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2

Operation

Chapter 2 describes the operating states of the 
BC Series and provides procedures for charging a 
battery and performing an equalization.

BC_Charger_User.book  Page 1  Friday, August 12, 2005  3:31 PM

Summary of Contents for BC3012

Page 1: ...12 V 30 A 12 V 50 A 24 V 15 A 24 V 25 A Xantrex BC3012 BC5012 BC1524 and BC2524 Battery Charger User Guide BC_Charger_User book Page 1 Friday August 12 2005 3 31 PM...

Page 2: ...BC_Charger_User book Page 2 Friday August 12 2005 3 31 PM...

Page 3: ...Xantrex BC3012 BC5012 BC1524 and BC2524 Battery Charger User s Guide BC_Charger_User book Page i Friday August 12 2005 3 31 PM...

Page 4: ...24 Battery Charger User s Guide August 2005 Xantrex International All rights reserved Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING XANTREX TECHNOLOGY INC XANTREX a MAKES NO WARRANTY AS TO THE A...

Page 5: ...d for anyone who needs to operate the Xantrex BC3012 BC5012 BC1524 and BC2524 Battery Charger Organization This Guide is organized into 3 chapters and 1 appendix Chapter 1 Introduction Chapter 1 descr...

Page 6: ...Charger 24 V 25 A will be referred to as the BC2524 when it is being referenced individually When the Xantrex BC3012 BC5012 BC1524 and BC2524 Battery Chargers are being referenced together they will...

Page 7: ...It is the responsibility of the installer to ensure that the installation of the BC Series complies with all relevant electrical codes 5 To avoid a risk of fire and electric shock make sure that exis...

Page 8: ...Series has been approved as Ignition Protected It may be installed in areas containing gasoline tanks and fittings which require Ignition Protected equipment Xantrex recommends nevertheless that it i...

Page 9: ...s are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and...

Page 10: ...viii BC_Charger_User book Page viii Friday August 12 2005 3 31 PM...

Page 11: ...Switches 1 9 Configuring with Remote Display 1 11 2 Operation About Charging 2 2 Multiplex 3 Stage Charging 2 2 Sequential 2 Stage Charging 2 3 Charging Overview 2 3 Charging Batteries 2 6 Equalizing...

Page 12: ...s on Optional Remote Display 3 4 Problem Solving 3 7 A Specifications Physical Specifications A 2 Electrical Specifications A 2 AC Input Specifications A 3 Temperature Specifications A 4 Protection Fe...

Page 13: ...1 Introduction Chapter 1 describes the BC Series standard features and lists the procedures to configure the BC Series BC_Charger_User book Page 1 Friday August 12 2005 3 31 PM...

Page 14: ...charging voltage for your batteries when connected to almost any single phase AC power outlet in the world The BC Series provides the following protection features true fuseless reverse polarity prote...

Page 15: ...Series Figure 1 3 shows the BC Series Figure 1 1 BC Series Item Description 1 Configuration DIP switches and equalize push button 2 Onboard status panel for monitoring charger status and charging curr...

Page 16: ...arger Status READY Ready indicator light illuminated indicates all batteries are fully charged and are now in float or rest 3 Charger Status CHARGING Charging indicator light illuminated indicates uni...

Page 17: ...before 2 seconds have elapsed Figure 1 3 BC Series Remote Display Item Description 1 ON STANDBY push button Press to turn on or disable the charger while AC power is connected Press and hold to apply...

Page 18: ...5 BANK selection push button Press to select a bank during setup Press at the same time as MODE to enter or exit equalization mode 6 TYPE selection push button Press to select flooded lead acid gel AG...

Page 19: ...nsor for bank 1 connector 3 BTS2 battery temperature sensor for bank 2 connector 4 BTS3 battery temperature sensor for bank 3 connector 5 Battery negative common for all 3 banks 6 mm stud 6 Battery po...

