INSTALLATION & OPERATION MANUAL BCD615 SERIES DC Battery Charger An ISO9001 and AS9100 Registered Company Battery Chargers • Inverters • Power Supplies • Voltage Converters 8128 River Way, Delta B.C. V4G 1K5 Canada T. 604.946.9981 F. 604.946.9983 TF. 800.668.3884 (US/CANADA) www.analyticsystems.
Copyright (2005-2014) Analytic Systems Ware (1993) Ltd.
IMPORTANT & SAFETY INSTRUCTIONS 1. SAVE THESE INSTRUCTIONS — This manual contains important safety and operating instructions for battery charger 2. Do not expose battery charger to rain or snow. 3. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fire, electric shock, or injury to persons. 4. Do not disassemble battery charger; take it to a qualified serviceman when service or repair is required.
v. NEVER smoke or allow a spark or flame in vicinity of battery or engine. vi. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery or other electrical part that may cause explosion. vii. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn. viii.
Introduction All new Current Mode switching design offers increased power and reliability in a compact package. Extra input and output filtering reduce EMI to extremely low levels. Reliability features include an input fuse, thermal shutdown, current limiting, reverse battery hookup protection and output short circuit shutdown with automatic recovery. The output voltage is easily adjusted 1.0 volts above or below the standard output voltage to accommodate special charging requirements.
General Battery Banks 1 or 2 Stages 2 or 3 Switching Frequency 60 ± 2 KHz Idle Power < 10 Watts Noise on Input < 50 milli-Volts Noise on Output < 50 milli-Volts Transient Response < 2V for 50% Surge (Output Amps/2) Efficiency > 75 % @ maximum output Temp. Range -25 to 40 deg. C @ maximum output Isolation Input-Output & Input-Case 1500 Vdc (500 Vdc @ 24 V In), Output-Case 500 VDC (1500Vdc @ 48 V Out) Dimensions 14.5 x 10 x 4 in / 37 x 25 x 10 cm Clearance 1 Inch (2.
All connections should be made inside an appropriate junction box. Refer to the specifications table for the correct sizing of the circuit breaker in the distribution panel. A ground stud is provided to bond the chassis to local ground to reduce or eliminate EMI. OUTPUT CONNECTIONS Two Positive output terminals and two Negative output terminals are provided. Connect only one wire to each terminal. Ensure that the total average load connected does not exceed the continuous current rating of the unit.
light will go off, and if set to 3-stage charging the voltage will drop to the float level. You may check this voltage at the output terminals of the unit with a good digital voltmeter. As shipped from the factory, the unit is preset for a float voltage of 13.6, 27.2 or 54.4 VDC, which is generally recommended for lead-acid batteries. If you wish to adjust this voltage, remove the cover plate (secured by 2 screws) to expose the Output Adjust potentiometer.
2 or 3 Stage Charging This charger features user selectable 2 or 3 stage charging. The charging profile is selected by moving the slide switch on the front panel up to 3 stage or down for 2 stage charging. Bulk Float (Constant Current) (Constant Volts) Volts 100% 75% 50% 25% Amps 0% Time Two Stage Charge A two-stage charger provides a constant current until the battery reaches its rated capacity and then switches to a “float” voltage.
Troubleshooting This unit provides LED indicators and a buzzer to help diagnose any problems. The unit should sound the buzzer to alert you prior to shutting itself down. You should immediately check the indicators to determine the cause of the shutdown. CHARGING Indicates that the battery charger is charging the batteries: If the LED is not on, the batteries may be fully charged and the charger is supplying a float voltage to the batteries to keep them fully charged.
Dry Contact Relay To use your dry contact output fail relay you must connect a 9-pin D connector to the unit. You must use pins one and six as is indicated on page 6 in the remote connector diagram. The relay is factory preset to fail in the closed position when the low output LED and buzzer come on. If you wish to have the relay fail in the open position when the low output LED and buzzer come on, you must take the cover off the unit and move the jumper to the other position on J10.
Remote Control Option IMPORTANT: This remote is to be used only on Battery Chargers manufactured by Analytic Systems.t A remote control panel may be connected to the battery charger using a 9-pin D-connector that attaches to the side of the battery charger. The remote control panel and D connector are part of the remote control option. The remote control panel allows the unit to be operated remotely as well as duplicating all the diagnostic indicators and audible alarm.
The charger will charge the battery at approximately 10% of its normal rate (i.e. 4 amps for a 40 amp charger) until the battery reaches equalize voltage and then the current reduces as necessary to maintain the battery at that voltage. Three hours after the Equalize cycle begins, the charger will return to the float mode where the battery can be maintained indefinitely.
Special Services & Options Conformal Coating INCLUDED ON ALL UNITS UNLESS REQUESTED NOT TO as of April 1, 2014 Option “c” Ruggedization Package (EXTRA Conformal Coating and RTV Compound) Option “v” Marine / Industrial Pkg (EXTRA Conformal dipping and RTV Compound) Option “MS” Military Pkg (incl.
Limited Warranty 1. The equipment manufactured by Analytic Systems Ware (1993) Ltd. (the “Warrantor”) is warranted to be free from defects in workmanship and materials under normal use and service. 2. This warranty is in effect for: a. 3 Years from date of purchase by the end user for standard products offered in our catalog. b. 2 Years from date of manufacture for non-standard or OEM products c. 1 Year from date of manufacture for encapsulated products. 3.
An ISO9001 and AS9100 Registered Company Battery Chargers • Inverters • Power Supplies • Voltage Converters 8128 River Way, Delta B.C. V4G 1K5 Canada T. 604.946.9981 F. 604.946.9983 TF. 800.668.3884 (US/CANADA) www.analyticsystems.
