BDX Battery Load Test Analyzer
Contents
1. Caution This operation can be dangerous for the user Attention This operation is important for the proper operation of the equipment gt gt gt Inside the equipment this picture is placed near devices having dangerous electrical current The equipment is marked with a technical label reporting the following data CE mark Model Serial number Weight Input voltage Maximum input current A Maximum input voltage V RESPONSIBILITY DISCLAIMER The manufacturer of the BDX battery discharger analyzer will not be responsible for damages and or injuries caused by the equipment in these situations The equipment is not installed properly by a qualified electrician Maintenance operations are not done by a qualified electrician The equipment is not used according to the instructions included in this manual The equipment is not connected to the correct input supply see data label on the box The battery is damaged during the test The equipment has been modified without the authorization of the manufacturer Non original spare parts are used in the equipment Wrong spare parts are used in the equipment Page 3 9 2 SAFETY INSTRUCTIONS AND WARNINGS GENERAL Battery discharging units like the BDX can cause serious injury or death or damage to other equipment and property if the operator does not strictly observe all safety rules and take precautionary actions Safe practices must be learned th2. and press the SET button to proceed 8 The BDX is now ready to start the test The display will show the message rdy 9 Press both buttons and TOGETHER to start the test e If the potentiometer 0 100 is in position ZERO the BDX will start the test and the display will show the discharge current in AMPS At this point use the two potentiometers 0 100 and 5 to adjust the discharge current to the desired value If the potentiometer 0 100 is not in position ZERO rotated all the way to the left the BDX will not start and the display will show the message POT It s necessary to rotate the potentiometer 0 100 left to the position ZERO then the BDX will start TEST PARAMETERS While the test is in progress all the partial results of the test can be displayed by pressing the SET button PARAMETER UNITS DISPLAY LETTER CURRENT AMPS p CAPACITY DISCHARGED AMPS HOURS c TIME HOURS MINUTE DECADES h PROGRAMMED STOP VOLTAGE VOLTS E BATTERY VOLTAGE VOLTS y While the test is in progress it s also possible to change the programmed parameters by pressing one of the buttons or In this case the BDX will suspend the test and return to programming mode EXAMPLE This is a 24V battery The programmed stop voltage is 22 0 V The discharge current has been set at 85 Amps After 2 hours of discharge the total capacity discharged is 170 Ah and the battery voltage is 22
3. 7 V E All these parameters can be displayed by pressing the SET button Page 7 9 THERMAL PROTECTION If the cooling system fails and or the power electronic components of the BDX reach a temperature higher than a maximum value the current is automatically set to ZERO until the temperature decreases below the limit Make sure that the ventilation ducts are not obstructed END OF TEST The test is terminated automatically when the battery voltage reaches the programmed STOP VOLTAGE or the time exceeds the programmed MAXIMUM TIME At this point the display shows the test results together with the message END DATA DOWNLOAD TO PC The BDX control panel incorporates a Data Logger that saves the entire discharge data current voltage capacity At the end of the discharge it s possible to download this data to a personal computer via RS232 serial interface This function in combination with the dedicated software TrendCOM 2006 makes it possible to create and print complete test reports automatically A Caution NEVER connect the personal computer to the data port of the BDX while the battery is still connected to the BDX This operation can damage the devices and can be dangerous for the user AN Attention The Data Logger memory is erased at the beginning of each discharge cycle DON T start a new discharge cycle before downloading the existing data to the PC DOWNLOAD PROCEDURE 1 Make sure t
4. REVENTION When batteries are being charged they generate hydrogen gas that is explosive in certain concentrations in the air the flammability or explosive limits are 4 1 to 72 hydrogen in air The spark retarding vents help slow the rate of release of hydrogen but the escaping hydrogen may form an explosive atmosphere around the battery if ventilation is poor The ventilation system should be designed to provide an adequate amount of fresh air for the number of batteries being charged This is essential to prevent an explosion Always keep sparks flames burning cigarettes and other sources of ignition away from the battery recharging area Do not break live circuits at the terminals of batteries Do not lay tools or anything that is metallic on top of any battery ARCING AND BURNING OF CONNECTOR To prevent arcing and burning of the connector contacts be sure the discharger is OFF before connecting or disconnecting the battery The ammeter should NOT indicate current flow MEDICAL AND FIRST AID TREATMENT First aid facilities and a qualified first aid person should be available for each shift for immediate treatment of electrical shock victims EMERGENCY FIRST AID Call physician and ambulance immediately and use First Aid techniques recommended by the American Red Cross IF PULSE IS ABSENT BEGIN ARTIFICIAL CIRCULATION such as external heart massage In case of acid in the eyes flush very well with clean water and obtain pr
