VALERE Power BC Series User manual

Page 1 of 42 Version 1.00
November, 2004
BC Series Controller
Operation Manual
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BC Series Controllers
Operation Manual
Table of Contents
1Overview.................................................................................................................... 3
2Controller Connections ............................................................................................ 3
2.1 Temperature Probes..................................................................................................................... 4
2.2 Alarm Cable Connection............................................................................................................. 4
2.3 Auxiliary Input Alarms ............................................................................................................... 4
2.4 Expansion Controller Connection ............................................................................................... 4
2.5 Ethernet LAN Connection........................................................................................................... 5
3Navigation.................................................................................................................. 6
4Controller Login........................................................................................................ 7
5Controller Configuration Menu .............................................................................. 8
5.1 Language..................................................................................................................................... 8
5.2 Review Module ........................................................................................................................... 9
5.3 Setpoints...................................................................................................................................... 9
5.4 Alarms....................................................................................................................................... 11
5.5 Tests .......................................................................................................................................... 14
5.6 Thermal ..................................................................................................................................... 18
5.7 LVD Menu ................................................................................................................................ 22
5.8 Ringer........................................................................................................................................ 23
6Troubleshooting ...................................................................................................... 28
Appendix A......................................................................................................................32

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BC Series Controllers
Operation Manual
1Overview
This manual is intended to be a supplement to the Compact and Integrated shelf
Installation, Operation, and Maintenance manuals. This manual also only covers
operation of the BC-series controller from the front display. For remote operation via a
LAN card or Modem, please see Application Bulletin 201 for LAN operation and
Application Bulletin 202 for modem operation.
2Controller Connections
The BC series controller has several external connections. These connections are
discussed below.
Figure 1 - Controller connections
LAN
Connection
Expansion
controller
co
nn
ec
ti
o
n
Alarm cable
connection
Display
connection

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Operation Manual
2.1 Temperature Probes
Up to three, battery temperature probes (10’ length) may be installed for battery
temperature compensation. Attach the ring terminal to a battery post and insert the
connector end into the mating end as shown in Figure 1. The temperature probes are
denoted as Temp 1, Temp 2, and Temp 3 from left to right. Temperature compensation
must be enabled for the system to take advantage of the temperature probes. Also T
SENSE must be set to external. See section 6.6 for instructions on setting up temperature
compensation.
2.2 Alarm Cable Connection
Six form C contacts are available through a connector directly below the temperature
probe connections as shown in Figure 1. The cable from Table 1 can be used to
understand the alarm contacts and color code of the cable. The cable is 10 feet long
(available in 50’ and 100’ lengths), has a shelf mating connector on one end and bare
tinned wire on the other. Relay test can be used to verify that the alarm cable is
connected properly. See section 6.5 for setting up the relay test.
2.3 Auxiliary Input Alarms
To use the temperature probe input port or the input alarm (white & black wire) on the
alarm cable as an external alarm channel, simply connect a normally open dry contact
relay into any of the input connectors using the 10’ alarm input cable. The controller will
automatically detect a contact closure and set a minor alarm. If your system is equipped
with a BC1000 controller, alarms can be user mapped through the Ethernet LAN port
using the software utility provided by Valere. Refer to Application Bulletin 201,
“Connecting to the LAN Port”, that is included with the BC1000 controller, for mapping
alarms.
2.4 Expansion Controller Connection
The expansion controller connection is only used on the Integrated system with external
distribution and/or multiple power shelves as seen in Figure 2. This connection will be
made at the factory.

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BC Series Controllers
Operation Manual
Figure 2 - Expansion connection
2.5 Ethernet LAN Connection
The Ethernet LAN connection is only available on BC1000 style controllers. Refer to
Application Bulletin 201, “Connecting to the LAN Port” for further information on how
to connect to and use the Ethernet LAN port.

