BC-2415P-20P-30P April 2014 Manual
Contents
1. care must be exercised Caution Only flooded lead acid battery which must have one complete charge cycle before equalization charge Make sure electrolyte level is sufficient Disconnect all DC load connected to the battery Exercise extreme care to comply with the above cautions when Auto Equalization is selected Wet lead acid batteries requires periodic higher voltage charging about 10 over usual absorption voltage to balance the Voltage of each cell reverse the high concentration of electrolyte at the bottom and clear up large sulfate crystals on the plates You can use the Equalization Selection Switch 8 to perform the manual equalization through optional remote display or Auto equalization by charger itself Once Auto it is selected the charger will start Equalization automatically if charger keeps at Float mode for over 21 days After entered into this mode the Absorption indicator will flash This will put the charger keep Equalization for 240 minutes The charger will go to Float once completed Remark 1 This mode only can be operated at Flooded battery selected Battery Selection Switch 4 set to positions 1 9 or 0 2 During this mode operator can press the FUNC button optional remote display for 5 seconds to force the charger to Float mode anytime 3 Take special precautions as battery will emit explosive gas during equalization charge Dual bank charging This feature is for caravans and vehicles with two separate batt2. too low Battery has damaged cell or battery is too old Wrong set the lower power level Charger internal fault Wrong battery type selection Battery is excessively depleted and the soft charging is triggered Battery temperature too high Check AC connections are correct Replace with correct AC fuse by qualified electrician Check DC connections between charger and battery Charger can auto reset if remove the fault within 20 seconds Check air intake vent at bottom of charger is blocked or not Check charger ambient ventilation Check battery AH capacity within recommended range Check for correct polarity replace car blade fuse 6 Check DC fan Check for loose contact right cable size cable integrity Recheck battery type and change to correct battery selection Make sure charger rating matches battery capacity Move battery to a room temperature location or get an optional temperature sensor Replace battery Recheck the current selection switch 5 to correct right setting Return the charger to distributor to repair Check charged battery label and change battery type selection to correct setting Recharge the battery after a day if bulk light remains after several hours the battery is most likely damaged and cannot accept charge Replace battery Use accessory temperature sensor O Specifications Sot SenBukGhawe OOOO OO Soft Start Bulk Charge Battery Voltage to Trigger cut i
3. VOLTECH gt BC 2415P 2420P 2430P Multi Stage Battery Chargers User Manual 00 amp CHARGER BULK ABSORPTION FLOAT OVERTEMP FAULT ON Advanced Multi Stage Battery Charger Keep this manual in a safe place for quick reference at all times This manual contains important safety and operation instructions for correct use of the battery charger Read through the manual And pay special attention to the markings and labels of the charger battery and any equipment connected into the system Pay special attention to these two types of notices used in this manual WARNING Failure to heed this warning may cause injury to persons and damage to Equipment CAUTION Failure to observe this warning may result in damage to equipment and improper functioning of the Charger WARNING e The charger is designed for in door use Protect the charger from ingress of water e This charger is made to charge only properly sized lead acid batteries e Don t recharging non rechargeable batteries e Charging other types of battery or under sized lead acid batteries may cause fire or explosion e Install the charger in accordance with all local codes e Do not use the charger if it has been dropped or damaged e Do not remove casing of the charger there is no user serviceable parts inside e Never attempt to charge a frozen battery e Never attempt to charge a damaged battery e Wear protective goggles and turn your fa
4. atteries charger output protection status hours of operation and etc Intended Use All Automotive Marine Mobile Home Electric Scooters Golf Carts Solar Deep Cycle UPS Standby Industrial amp Commercial Applications A Control and Indicators CHARGER BULK ABSORPTION FLOAT OVER TEMP FAULT ON ZAAWARNING Disconnect AC mains before plug in Remote Display HBR 3100 REMOTE CONTROL a 3 10 11 12 Power Switch To turn ON and OFF AC power to charger Charger status LED display Charger ON LED Green Lights up when power ON Bulk LED Red Bulk charging with Constant Current max Absorption LED Orange Absorption charging with preset Constant Voltage Float LED Green Float charging with preset Constant Voltage Over Temp LED Red Lights up when over temperature protection Flashing when current de rating Fault LED Red Charger malfunction overload output short circuit reverse polarity output over voltage protection Programming Port Factory use only Battery selection switch For AGM GEL LiFePO4 Calcium Calcium 2x user define amp WET Flooded batteries default at GEL P 1 Charging current selection switch Current can be selected from 10 to 100 Details please see the table on front panel Default at 100 USB port Connect charger to a computer for utilizing User define setting or Data logging upload See Sec P Remote display Port Co