5. TOTALIF1 BDX Industrial Battery Load Test Analyzer SS SSS SSS A Sy pg SSS OSS SSS SH _ SSS _ _ _ 4 a pN EEN SSS SSS SS Index 1 MACRO CTIO Di scsarsseeondiacspaatatsiedecee ints ances eoadies Responsibility Disclaimer c c000 2 Safety Instructions and Warnings Geel dle cet cece ete tees Shock PreVeNntiON cccccsscecsececesesseceeees Burn amp bodily injury prevention Fire amp Explosion prevention 06 Arcing amp burning of connectot Medical amp first aid treatment Equipment warning labels 0006 Be Descriptio N inana Control panel cecescesesseecsecseeseeeseees Sequence Of OperatiON cccseeeseeseees Test ParaMetelS csscccccccecssssrerecseceeeees Thermal protectiOn ccccccesseceseeeeees End of testein nha E Data download to PC ssseseensesseseeses ese Page 2 9 o oo N DHA HU UN HNN SP A A BPW W 1 INTRODUCTION Before using your BDX battery discharger analyzer please take the time to read these instructions carefully The owner s manual is an important part of the equipment It s recommended to keep it in good condition for the lifetime of the equipment It should be kept in a dry and clean place always available to the users To indicate important instructions the following pictures are used
6. efore using equipment The grounding conductor must be of a size equal to or larger than the size of the line conductors DISCHARGING LEADS Inspect leads often for damage to the insulation Replace or repair cracked or worn leads immediately Use leads having sufficient capacity to carry the operating current without overheating BATTERY TERMINALS Do not touch battery terminals while equipment is operating SERVICE AND MAINTENANCE Shut OFF all power at the disconnect switch or line breaker BEFORE inspecting adjusting or servicing the equipment Lock switch OPEN or remove line fuses so that the power cannot be turned ON accidentally Disconnect power to equipment if it is to be left unattended or out of service Disconnect battery from charger Measure voltage on capacitors and if there is any voltage reading wait 5 minutes before proceeding Keep inside parts clean and dry Dirt and or moisture can cause insulation failure This failure can result in high voltage at the charger output BURN AND BODILY INJURY PREVENTION The battery produces very high currents when short circuited and will burn the skin severely if in contact with any metal conductor that is carrying this current Do not permit rings on fingers to come in contact with battery terminals or the cell connectors on top of the battery Page 4 9 Battery acid is very corrosive Always wear correct eye and body protection when near batteries FIRE AND EXPLOSION P
7. hat the discharge cycle is finished The display shows the message END together with the final results Turn OFF the BDX by moving the general switch 0 1 to position 0 Disconnect the battery from the BDX Connect the data ports RS 232 of the PC and the BDX using the appropriate cable supplied with the BDX Turn ON the BDX by moving the general switch 0 1 to position 1 Turn ON the PC and launch the application TrendCOM 2008 Start the download of the data and wait for the confirmation message AON NO o1 Page 8 9 8 Switch off the BDX and disconnect the serial cable At the end of the download the Data Logger memory is NOT erased therefore the discharge data remains available for other downloads The Data Logger memory is erased when a new battery is connected and a new discharge cycle starts A Caution Never leave the PC connected to the BDX after the data download This may cause data loss and or damage to the equipment END OF MANUAL Page 9 9
8. ofessional medical attention immediately EQUIPMENT WARNING LABELS Inspect all precautionary labels on the equipment Order and replace all labels that cannot be easily seen Page 5 9 3 DESCRIPTION The BDX battery discharger analyzers have been designed to test the efficiency of batteries of any type voltage and capacity These units perform a controlled discharge of the battery while the current is kept constant by a high frequency DC DC converter based on MOSFET technology for smaller units and IGBT technology for bigger units The operation of the BDX is completely automatic it s sufficient to connect the battery to set the stop voltage the maximum time and the discharge current The entire test is processed automatically while the digital display shows the partial results CONTROL PANEL gy 5 N SEQUENCE OF OPERATION 1 Make sure the PC is NOT connected to the BDX data port 2 Connect the battery to be tested 3 Turn on the BDX by moving the general switch 0 1 to position 1 Page 6 9 4 The display will show the BATTERY VOLTAGE for 3 seconds then it will show the proposed STOP VOLTAGE with the flashing letter U 5 If needed adjust the STOP VOLTAGE with the buttons and and press the SET button to proceed 6 The display will show the MAXIMUM TIME ALLOWED FOR TEST with the flashing letter h 7 If needed adjust the MAXIMUM TIME ALLOWED FOR TEST with the buttons and
9. rough study and training before using this equipment Only qualified personnel should install use or service this equipment SHOCK PREVENTION Bare conductors or terminals in the circuit or ungrounded electrically live equipment can fatally shock a person To protect against shock have a certified electrician verify that the equipment is adequately grounded and identify what terminals and parts are electrically HOT The body s electrical resistance is decreased when wet permitting dangerous current to flow through the body Do not work in a damp area without being extremely careful Stand on a dry rubber mat or dry wood and use insulating gloves when dampness or sweat cannot be avoided Keep clothing dry INSTALLATION AND GROUNDING A power disconnect switch must be located at the equipment Check the data label for voltage and phase requirements If only 3 phase power is available connect single phase equipment to ONLY TWO WIRES of the 3 phase line DO NOT CONNECT the equipment grounding conductor to the third live wire of the 3 phase line as this makes the equipment frame electrically HOT which can cause a fatal shock If a grounding conductor is part of the power supply cable be sure to connect it to a properly grounded switch box or building ground If not part of the supply cable use a separate grounding conductor Don t remove a ground prong from any plug Use correct mating receptacles Check ground for electrical continuity b
Download Pdf Manuals
Related Search