Page 20: ...ividual battery bank to provide optimal charging and protection of each bank If no BTS is connected the charger defaults to the charging conditions for 40 C 104 F At this temperature the charging volt...

Page 21: ...DIP switches but if not the configuration will need to be set appropriately for each installation Use Table 1 2 to set the DIP switches to match each configuration Figure 1 5 shows the location of the...

Page 22: ...nk 3 AGM Bank 3 Lead Calcium 6 Bank 3 Flooded Bank 3 AGM Bank 3 Gel Bank 3 Lead Calcium 5 Bank 2 Flooded Bank 2 Gel Bank 2 AGM Bank 2 Lead Calcium 4 Bank 2 Flooded Bank 2 AGM Bank 2 Gel Bank 2 Lead Ca...

Page 23: ...e BC Series will default to Bank 1 and will show the present battery type setting 3 Press BANK repeatedly to select which bank you are setting up The bank indicator light will illuminate to show which...

Page 24: ...he charging type 1 Press and hold MODE until set setup is displayed 2 Press MODE to select 2 stage 2st or 3 stage 3st charging When you have selected a charging type that is different from the present...

Page 25: ...peration Chapter 2 describes the operating states of the BC Series and provides procedures for charging a battery and performing an equalization BC_Charger_User book Page 1 Friday August 12 2005 3 31...

Page 26: ...ion and Float During the Bulk stage the battery is accepting high current In the Absorption stage the battery voltage is held constant and the current declines A battery will also gas produce hydrogen...

Page 27: ...arger will automatically restart charging in order to refresh the batteries Charging Overview The BC Series will perform a battery detection sequence every 15 minutes or on reapplication of AC to dete...

Page 28: ...ble to accept charge If disqualification occurs during Bulk or Absorption the battery is damaged or there is another charging source present other than the charger itself The optional remote display w...

Page 29: ...e disqualified Because the charger is able to detect unhealthy batteries and disqualify them batteries that may have appeared healthy before will now be correctly identified as needing attention Perfo...

Page 30: ...r initialization the charging indicator light illuminates During charging the charging current indicator lights show the total current being delivered to the selected battery bank as well as any DC lo...

Page 31: ...e and will maintain the batteries charge Rest mode If you selected the 2 stage charging mode the Ready indicator light shows the charger is now in rest mode and is checking battery voltage and elapsed...

Page 32: ...mal charge cycle on the batteries before you equalize them WARNING Explosion hazard During equalization the battery generates explosive gases Follow all the battery safety precautions listed in this g...

Page 33: ...s the equalize push button beside the DIP switches once to equalize bank 1 twice within three seconds to equalize bank 2 and three times within three seconds to equalize bank 3 4 Monitor the specific...

Page 34: ...he display will show no Check that the battery is flooded and in float mode 6 When the charger is in equalize mode the display will show equ 7 Monitor the specific gravity of each cell of the battery...

Page 35: ...t will not charge them There is only one way to safely turn the BC Series off disconnect the AC power at the source and disconnect all DC batteries This is the only state where the BC Series is comple...

Page 36: ...mote display is designed to report on the active status of the charger While the unit is charging the optional remote display reports only on the battery being charged at that moment It does not repor...

Page 37: ...e every four seconds if bank 2 is being equalized and three times every four seconds if bank 3 is being equalized Charging indicator light flashes EQU Float mode of three stage charging or rest mode o...

Page 38: ...te Display Reporting While Battery Monitoring The BC Series is considered to be battery monitoring if it is experiencing a charger level fault If there is a charger level fault affecting all banks all...

Page 39: ...y wish to see the present status of the banks To view the present status of the banks Press ON STANDBY on the optional remote display If AC power is disconnected the optional remote display will show...

Page 40: ...ine the size of generator you need Many generators provide output voltage that is modified sine wave or modified square wave MSW rather than the true sine wave TSW that your utility provides The BC Se...