5. attery in good working condition during long periods of storage of the Caravan RV or back up battery applications Remark Charger can give out full selected max current in Float or Standby mode If battery voltage drops to 25V for approx 10 minutes in Float or Standby mode The charger will start a new cycle of charging G STORAGE If the RV etc is in storage for an extended period of time and no solar panels are available to charge the battery To help guard against Self discharge of the Battery e Leave the AC power connected amp the Battery Charger turned on First ENSURE ALL loads are turned OFF or Dis connected from the Battery The charger has an automatic Standby Charge Mode and a 21 day New Cycle charge to take care of the battery in storage e Or disconnect the Battery charger from the vehicle battery if the AC Mains is to be disconnected or turned off Warning Batteries on charge should not be left unattended for extended periods The charging process amp battery condition should be checked regularly User Define Charging Profiles Connect the charger to a personal computer through USB port 6 then you can set your own charging configuration There are two charging positions allocated to store the preset algorithm s by the user Battery Selection Switch 4 set to position 7 or 8 Equalization Charging for wet type battery only Warning Explosion Hazard Explosive gases from battery during equalization extreme
6. ce away when connecting or disconnecting the battery e Never place the charger on top of a battery e Never smoke use an open flame or create sparks near battery or charger during normal charging operation as Batteries may give out explosive gas e Do not charge batteries in a sealed enclosure boxed in due to possible explosion of entrapped explosive gas e Use of accessories not recommended may cause risk of fire electric shock or equipment damage e Disconnect the mains supply before connecting or disconnecting the links to the battery e Ifthe charger does not work properly or if it has been damaged unplug its AC and DC connection e Do not use this charger in connection with any medical device or life support system CAUTIONS e Refer to battery manufacturer s specific recommended values for battery type settings and float voltage setting e Ensure all ventilation ports are not obstructed for efficient fan cooling keep loose soft material such as paper cloth etc away from the Charger e During charging the battery must be placed in a well ventilated area e If longer output charging cable are required make sure the cable diameter is adequate for the Current amp Cable length e AC source from portable generator The VA rating of standard generator should be at least 4 times the maximum rating of the charger Inverter type generator can have 2 to 3 times the maximum rating of the charger Itis recommended that the ac output is stabi
7. eries The two batteries must be of same chemical make up and type to avoid over and under charging because only one setting of charging profile for both Two batteries are charged simultaneously and the battery with the lowest level gets most share of the current in the Bulk charge stage until it is up to the same voltage level of the second battery battery with higher initial level Both batteries will go to the Absorption and the Float Charge at the same time Temperature Sensor Warning The temperature sensor must be installed at the Negative Terminal of the battery terminal In correctly connecting to the Positive Terminal will damage the charger and the sensor The temperature sensor accessory is used for optimal charging over a wide ambient temperature range The Temperature sensor should be positioned so as not to be affected by any other cooling or heating source Plug in the temperature sensor before switching on the charger to activate the temperature control function Never plug in the Sensor during charging Compensation voltage for this temperature sensor is 20mV C the higher the battery temperature the lower the charging voltage When battery temperature reaches 60 C the charger will shutdown Fault and OTP indicator will light up L Cable Size Selection Wire Size AWG Area mm Maximum one way distance Maximum one way distance Maximum one way distance feet for 2 Voltage loss feet for 2 Voltage lo
