Datron PRC-BC4 Technical Manual Download

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PRC-BC4

Multiple Battery Charger

Operator/Technical Manual

Manual Part No. PRC-BC4-MS

Release Date: May 2016

Revision: G

Summary of Contents for PRC-BC4

Page 1: ...PRC BC4 Multiple Battery Charger Operator Technical Manual Manual Part No PRC BC4 MS Release Date May 2016 Revision G ...

Page 2: ...Datron World Communications Inc 995 Joshua Way Suite A Vista CA 92081 U S A Phone 760 597 1500 Fax 760 597 1510 E Mail customerservice dtwc com www dtwc com ...

Page 3: ...06 E Convert to FrameMaker and overall update All 06 11 F Updated the Charger board component locations diagrams 738100 and parts list PRC BC4CHG Updated the Display board component locations diagram 738101 and parts list PRC BC4DIS 4 4 4 7 4 16 4 17 05 16 G Update manual format Update parts lists to latest revisions All 4 7 4 11 ...

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Page 5: ...e Licensee further agrees they or their agents are not authorized to make derivative versions or changes to the Software Title to and ownership of the Software shall at all times remain with Datron and or its licensors Further no license is granted to copy or reproduce in any form whatsoever the Software supplied without the express written permission of Datron prior to any such contemplated actio...

Page 6: ...tempts to repair or modify the equipment Defects or failures caused by Buyer abuse or misuse Return of Equipment Domestic To obtain performance of any obligation under this warranty the equipment must be returned freight prepaid to Technical Support Services Datron World Communications Inc 3055 Enterprise Court Vista California 92081 The equipment must be packed securely Datron shall not be respon...

Page 7: ...e ground has been established Consult the manual section on grounding Servicing Only trained personnel should perform product repair To avoid electric shock DO NOT open the case unless qualified to do so Various measurements and adjustments described in this manual are performed with AC power applied and the protective covers removed Capacitors particularly the large power supply electrolytic type...

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Page 9: ...3 1 Status LED Indications 3 2 Figure 3 2 Charging Configuration 3 2 Chapter 4 Technical Description 4 1 Input Power 4 1 4 2 Charging Circuit 4 2 4 3 Status LEDs 4 3 4 4 Component Locations Schematic and Parts List 4 3 Figure 4 1 Charger Board Component Locations 738100 Rev F 4 4 Figure 4 2 Charger Board Schematic Diagram 994003 Rev E 4 5 Table 4 1 Charger Board Parts List PRC BC4CHG Rev T 4 7 4 5...

Page 10: ...viii PRC BC4 MS Chapter 5 Maintenance 5 1 Functional Test 5 1 Figure 5 1 Charger Output Check Setup 5 2 Figure 5 2 DC Current Check Setup 5 3 5 2 Troubleshooting 5 4 Table 5 1 Troubleshooting Index 5 4 ...

Page 11: ... simultaneously The PRC BC4 can use a 110 or 220 VAC power source 50 or 60 Hz it can also use a 20 to 30V DC power source The PRC BC4 includes the following features Up to four battery charging capacity 3 level charging circuitry AC or DC power source Front panel status LEDs for each charging station Front panel reset button for each charging station ...

Page 12: ...k charging rate 1 1A C 5 Bulk to overcharge transition voltage 14 0 VDC Overcharge terminate current 110 mA c 50 Float charge voltage 13 3 VDC Float to bulk transition voltage 12 0 VDC Temperature coefficient on voltage levels 12 mV C Current drain on battery with power off 5 µA max Nominal charge time with 80 discharged battery 6 hrs Mechanical Weight 4 3 kg 9 5 lbs Size HWD 4 0 in x 9 5 in x 11 ...

Page 13: ... 12 VDC Max instantaneous output current 30A at 20 C Max continuous output current 7A at 20 C Internal resistance 0 02 ohm max fully charged Percent of original capacity versus storage time 90 after 3 months 80 after 6 months 60 after 12 months Mechanical Weight 5 5 lbs 2 5 kg Size HWD 3 7 in x 9 5 in x 2 3 in 9 4 cm x 24 2 cm x 5 8 cm Characteristic Description Mechanical Weight 0 5 lbs 0 23 kg S...

