the risk of overcharging.
Charging Times
The estimated time to charge a battery is shown below. The size of the battery (Ah) and its depth of discharge (DOD)
greatly affect its charging time. The charge time is based on an average depth of discharge to a fully charged battery
and is for reference purposes only. Actual data may differ due to battery conditions. The time to charge a normally
discharged battery is based on a 50% DOD.
Battery Size Approx. Time to Charge In Hours
12V
50
75
100
150
200
1.0
1.4
1.9
2.9
3.8
1.9
2.9
3.8
5.8
7.7
24VAh
USE AND CARE
Unauthorized modification may impair the function and/or safety of this device and could affect the life of the equipment.
Always check for damaged or worn out parts before using the device. Store it in a secure place out of the reach of
children when not in use.Inspect for good working condition prior to storage and before re-use.
REPLACEMENT PARTS
The EXP-BCHR-120V-2X0.75-26A-4X is designed to provide years of reliable performance. Should the need for
replacement parts arise, please contact Larson Electronics.
THESE INSTRUCTIONS MAY NOT COVER ALL DETAILS OR VARIATIONS OF THIS PRODUCT FOR YOUR EQUIPMENT OR INSTALLATION REQUIREMENTS.
SHOULD FURTHER INFORMATION NOT COVERED BY THESE INSTRUCTIONS BE REQUIRED, PLEASE CONTACT LARSON ELECTRONICS BY EMAIL AT
SAL[email protected] OR BY PHONE AT 1-877-348-9680 FOR FURTHER ASSISTANCE.
PLEASE VISIT LARSONELECTRONICS.COM FOR WARRANTY AND RETURN INFORMATION.