8. es the selected Absorption voltage level the charging switches to Constant voltage charging Absorption stage Charging current will decrease gradually until a pre set value at which the charger then automatically switches to Float Stage The max Absorption time is also controlled by the time in Bulk charge and battery type selected Stage 3 THE UO PHASE The constant voltage charging Float LED is ON In Float stage the battery is full and only takes in the amount of current necessary for maintaining the capacity The float voltage is preset according to the type of battery selected by the user Battery Select Switch 4 If the charger stays in this mode with charging current less than 5A for over 72 hours Then the charger will automatically Switch into the Standby mode Stage 4 THE UO PHASE The constant voltage charging Float LED is ON In Standby stage The charging voltage at this mode will be 4 less than the Float voltage only for maintaining the capacity This lower charging voltage level reduces drying out of electrolyte liquid prolongs the life of an inactive battery New Cycle Charge every 21 days The Charger will start a new charging cycle of Bulk to Absorption to Float every 21 days in either standby or float mode This new cycle of charging will refresh the battery to prevent separation of the electrolyte amp keep the electrode plates in good condition This automatic New Cycle charge after 21 days is designed to keep the b
9. ging current Charger Model BC 2415P 15A BC 2420P 20A BC 2430P 30A Battery Capacity 6 AH 150 AH 8 AH 200 AH 10 AH 300 AH Testing the charger with output open circuit nothing connected to the output terminal On power up the charger will do a self check during which all the LED indicators are on and fan in full speed for a few seconds Then the Charger On and the Absorption LED are on if charger is checked out OK After 5 minute the Float LED will be on and Absorption LED off Remark You can connect a load to the output terminal and the charger will provide a constant DC source voltage according to the Battery type and available Output power current settings selected as detailed in Sections B3 and C This feature is handy for caravan installer to check the operation of connected powered appliance or connections Battery Charger Installation and Connection Observe the warnings amp safety precautions before rushing to install and operate the charger Check battery condition fill up cells for wet battery clean battery poles Secure the battery charger in a well ventilated place make sure the mounting surface is flat and without soft covering material or loose paper sheet The air intake is at the bottom and air outlet at the back Make sure both intake and outlet are not blocked Never place charger on top of battery Plug in the AC mains and turn on Power Switch All the indicators on the front panel wil
10. ium Iron Phosphate batteries The selected battery type can be viewed at the optional remote panel Warning ONLY Calcium Calcium type batteries are to be charged in this mode and only when a boost charge is required 15 1 Volts No load is to be connected to the battery during this charge mode Charge through one cycle only then set the battery selector back to The WET setting C Power Level adjustment End users can Preset the maximum output charging current in 10 increments to make the charger suitable for different Battery capacities amp or loading conditions Make sure the Main Switch is OFF before adjust the power level Use a small slot type screw driver to select the maximum output current via the Charging Current Selection Switch 5 The selected max output current can be viewed on the optional remote panel Position 0 100 of the rated current Position 9 90 of the rated current Position 8 80 of the rated current Position 7 70 of the rated current Position 6 60 of the rated current Position 5 50 of the rated current Position 4 40 of the rated current Position 3 30 of the rated current Position 2 20 of the rated current Position 1 10 of the rated current Recommended Battery Capacity The extended range of AH capacity is based on the appropriate charging current selection 10 to 100 Some battery type can take higher charge current When in doubt check with battery manufacturer for recommended char
11. l lit up cooling fan spins at full speed for 10 seconds by means of Self Testing After self test mode the Charger ON LED and either Bulk LED or Absorption LED will be lit initially depending on the state of the battery After 5 minutes if the battery is in a high state of charge the charger float LED will be lit otherwise the charger can stay in either Bulk Or Absorption mode for longer periods if needed Before connecting or disconnecting the charging cable turn off the Power Switch and unplug AC cord from the mains First connect the Battery Chargers Positive terminal to the Battery Positive Post Then connect the Chargers Negative terminal to the Battery Negative Post Make sure all the connections are clean secured and tight Double check for correct polarity Double check again for correct selection of Battery Selection Switch 4 for battery type default at GEL P 1 and Charging Current Selection Switch 5 for output current setting default at 100 When installed in caravans and similar vehicles the connection to the supply mains is to be in accordance with national wiring rules When charging automotive batteries The battery terminal not connected to the chassis has to be connected first The other connection is to be made to the chassis remote from the battery and fuel line The battery charger is then to be connected to the supply mains After charging disconnect the battery charger from the