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Operation Manual
Alarm Cable
CA210203104
Alarm
Channel
Functional
Designation Wire Color Alarm
Behavior
NC Orange/White
stripe
Contact Opens
On Alarm
C Orange Common
A
(Power
Major) NO Orange/Black
stripe
Contact Closes
On Alarm
NC Red/White
stripe
Contact Opens
On Alarm
C Red Common
B
(Power
Minor) NO Red/Black
stripe
Contact Closes
On Alarm
NC Green/White
stripe
Contact Opens
On Alarm
C Green Common
C
(AC Fail)
NO Green/Black
stripe
Contact Closes
On Alarm
NC Yellow/White
stripe
Contact Opens
On Alarm
C Yellow Common
D
(BD)
NO Yellow/Black
stripe
Contact Closes
On Alarm
NC Lt Blue/White
stripe
Contact Opens
On Alarm
C Lt Blue Common
E
(LVD
Open) NO Lt Blue/Black
stripe
Contact Closes
On Alarm
NC Tan/White
stripe
Contact Opens
On Alarm
C Tan Common
F
(Fuse/C
B Open) NO Tan/Black
stripe
Contact Closes
On Alarm
Input (+) White
Input
Alarm Input (-) Black
Closed =
Alarm
Table 1- Alarm Cable color code
Table 1 is the alarm cable color coding table. The table can help you determine which
alarm contacts correspond to the wire color.
3Navigation
The controller is factory equipped with default settings as shown in Table 2 to assure safe
power up operation. Figure 3 shows the controller front display and three button keypad

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Operation Manual
and Appendix A contains the complete menu tree for the controller. The UP and DN
buttons are used to scroll through the functions and the MENU button is used to select
and/or drop down into a sub-menu.
There are three controller menu levels Basic, Main/Review, and Administrator. When
the controller displays “System OK”, the controller is at the Basic menu level. The
UP/DN buttons can be used to sequentially view basic plant parameters such as float
voltage and plant current, temperature compensation state, battery temperature (if thermal
probe is equipped), and internal plant temperature. By holding the MENU button down
for 5 seconds, the Main/Review level is accessed. All plant parameters can be viewed
from this level by scrolling to and selecting “Review.” Follow the menu tree for exact
navigation directions. By scrolling to and selecting “Log In”, the Administrator level is
accessed. The default username is “Admin” (case sensitive) and the default password is
“5001”. This level allows you to make changes to all the plant settings. Table 2 is a
complete list of adjustable parameters.
Figure 3 - Controller display
4Controller Login
The following steps will walk you through the process of logging into the controller as an
administrator. All setpoints and features require login to change values or enable
features. Tests such as battery discharge test, boost test, and lamp test do not require
logging in to execute, provided the feature has been enabled. Default password is 5001.

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1. With display showing “System OK”, press and hold MENU button for 5
seconds. Release MENU button when Welcome screen appears.
2. Press the UP button to scroll to CHOOSE: >LOGIN and press MENU.
Display shows PASSWORD ->0000<-, and first 0 flashes.
3. Press MENU to change first digit to desired value. Each press of the MENU
button advances by one. Pressing UP selects that value for the first digit,
which stops flashing, and advances to the second digit, which will begin to
flash.
4. Repeat procedure above for all four digits.
5. Press UP to select <, which will then flash, and press MENU to enter the
password.
6. Controller displays OK: ADMIN for 5 seconds.
5Presets
Once you have logged into the controller, you can set all controller values to one of three
preset values by selecting either PRESET A, PRESET B, or PRESET C. This can be
done by pressing the UP button to scroll to CHOOSE: PRESET and press the MENU
button. This will enter the preset submenu. Press the UP button to scroll to the
appropriate preset value, and press the MENU button, you may need to hold it for about 1
or 2 seconds. The controller will exit out to the previous menu, indicating that the preset
values have been set.
EXIT INSTRUCTIONS: Press the UP button to scroll to CHOOSE: EXIT and press the
MENU button. This will return you to the SYSTEM OK menu.
6Controller Configuration Menu
Once you have logged into the controller, you can make adjustments to any of the
following setpoints by pressing the UP button to scroll to CHOOSE: CONFIG and
pressing the MENU button. This will enter the configuration submenu list. The
configuration menu can be navigated by pressing the UP button to scroll through all the
menu choices.
EXIT INSTRUCTIONS: You can exit and logout of the configuration menu by pressing
the UP button to scroll to the end of the menu string and pressing the MENU button at the
BACK TO MAIN screen. This will send you back to the main menu. All changes
require logging out to take effect. Press UP button to scroll to CHOOSE: EXIT and press
the MENU button to exit back to the SYSTEM OK menu.
6.1 Language
The language menu allows you to select the controller’s displayed language.

