THOMSON BCM 1220 User manual
9087A – 198th Street, Langley, BC Canada V1M 3B1 yTelephone (604) 888-0110
BCM 1220
AUTOMATIC BATTERY CHARGER
INSTALLATION, OPERATING &
SERVICE MANUAL
PM004 Rev 2 00/09/21
BCM 1220 BATTERY CHARGER
PM004 Rev 2 00/09/21 Thomson Technlogy
1
1. INSTALLATION
Ensure that the battery charger is securely installed in a dry location where it will receive adequate
ventilation. The ambient air temperature around the battery should not exceed 40°C. Connect a
120VAC or 240VAC, 50/60Hz, 15AAC supply circuit, c/w grounding conductor, to the battery charger
supply terminals. Note: The internal transformer is reconnectable with jumpers for 120 or 240VAC
input. Caution: The charger is supplied for 120 VAC input as standard. Connect the DC output to the
battery to be charged. Excessively long or undersized DC leads will reduce the battery charger's
output and will increase the time required to re-charge the battery. It is essential to observe the DC
polarity. Ensure that all electrical connections are made in accordance with the applicable regulatory
authorities.
CAUTION!
Batteries may produce explosive gases when being
charged. Do not make electrical sparks or introduce
flame of any kind in vicinity of a battery. It is
recommended that all electrical loads be disconnected
from the battery and charger during adjustment
procedures. Always isolate the charger from the supply
and the battery before making any electrical connections
or adjustments. All servicing procedures should be
undertaken by a qualified technician only. Dangerous
voltages are present within the charger which may cause
injury or death.
2. FLOAT & EQUALIZE MODES
NOTE: If the charger is equipped with an APB 1210 alarm/control module, please refer to section 6.
The charger has been factory adjusted for correct "float" and "equalize" voltage levels for standard
lead-acid batteries. The selection of "float" or "equalize" is controlled by the "float/equalize" switch or
an optional manual equalize timer.
The "float" voltage is adjusted to a specific voltage in order to maintain the battery in a fully charged
condition. This is the normal mode for continuous operation. The "equalize" voltage is adjusted to a
specific voltage higher than "float". A battery should be "equalized" periodically in order to ensure that
all cells are equally and fully charged.
In either "float" or "equalize" mode, the charger will automatically adjust its output current between zero
and full output as required to maintain the correct voltage.
BCM 1220 BATTERY CHARGER
PM004 Rev 2 00/09/21 Thomson Technlogy
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WARNING:Never leave the switch in the "equalize"
position for long periods of time (6 hours per month is
adequate for most installations). Excessive "equalize"
charging will cause cells to gas (through electrolysis) and
consume excessive quantities of electrolyte. Never let the
electrolyte level drop below the minimum level line of the
battery.
Factory preset levels (for lead-acid batteries):
Battery Voltage Float Equalize
12VDC Nominal 13.5 14.5
24VDC Nominal 27.0 29.0
Current Limit is set at 100% of nameplate rating.
3. OUTPUT ADJUSTMENTS
3.1. "FLOAT" VOLTAGE ADJUSTMENT
CAUTION!
Do not leave battery charger energized if
the current output exceeds the unit
nameplate rating. If necessary re-adjust the
battery charger’s current limit setting before
adjusting float/equalize settings.
3.1.1. Attach a precision voltmeter of the correct range in parallel with the battery.
(Accuracy should be better than +/- 0.5%.)
3.1.2. Switch the charger's switch to "float". (If the charger is equipped with an
automatic timer, the timer may have the unit in equalize. Allow the charger to
equalize charge until the timer times out.)
3.1.3. Wait until the battery voltage stabilizes. (The output current should be almost
zero, unless a load is also connected to the battery. This may take many hours!)
3.1.4. If the voltage is incorrect adjust the float potentiometer located on the printed
circuit card. Turn the adjusting screw clockwise to increase voltage, and
counterclockwise to reduce voltage. Adjust in small increments, allowing voltage
to stabilize after each adjustment. (If the float adjustment is changed, it will be
necessary to recalibrate the equalize adjustment also.)
BCM 1220 BATTERY CHARGER
PM004 Rev 2 00/09/21 Thomson Technlogy
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3.2. "EQUALIZE" VOLTAGE ADJUSTMENT
NOTE: Set "float" before proceeding with equalize adjustment.
3.2.1. Switch the charger to the "equalize" mode with switch.
3.2.2. Wait until the battery voltage stabilizes. (The output current should be almost
zero, unless a load is also connected to the battery. This may take many hours!)
3.2.3. If the voltage is incorrect, adjust equalize potentiometer located on the printed
circuit card. Turn the adjusting screw clockwise to increase voltage, and
counterclockwise to reduce voltage. Adjust in small increments, allowing voltage
to stabilize after each adjustment. When properly set, return the switch to "float".
3.3. "CURRENT LIMIT" ADJUSTMENT
NOTE: The "current limit" potentiometer is located on the printed circuit card. It is factory set at
100% of the nameplate rating. Do not exceed this setting or damage to the charger may
result.
During any testing or adjustment of the charger, observe the charging current. In the event that
the current exceeds the nameplate rating, current limit adjustment is required before further
operation.
3.3.1. It is necessary to connect the charger to a lower than nominal voltage load. This
may be accomplished by either:
- Cranking the engine, preferably with the engine disabled to prevent it
from cranking, or;
- Connecting the charger to a partial battery (if inter-cell jumpers are
exposed) or one of a lower voltage (eg. 12 volt battery for 24 volt
charger).
3.3.2. Observe the output current. If the current is within 10% of the nameplate rating,
adjustment is not required.