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Page 15: ...Input Power The PRC BC4 can be configured for 110 or 220 VAC by opening the case and changing the connections on the power transformer A label on the case indicates to what input voltage the transformer is set however it is prudent to visually inspect the power transformer to verify what input voltage it is configured to accept refer to Figure 2 2 on page 2 3 CAUTION Always remember to remove the ...

Page 16: ...se 5 Note the connections on the power transformer behind the regulator circuit board To configure the PRC BC4 for a 220 VAC power source 1 Desolder terminals 3 4 5 and 6 2 Remove the jumper wires between terminal 3 and terminal 4 and the jumper between terminal 5 and terminal 6 refer to Figure 2 2 on page 2 3 3 Install one of the jumpers between terminal 4 and terminal 5 4 Resolder terminals 3 4 ...

Page 17: ...d to connect to a DC power source The power source must provide 20 to 30 VDC and be capable of supplying 5A A vehicle battery is a typical DC power source The front panel DC INPUT connector is wired according to Figure 2 3 below Figure 2 2 Power Transformer Connections 110 3 VAC AC FUSE A 220 1 5 VAC AC FUSE A 1 2 3 4 5 6 7 8 SWITCH AC PLUG 1 2 3 4 5 6 SWITCH AC PLUG 1 2 3 4 5 6 Wire Type US Stand...

Page 18: ... not operate the PRC BC4 when connected to both an AC and DC power source The PRC BC4 does not require any alignment or adjustment for normal operation 2 2 3 Output Power The PRC BC4 provides 12 VDC to up to four BB LA6 lead calcium batteries ...

Page 19: ... set up the PRC BC4 for charging operation 1 Make sure the power transformer is configured correctly for the intended power source refer to Figure 2 2 on page 2 3 2 Do one of the following Connect the AC power cable to the front panel AC INPUT connector and an AC 110 or 220 VAC power source Connect the DC power cable C991609 to the front panel DC INPUT connector and a DC 20 to 30 VDC power source ...

Page 20: ... 1 below provides additional LED indications Table 3 1 Status LED Indications LED Meaning Required Action FAULT Battery fuse is blown or battery voltage is below 4 VDC Note It is normal for the FAULT LED to go on if you press RESET when a battery is not installed Check battery fuse If the battery fuse is okay the battery is faulty Discard the battery CHARGING Battery is charging normally None READ...

Page 21: ...cuit that limits ripple to about 2 Vpp at the full rated output Switch S5 is a normally closed thermostat that opens at approximately 167 F 75 C The thermostat switch is wired in series with DC fuse F2 so that if the chassis temperature exceeds the 167 F set point the PRC BC4 temporarily turns off The Display board includes transient absorbing diode D13 that provides protection against large spike...

Page 22: ...f the battery voltage is lower than 5V the charger remains in fault condition and no current flows to the battery This protects the PRC BC4 from BB LA6s with shorted cells Series pass transistor Q1 controls the charge current to the BB LA6 In the bulk charge state charger IC U1 drives Q1 through pin 16 Resistor R4 in series with the Q1 emitter provides current limiting and current sensing that all...

Page 23: ... where it drives the FAULT LED through current limiting resistor R2 It also drives the base of Q1 that shunts voltage away from diodes D1 and D2 when it is conducting preventing the CHARGING and READY LEDs from lighting 4 3 2 Charge LED The state level output pin 10 drives the inverting input to operational amplifier U5B The non inverting input is fixed at 1 3 VDC Pin 10 is at ground potential dur...

Page 24: ...4 Technical Description 4 4 PRC BC4 MS Figure 4 1 Charger Board Component Locations 738100 Rev F ...