Page 41: ...3 Troubleshooting Chapter 3 contains information on error codes and procedures for troubleshooting your BC Series charger BC_Charger_User book Page 1 Friday August 12 2005 3 31 PM...

Page 42: ...ssolve To clean battery terminals 1 Disconnect all loads and charging sources 2 Using the appropriate tool remove the negative battery cable first and re install it last 3 To remove any stubborn resid...

Page 43: ...e display shows details of fault Example Err BAT PoL battery reverse polarity detected Fault indicator light flashes Charger fault condition remote display shows err followed by CHf The charger is dam...

Page 44: ...hing Charger Hardware Fault Call for service CHg Hot Over temperature Warning Allow the BC Series to cool Improve ventilation or install in cooler location If the temperature increases the BC Series w...

Page 45: ...luminated Over Voltage Shutdown Warning Check battery Do not charge a battery rated at more than 12 volts nominal BC3012 BC5012 or 24 volts nominal BC1524 BC2524 Disconnect or turn off other charging...

Page 46: ...indicator light illuminated Green 100 indicator light flashes Green bank indicator light for affected battery bank illuminated Battery too Hot Shutdown Allow battery to cool Improve ventilation or ins...

Page 47: ...No power at AC source and no battery connected on bank 1 Defective AC wiring Charger level fault Ensure that power is available at the source and you have a battery or bank connected to bank 1 Replace...

Page 48: ...cool Improve ventilation or install in cooler location It may indicate a shorted cell in the battery or excessive water loss Possible Cause Solution Battery temperature is too cold for safe charging A...

Page 49: ...Use a higher capacity charger Disconnect load or switch load off Replace battery Possible Cause Solution Battery is the wrong type or set to the wrong type to equalize Not all batteries are fully char...

Page 50: ...3 10 BC_Charger_User book Page 10 Friday August 12 2005 3 31 PM...

Page 51: ...A Specifications Appendix A details the specifications for the BC Series BC_Charger_User book Page 1 Friday August 12 2005 3 31 PM...

Page 52: ...ns Four right angle M6 studs 3 positives and 1 common negative for battery cable ring terminals and one M6 mm DC equipment ground Number of battery bank outputs 3 isolated independently controlled out...

Page 53: ...current draw with remote installed BC3012 20 mA BC5012 20 mA BC1524 15 mA BC2524 15 mA AC input voltage range 100 260 VAC at full power 90 105 VAC at 80 restricted load Note Charger may not start wit...

Page 54: ...n voltage It will restart when this voltage is 0 2 V Output current limit BC3012 30 33 ADC BC5012 50 55 ADC BC1524 15 16 5 ADC BC2524 25 27 5 ADC Over temperature Internal charger temperature is measu...

Page 55: ...Systems on Boats ABYC A20 Battery Charging Devices NFPA70 1996 US NEC for home and RV installation requirements EMC FCC Class B CE marked meeting EMC Directive 89 336 EEC referencing EN55014 1 EN55014...

Page 56: ...A 6 BC_Charger_User book Page 6 Friday August 12 2005 3 31 PM...

Page 57: ...both parts and labor necessary to repair the product and return shipment to the customer via a Xantrex selected non expedited surface freight within the contiguous United States and Canada Alaska and...

Page 58: ...ARTICULAR PURPOSE ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PE...

Page 59: ...failure and or reason for the return A copy of your dated proof of purchase When you ship 1 Package the unit safely preferably using the original box and packing materials Please ensure that your prod...

Page 60: ...arger has been installed ___________________________________________ Battery battery bank size ___________________________________________ Battery type e g flooded sealed gel cell AGM ________________...

Page 61: ...BC_Charger_User book Page 5 Friday August 12 2005 3 31 PM...

Page 62: ...world Fax 1 800 994 7828 toll free North America 34 93 473 6093 Europe 1 360 925 5143 direct and rest of world Email customerservice xantrex com North America support europe xantrex com Europe custome...

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