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This menu can be accessed by pressing the MENU button at the CHOOSE: LANGUAGE
menu. Once the menu has been entered the screen will display the current language
setting. For example by default the screen would display LANGUAGE: ENGLISH.
This setting can be changed by pressing the MENU button. The screen will then change
to CHOOSE: ENGLISH. The value can then be adjusted by pressing the UP and DN
buttons. Once the desired language is showing on the display, press the MENU button to
select that value.
NOTE: Please note that once a new language has been selected the screen will be
displayed in that language. If you do not understand that language, navigation through
the menu will be very difficult.
To exit this menu press the UP button until EXIT LANGUAGE is displayed on the
screen, and press MENU to exit. This will take you back to the configuration menu.
Continue to the next menu for adjustment or follow the exit instructions at the beginning
of this section.
6.2 Review Module
The review module menu allows you to see the DC current output of each individual
rectifier in the system.
This menu can be accessed by pressing the MENU button at the REVIEW: MODULE
menu. Once the menu has been entered the screen will display the current value of the
first rectifier in the first shelf (designated S1>) in the system. The display will also show
five slots representing the five possible rectifier slots in a Valere System. The solid
square represents the rectifier currently being viewed, and the non-solid square represents
the remaining rectifiers installed in the system. Pressing the UP button at this point will
scroll through the remaining rectifiers in order. If the system is equipped with a second
power shelf (designated as S2>) the controller will also display that shelf’s rectifiers in
order after shelf 1.
To exit this menu press the UP button until EXIT MODULE is displayed on the screen,
and press MENU to exit. This will take you back to the configuration menu. Continue to
the next menu for adjustment or follow the exit instructions at the beginning of this
section.
6.3 Setpoints
The setpoints menu allows you to adjust controller setpoints such as float voltage,
rectifier current limit, and battery current limit. Please note that some features require a
low voltage disconnect (LVD) or shunt to be visible.
This menu can be accessed by pressing the MENU button at the CONFIG SETPOINTS
menu. The first setpoint displayed will be the float voltage of the system. Press the UP

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Operation Manual
button to continue scrolling thru the setpoints menu. The menu will circle back to
FLOAT once the end has been reached.
To exit this menu press the UP button until EXIT SETPOINTS is displayed on the
screen, then press the MENU to exit. This will take you back to the configuration menu.
Continue to the next menu for adjustment or follow the exit instructions at the beginning
of this section to exit.
6.3.1 Float Voltage (Float)
Float voltage is the DC voltage which the rectifiers will output.
To adjust the float voltage, scroll to FLOAT V = xx.xx, press the MENU button,
and the screen will display CHOOSE: V = xx.xx. The value can then be adjusted
by pressing the UP and DN buttons in the corresponding directions. This value
can be adjusted in 0.5 V increments, and a range between 42 and 58 volts. Once
the desired value is reached ,press, the MENU button to accept the new value.
Press the UP button to move to the next setpoint or scroll to EXIT SETPOINTS
and press MENU.
6.3.2 Rectifier Current Limit (Rect CL)
Allows the user to set a limit, below the maximum capacity of the rectifier, on the
amount of current each rectifier will output
To enable rectifier current limit, scroll to RECT CL DISABLED press the MENU
button, and the screen will display RECT CL ENABLED.
Press the UP button to scroll to RECT CL I = xx. Press the MENU button and the
screen will display CHOOSE: I = xx. The value can then be adjusted by pressing
the UP and DN buttons in the corresponding directions. This value can be
adjusted in 2 amp increments, and a range between 0 and 200 amps. Once the
desired value is reached, press the MENU button to accept the new value.
For example, a system with three 50A rectifiers with an RECT CL I set to 20 A
will limit each rectifier to 20 A for a total output of 60 A.
Press the UP button to move to the next setpoint or scroll to EXIT SETPOINTS
and press MENU.
6.3.3 Battery Current Limit (Batt CL)
Allows the user to set a limit on the amount of current being sent to the batteries.
This feature requires an LVD or shunt to be visible in the menu structure. Also