Page 25: ...LM324 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 15 U4 UC3906N Q4 TIP2955 D4 1N5400 R22 0 22 1 2W C12 2 2uF 50V C11 0 1uF 50V C10 0 22uF 35V R23 100K R20 100K R19 20K 1 C25 0 1uF R24 100K 1 R21 330K 1 D7 D6 C18 2 2uF R28 10K 8 9 10 U5C LM324 4 11 U5E LM324 1 2 3 4 PL4 S3 RESET A B J3 S4 RESET 2 1 PL6 C14 4 7K 35V C15 4 7K 35V C16 4 7K 35V D5 MBR1645 C13 0 1uF 50V 1 2 3 PL7 S6 A B J5 BEAD BR1 T1 F2 S5 75c...

Page 26: ... C2 275104 CAP 0 1UF X7R 50V 10 RAD 0 1S C20 241020 CAP 2 2UF TA 16V 20 DIP 0 1LS C21 230020 CAP 2 2MF ELECT C22 275104 CAP 0 1UF X7R 50V 10 RAD 0 1S C23 275104 CAP 0 1UF X7R 50V 10 RAD 0 1S C24 275104 CAP 0 1UF X7R 50V 10 RAD 0 1S C25 275104 CAP 0 1UF X7R 50V 10 RAD 0 1S C3 230020 CAP 2 2MF ELECT C4 254224 CAP 0 22UF POLY 100V 5 11X13X10LS C5 275104 CAP 0 1UF X7R 50V 10 RAD 0 1S C6 230020 CAP 2 2...

Page 27: ...HEADER MLX 3PIN 156 POLAR Q1 310137 XSTR TIP2955 PNP 15A TO 218 Q2 310137 XSTR TIP2955 PNP 15A TO 218 Q3 310137 XSTR TIP2955 PNP 15A TO 218 Q4 310137 XSTR TIP2955 PNP 15A TO 218 R1 127203 RES 20K OHM 1 4W 1 MF R10 144002 RES 0 22 OHM 1W 5 MOX R11 124104 RES 100K OHM 1 4W 5 CF R12 127104 RES 100K MF 1 4W 1 TH R13 127203 RES 20K OHM 1 4W 1 MF R14 124104 RES 100K OHM 1 4W 5 CF R15 127334 RES 330K OHM...

Page 28: ...5 CF R32 124391 RES 390 OHM 1 4W 5 CF R4 144002 RES 0 22 OHM 1W 5 MOX R5 124104 RES 100K OHM 1 4W 5 CF R6 127104 RES 100K MF 1 4W 1 TH R7 127203 RES 20K OHM 1 4W 1 MF R8 124104 RES 100K OHM 1 4W 5 CF R9 127334 RES 330K OHM 1 4W 1 MF U1 330325 IC UC3906N U2 330325 IC UC3906N U3 330325 IC UC3906N U4 330325 IC UC3906N U5 330030 IC LIN LM324N DIP14 OP AMP XU1 621004 SOCKET IC DIP 16 PIN XU2 621004 SOC...

Page 29: ...l Description 4 10 PRC BC4 MS 4 5 Display Board The Display board includes all the FAULT CHARGING and READY LEDs for each charging station on the PRC BC4 Figure 4 3 Display Board Component Locations 738101 Rev D ...

Page 30: ...8D T1 3 4 D18 320415 LED RED D19 320417 LED YELLOW D2 320002 DIODE 1N4148 1N4150 DO 35 D20 320416 LED GREEN 28D T1 3 4 D21 320415 LED RED D22 320417 LED YELLOW D23 320416 LED GREEN 28D T1 3 4 D24 320415 LED RED D25 320417 LED YELLOW D26 320416 LED GREEN 28D T1 3 4 D3 320002 DIODE 1N4148 1N4150 DO 35 D4 320002 DIODE 1N4148 1N4150 DO 35 D5 320002 DIODE 1N4148 1N4150 DO 35 D6 320002 DIODE 1N4148 1N41...

Page 31: ...103 RES 10K OHM 1 4W 5 CF R16 137332 RES 3 3K OHM 1 2W 1 MF R17 124182 RES 1 8K OHM 1 4W 5 CF R2 137272 RES 2 7K OHM 1 2W 5 CF R3 124103 RES 10K OHM 1 4W 5 CF R4 137332 RES 3 3K OHM 1 2W 1 MF R5 124182 RES 1 8K OHM 1 4W 5 CF R6 137272 RES 2 7K OHM 1 2W 5 CF R7 124103 RES 10K OHM 1 4W 5 CF R8 137332 RES 3 3K OHM 1 2W 1 MF R9 124182 RES 1 8K OHM 1 4W 5 CF U1 330007 IC LM340T 12 VREG 12V 1A TO 220 Ta...