3.3.3. To adjust current limit, turn the potentiometer on the printed circuit board
(clockwise to decrease). Do not energize the AC supply, except momentarily,
until you are sure the current limit is not set too high.
4. DISCONNECTING THE BATTERY (e.g. For Engine Servicing)
Always turn off the AC supply before disconnecting the battery. This will prevent sparks, and will
ensure that electrical circuits are not fed by the charger alone, which could cause damage.
BCM 1220 BATTERY CHARGER
PM004 Rev 2 00/09/21 Thomson Technlogy
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5. CONNECTIONS
CAUTION!
Before energizing battery charger AC supply,
verify correct AC supply voltage as indicated on
the unit rating plate.
CAUTION!
Before connecting live battery to the battery charger,
verify DC voltage output as indicated on the unit
rating plate and correct polarity.
Note: Reverse polarity will result in zero output from battery charger.
NOTES:
1. Recommended Wire Size (AWG):
Output 5A 10A 15A 20A
Up to 10 ft. 14 12 10 10
Up to 25 ft. 12 10 8 8
2. 2 - ½” knockouts are provided in the
bottom of the enclosure.
3. Install the battery charger where it will
have unrestricted airflow; maximum
recommended ambient temperature
104ºF.40ºC.
4. The transformer is reconnectible with
jumpers for 120 or 240VAC input.
FACTORY
USE ONLY
BCM 1220 TERMINAL STRIP
2345678
1
120 VAC or 240 VAC
INPUT (15A CIRCUIT)
#14 AWG MINIMUM
(SEE NOTE 4)
POSITIVE
NEGATIVE
GROUND
LINE 1
LINE 2 - NEUTRAL
OUTPUT TO
BATTERY
(SEE NOTE 1)
Note: Specifications subject to change without notice.
BCM 1220 BATTERY CHARGER
PM004 Rev 2 00/09/21 Thomson Technlogy Inc.
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6. OPTIONAL APB 1210 ALARM / CONTROL MODULE
The optional APB 1210 alarm/control module is divided into two sections, as follows. (Any or all of
these features may be provided according to requirements):
6.1. ALARM SECTION
6.1.1. A.C.Fail
Indicates a loss of A.C. power supply to the charger (The charger must be
connected to the battery for visual indication to be operative. The alarm contact
does not require the battery to alarm).
6.1.2. Rectifier Fail
Indicates an S.C.R. failure in the power circuit of the charger.
6.1.3. Low Battery Voltage
Indicates that the battery voltage has dropped below a preset voltage for longer
than three minutes. The factory voltage setting is 95% of nominal FLOAT
voltage for lead acid batteries (12.8VDC for 12VDC battery, 25.6VDC for 24VDC
battery).
6.1.4. High Battery Voltage
Indicates that the battery voltage has risen above a preset voltage for longer than
10 seconds. The factory high voltage setting is 125% of nominal EQUALIZE
voltage for lead acid batteries (15.2VDC for 12VDC battery, 30.4VDC for 24VDC
battery).
6.2. ALARM CONTACTS
- Shown with charger in normal operation (float mode).
- Rated 0.5A @ 110VAC, 2A @ 24VDC, Form “C”.
- Connections to contacts are made to Terminal Block mounted on APB 1210 Printed Circuit
Board.
2 31 5 64 8 97 14 1513 17 1816
Equalize Low Battery
Voltage
High Battery
Voltage
AC Fail SCR Fail Not Used
221 1 1
Relay contacts shown in de-energized (non-alarm) state (relays pick-up upon alarm condition).
Relay contacts shown in de-energized (alarm) state (relay energizes upon normal state and drops out on failure).
1
2
11 1210
BCM 1220 BATTERY CHARGER
PM004 Rev 2 00/09/21 Thomson Technlogy Inc.
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6.3. CONTROL SECTION
NOTE: When the APB 1210 control section is provided, the standard "FLOAT/EQUALIZE"
switch on the charger upper faceplate is relabelled to "FLOAT ONLY/AUTO MODE". With this
switch in the "FLOAT ONLY" position, the control section of the APB module is effectively
bypassed and the charger will only float charge the battery. With this switch in the "AUTO
MODE" position, the charger is controlled by the APB module. With the APB 1210 removed,
the switch reverts to standard Float/Equalize functions. This is provided to allow servicing of the
APB module and retain use of the battery charger.
6.3.1. Float Mode Control
Operation of the pushbutton in this section called "return to float" will cause the
charger to return to float, from the equalize mode as indicated by the green
"FLOAT CHARGING" L.E.D.
This will bypass the remaining duration of the equalize timer, and allows the
operator to test the equalize mode, without going through a full time period.
6.3.2. Equalize Mode Control
Equalize mode may be initiated by depressing the manual start button until the
yellow L.E.D. (Equalize timer running light) illuminates. Equalize mode may also
be optionally initiated by the following, as indicated by the labeling on the APB
faceplate:
6.3.2.1. Automatic Period Timer
Factory set for once every 28 days unless otherwise specified.
6.3.2.2. Battery Voltage Dip
Factory set at 75% of nominal battery voltage.
6.3.2.3. Return of AC power supply.
7. CONNECTION OF LOOSE APB TO BCM BOARD
Insert all the way down the header female connector of APB Board into the six pin white male
connector of BCM Board.
Note: APB header female connector can plug in only in one direction.
NOTES:
1) It is recommended that adjustments to the APB 1210 be done at the factory only, since instruments
are required.
2) The equalize period is the same for all methods of initiating. Factory setting is 6 hours unless
otherwise specified.
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