12. lized by running the generator for 2 3 minutes before switching on the charger e This charger is for stand alone application only parallel or series connection will cause damage to charger and connected battery or load Introduction Congratulations on purchasing our new Multi Stage IUOU Switching Mode Battery Charger This series of advanced chargers use Micro Processor to control the charging profiles and protective functions The special charging programs are designed to charge both stand alone battery and battery with connected loads Innovative charging profiles blend in with the ever changing state of charge of the batteries to give just the right amount of current and voltage so your batteries will not be under or over charged There are 8 sets of selectable charging profiles specifically designed for a wide range of Wet Gel AGM LiFePO4 and Calcium Calcium lead acid batteries There are two user programmable charging profiles for the professional users through USB port by personal computer In addition the programmed maintenance charge provides a timely Equalization charge for the Wet lead acid battery and refreshing charge to the sealed batteries Almost all the protections are controlled by the Micro Processor On start up the charger run a series of self tests on the protective functions displays and critical components like the cooling fan The optional detachable Remote Control Panel provides exceptional monitoring of the b
13. n Soft Start lt 24 6V Bulk Charge Mode Soft Start Bulk Charge Current Current Limit 1 2 of the charging 1 2 of the charging 1 2 of the charging current current current Ripple and Noise Peak to Peak lt 200mV lt 200mV lt 200mV AC Voltage Range 200 240V 50Hz Overload 90 110 Rated Output Current or 50 Rated Output Current Soft Charge Protection Type Constant Current Limiting recovers Automatically after Fault Condition is Removed Protection Otherwise the charger will shutdown until re start the charger again Remote Temperature sensor ac cable spare ac fuse at socket Accessories SUPPUENACCOSSONES CD Software USB Cable Optional Accessory Remote Control Panel Model HBR 3100 Safety Yes CE EN 60335 SAA AS NZS 60335 1 AS NZS 60335 2 29 Include clause 21 102 Vibration Test Approvals EMC EN 55014 EMF EN50366 Yes Dimensions and Weight 200x80x260mm 3 0kg 200x80x260mm 3 0kg 200x80x320mm 3 9kg All values are based on the standard ambient temperature 25 C and pressure 0 1Mpa P Optional Remote Display HBR 3100 Warning AC mains supply must be disconnected completely from the battery charger before plugging in of the Remote Display HBR 3100 Otherwise the charger will be damaged I Introduction The Remote Display comes with 10m extension cable with interconnector When the optional remote HBR 3100 is installed it will display the real time charging stage voltage amp ampe
14. nnect to accessory HBR 3100 remote display To remote display the charging voltage amp charging status and remote control the charger output ON OFF amp Equalization Equalization mode selection switch Can be selected by Manual or Auto Battery Connection DC Output Terminal s Ventilation Fan Inlet AC socket with Mains fuse holder Temperature Sensor Socket Connection to Battery Temperature sensor accessory Sensor to increase decrease charging voltage at low high battery temperature Using the charger Check the supplied accessories AC cord Remote Battery temperature sensor CD software amp USB cable are with the package Remove the magnetic dummy remote control panel on the front of the charger to select the battery type and the max output charging current you may need to ply it open to get a hold the edge of the panel in order to lift it out Battery Type Selection Check against the Absorption and Float Voltage with the battery type and specifications given in section N Make sure the charger is power OFF Use a small slot type screw driver to select the battery through Battery Selection Switch 4 AGM GEL Sealed type VRLA AGM GEL Maintenance Free Automotive or Deep Cycle lead acid batteries WET Flooded Type lead acid batteries to which water can be added Automotive or Deep Cycle Calcium Calctum Sealed type VRLA Lead Acid batteries with Calcium content Automotive or Deep Cycle LiFePO4 Sealed type Lith
15. ptions 1 Charger Name 2 Charger Status 3 Battery Type 4 Fault 5 Bat Bank 1 6 Bat Bank 2 7 Bat Bank 3 8 Total Run Time 9 Output Power Level 10 Software Version Remote Short cut 1 Press and hold the SET button for 5 seconds and release the button to enter Equalization mode Equalization selection slide switch on main unit should be selected at manual position 2 Press and hold the Func button for 5 seconds and release the button to force the charger to Float mode V Fault Indication 1 Charger High Temp 2 Bat Over Temp 3 Output V High 4 Overload 5 Output Shorted 6 Wrong Polarity 7 Fan Fault Charger over temperature Battery temperature over 60 C as detected by remote sensor Output over voltage Overload OCP Output short circuit Output reverse polarity Fan stuck or not working Q HBC SOFTWARE INSTALLATION PLEASE REFER TO THE USER MANUAL IN THE CD FOR INSTALLATION AND APPLICATION PROCEDURE REV 4 04 2014 7673 3215 3524