Page 32: ...minimum Electrolytic capacitor 30 000 to 150 000 µF 25 VDC Resistor 6 8 ohms 10W Resistor 2 2 ohms 5W Resistor 82 ohms 3W DC VOM high impedance input DC Ammeter 3A scale minimum Clip jumpers Heat gun or blow torch 5 1 2 Test Procedure The following checks use the electrolytic capacitor to simulate a BB LA6 battery Charging Circuit Check 1 Set up the PRC BC4 using an AC input power source Connect a...

Page 33: ...t them across the capacitor refer to Figure 5 2 on page 5 3 2 Measure the DC current It should be 1 1A 0 1A The CHARGING LED for charging station BATT 1 should be lit when the ammeter and resistors are connected 3 Disconnect the ammeter and resistors The READY LED should light up after a few seconds Figure 5 1 Charger Output Check Setup BATT 1 CHARGING READY FAULT RESET BATT 2 CHARGING READY FAULT...

Page 34: ...d light up Overcharge Voltage Check 1 Measure the DC voltage across the 82 ohm resistor It should be 14 0 0 2 VDC Undervoltage Protection Circuit Check 1 Connect the 2 2 ohm resistor across the capacitor 2 Observe that the FAULT LED lights up after a few seconds Repeat the previous checks for the other charging stations Figure 5 2 DC Current Check Setup BATT 1 CHARGING READY FAULT RESET BATT 2 CHA...

Page 35: ...hermostat until it trips 3 Check that the PRC BC4 shuts off until the thermostat trips back on This concludes the functional test If the PRC BC4 failed any of the previous steps refer to Troubleshooting below 5 2 Troubleshooting 5 2 1 Index to Test Procedure If the PRC BC4 fails a test procedure Table 5 1 refers to a specific place in the troubleshooting procedure Table 5 1 Troubleshooting Index F...

Page 36: ...of them are lit refer to Status LEDs on page 5 8 3 If the CHARGING LED is lit skip to step 7 4 With more than 6 VDC across the capacitor the FAULT LED should now be lit On the IC measure the DC voltage at pin 7 If it is more than 100 mV replace the IC 5 On the IC measure the DC voltage at pin 12 If it is less than 3 VDC check the resistive divider R5 R2 at pin 12 6 On the IC check for a short circ...

Page 37: ... resistor 4 Refer to Current Source on page 5 5 Float Charge Voltage This section assumes a failure occurred during the Float Charge Voltage procedure on page 5 6 if the float charge voltage is out of specification The float charge voltage should be 13 3 VDC 1 R1 20 k ohm and R6 100 k ohm are 1 resistors that form a voltage divider that sets the float charge voltage Turn the PRC BC4 off remove the...

Page 38: ...p 5 Reverse Current Protection This section assumes a failure occurred during the Reverse Current Protection procedure on page 5 7 if diode D5 fails to provide reverse current protection Turn the PRC BC4 off for the following checks 1 On the DC input power line measure the resistance across D5 If the forward resistance is less than 10 ohms and the reverse resistance in very high mega ohms the diod...

Page 39: ...e removed the short is on the inboard side of the fuse The short can be isolated by lifting the various connectors or pressing each RESET button one at a time 8 Measure the resistance of the power transformer windings The resistance should be a very low resistance typically less than 10 ohms Status LEDs This section assumes the status LEDs are either not lighting or lighting at the wrong time 1 Tu...

Page 40: ...in If it is not at 0 VDC replace the IC 2 Measure the voltage across the transistor on the Display board it should be near ground potential if it is conducting If it is always conducting the CHARGING and READY LEDs never light up If this is the case check the associated wiring 3 On the Display board measure the DC voltage at the 12 VDC regulator U1 output pin pin 3 If it is not 12 1 5 VDC turn off...

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