16. rage battery type set max power level set type of fault with alarm etc and can remote control the output terminal On OFF trigger the Equalization charging for wet battery and force charger to float mode It can be mounted on BC charger by replacing the dummy cover on the front panel or remotely mounted with 10m extension cable going through the unplugged hole at the front of the dummy panel II Connection 10 Meters Phone Cable In Line Coupler 6P6C 3 HBR 3100 Remote Display Module NO a Take out the dummy remote panel from charger and remove the black hole plug from the dummy remote panel Hole plug b Remote cable through the dummy remote panel s hole c Plug in the remote cable into the charger remote socket d III Control and Indicator Output On Off 1 Output ON OFF To switch the charger output ON and OFF Green LED is illuminated when output is ON 2 Alarm Can be silenced or audible by toggling this button default is audible Red LED will illuminate when fault occurred 3 Func To toggle charger setting Menu and select scrolling to make display continue to scroll all setting See optional remote programming section 4 Set To confirm the chosen feature you selected IV Programming using the optional remote A B Pressing Func Button to display Scrolling or until any setting you want to display Pressing Set button to confirm Remote Panel Scrolling Menu O
17. rge stage Overload Over Current Protection when output current OFF Manual power on off reset after fault is 10 higher than the rated pon ON JOBE cleared maximum level ekot Cae ta pO tes Solid ON OFE OFF Manual power on off reset after fault Alarm flash amp Buzzer on Output cleared Shorted nee gente een eee OFF OFF ON Charger returns to normal after fault cleared Reverse Polarity Protection Solid ON OFF OFF Manual Power on off reset after Alarm flash amp Buzzer on Thermal Fuse correct fuse replaced WRONG POLARITY Alarm flash amp Buzzer on Overload To protect charger N Trouble Shooting PROBLEM INDICATIONS POSSIBLE CAUSES SUGGESTED SOLUTION No AC power Charger does not work turn on No DC output not on Float and Fault LEDs are on Battery does not get All indicator LED work normally and sequentially OTP LED flashing Long charging time float light does not come on even after 12 hours charging time Bulk LED is on all the time Absorption light remains on all the time Bulk light remains on all the time Indicator lights not Charger On LED is AC input socket fuse blown Output short circuit Over temperature protection triggered Severe over loading charger Reverse polarity connection DC fan locked by foreign object or malfunction Bad battery connection Battery type select switch in wrong setting Battery capacity too large Ambient temperature
18. ss feet for 2 Voltage loss 20A Table Selection of cable size and length versus current M Fault Indications PROTECTIONS amp FAULT INDICATIONS WITH CAUSES PROTECTION FAULT FAULT lorp LED CHARGER OUTPU OFF No Output REMOTE CONTROL UNIT amp REMARKS LED LCD Fault Display Output power decreases due to ON At reduced power in 25 step leading Bho gs atte Auto return to full set i no specific indication for high high operating ambient OFF Flashing to output off high temperature protection power gradually as temperature decreased output temperature see next row unit temp cools down charger over heat OTP Solid ON Solid ON OFF Manual power on off reset after fault Alarm Hash amp Buzzer on Charger protection on cleared High Temp Charger preset to reduced output This ts not a fault BOWE OFF OFF ON At reduced output power as selected Indicates xx Power Set So no specific indication Battery over heat detected by remote temp sensor at 60 C Fan not working or stuck Flashing Flashing ie a Power Onion rescence taut Alarm flash amp Buzzer on Fan Fault oe OFF Manual power on off reset after fault Alarm flash amp Buzzer on Bat Over Flashing Solid ON ead Output Over Voltage Protection when output voltage is 4 OFF Manual power on off reset after fault Alarm flash amp Buzzer on Output V To protect battery and higher than it should be for the load connected battery type and cha
19. supply mains Then remove the chassis connection and then the battery connection F Normal 4 Stage IUoU Charging Operation The 4 stage IUOU charge algorithm ensures fast complete and at the same time gentle charging of the lead acid battery Charging Profile MULTI STAGE CHARGING DIAGRAM BATTERY 3 CHARGE CHARG CURRE Pe i BULK CHARGE ABSORPTION CHARGE FLOATING CHARGE STANDBY CHARGE CONSTANT CURRENT CONSTANT VOLTAGE CONSTANT VOLTAGE CONSTANT VOLTAGE Stage 1 THE I PHASE The constant current charging Bulk LED is ON Normally the battery is charged at constant maximum current until it rises to the selected Absorption voltage level The charging voltage changes with the battery voltage Soft Start Bulk Charging If at the initial bulk charging the battery voltage is at less than 24 6V the bulk charge current is reduced to half of the maximum until battery voltage rises to 25 6V This soft start charging is set for 10 minutes and will repeat until battery voltage rises to 25 6V At the end of 2 hours battery voltage cannot reach 25 6V alarm will sound and output is cut off Remark If the battery keeps the charger at Bulk mode for 12 hours the charger will automatically switch to Float mode Stage 2 THE UO PHASE The constant voltage charging Absorption LED is ON Battery Type Selection Gel P 1 28 2V Gel P 2 28 6V AGM 28 6V LiFePO4 29 2V Wet 28 8V Calcium 30 2V When the battery voltage reach
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