Capricorn Controls Data & Application Note Page 1 of 4

DA07BCM-2 Designed & manufactured in England by Capricorn Controls E. & O. E

BCM 3A, 5A & 10A Battery Chargers

Genset Controls - Timers - Monitors - Trips - Battery Charging -
Spares & Accessories - Custom Products


115 / 230VAC connectable

SLA (Gel), LA & NICAD Batteries

Fault Circuit & Alarm Relay

Boost Mode

Output Trim

The BCM series are CURRENT LIMITED,
CONSTANT POTENTIAL solid state battery
chargers which allow maintenance free charging
of Nicad & Lead-Acid batteries, over a wide
ambient temperature range. They are available in
3A, 5A and 10A for both 12V and 24V systems.
Note: These chargers are not suitable for
supplying the load with the batteries removed.

OPERATION : The electronic circuitry limits
the charge current to the rated maximum(DC
average) at all times and will switch off
completely should the battery terminal voltage
fall below a pre-set value (see Charge Inhibit)
enabling the charger to operate in parallel with a
charging alternator. As the battery is charged its
internal resistance rises, tapering the charge
current accordingly, until the battery terminal
voltage approaches the charger reference voltage,
whereupon the battery is trickle charged to the
constant potential float level.

VOLTAGE THRESHOLD : Unless specified
otherwise, all units arepre-set to the Float and
Boost voltage levels as listed on page 4.
The Output Trim potentiometer is calibrated as
shown on page 2. This allows user adjustment to
compensate for ambient temperature and also to
adjust between Lead-Acid and Ni-Cad cell types.

THERMAL PROTECTION :
5A and 10A versions of 24V Chargers have a
thermal trip fitted to each heatsink. If the preset
temperature is exceeded, the charger will switch
off. This is not a Fault Condition as the thermal
trip resets automatically.




BOOST MODE : By linking the boost terminal
to the battery -Ve, the float threshold is raised to
a higher volts/cell level (see page 4). This higher
voltage causes the cells to gass, equalising the
cell voltages. Although this level is set at
manufacture, the Output Trim potentiometer
also alter this level.
Boost link must only be fitted temporarily or
the batteries could be permanently damaged.

CHARGE INHIBIT : Charging will only
commence / continue charging if the battery
terminal voltage is above half the Float Voltage
as set by the Output Trimpotentiometer, see
page 2. This helps to prevent the charger from
operating into a short circuit.

OVERRIDE TERMINALS : Temporarily link
to override the Charge Inhibit protection in order
to start charging a battery with a low terminal
voltage (see above). In this mode, the maximum
output current on 5A & 10A, 24V chargers is
reduced to approx 3A and 6A respectively (3A
Chargers are not affected).
Never fit this link permantly.






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E. & O. E. The Proven Solution to Power Controls DA07BCM-2
CONNECTIONS















































Notes:
1. Charger ON =Amber LED
2. Charging Normal =Green LED
3. Charging Fault =Red LED ( note: Green & Red LEDs cannot be on together)
4. Fit Override link to commission batteries or to start charging if terminal voltage < Float Level.
5. Set switch to On for Fault circuitry powered from Battery if loss of AC supply not a fault condition.
6. Relay de-energised in the Fault condition.
7. Fault Condition =terminal voltage < Float Level or open circuit output.
On certain chargers each Heatsink has a Thermal Trip to protect the power transistor.
However, over-temperature is not a fault condition as the Thermal Trip resets automatically
switching the charger on again.
8. Typical Top Plate shown above but some models vary in layout
9. External Charger On lamp must be an incandescent bulb, an LED must not be used.

Override
Link. See
note-4 below
Charger-On
Lamp

Battery

230VAC Supply

BOOST MODE
Volt-Free Alarm
Contacts identified in
the FAULT condition
(Relay de-energised)
Fault Mode Switch
See note-5 below

27.4V
Capricorn Controls Data & Application Note Page 3 of 4

DA07BCM-2 Designed & manufactured in England by Capricorn Controls E. &
O. E

Dimensions & Electrical Ratings
























Dimensions and Weights :

Model Number System
Voltage
Current
Limit
Dimensions
L x H x D (mm)
Fixing Centres
X x Y x dia (mm)
Nett Weight
(Kg)
BCM03 / -- 12 3A 100 x 130 x 140 60 x 115 x M5 1.6
BCM03 / -- 24 3A 126 x 130 x 140 60 x 115 x M5 2.8
BCM05 / -- 12 5A 100 x 130 x 140 60 x 115 x M5 2.0
BCM05 / -- 24 5A 126 x 130 x 140 60 x 115 x M5 3.2
BCM10 / -- 12 10A 154 x 130 x 140 60 x 115 x M5 3.2
BCM10 / -- 24 10A 154 x 130 x 170 60 x 115 x M5 4.7

Fuse Ratings :

Model Number

System
Voltage
Current
Limit
Transformer
(VA)
Supply Fuse
gTr or T rating
Output Fuse
gG or HRC rating
BCM03 / -- / 115 12 3A 50 2A 4A
BCM03 / -- / 230 12 3A 50 1A 4A
BCM05 / -- / 115 12 5A 90 2A 6A
BCM05 / -- / 230 12 5A 90 1A 6A
BCM10 / -- / 115 12 10A 150 3A 12A
BCM10 / -- / 230 12 10A 150 2A 12A
BCM05 / -- / 115 24 5A 150 3A 6A
BCM05 / -- / 230 24 5A 150 2A 6A
BCM10 / -- / 115 24 10A 300 6A 12A
BCM10 / -- / 230 24 10A 300 3A 12A
Notes:
1/ The supply fuse should be placed as close to the source as possible, with identity & rating clearly labelled
2/ We recommend that an output fuse is always fitted, with identity & rating clearly labelled
3/ Unless ordered otherwise, all Battery Chargers are factory set for 25 deg.C operation
4/ Always check the Battery Manufacturers latest operating instructions

Float Charging Lead-Acid cells
Typically 2.28V/cell (4mV/cell/deg.C rise above 25 deg.C ambient Temperature)
i.e. 24V charger at +40 deg.C : Float voltage =27.4 (.004 x 12 x (40 25)) =26.68V (set mid scale at 26.8)
i.e. 12V charger at -10 deg.C : Float voltage =13.7 (.004 x 6 x (-10 25)) =14.54V (set at maximum 14.2V)

Float Charging NiCad Cells
Typically 1.4V per cell at +10 to +35 deg.C Ambient Temperature
i.e. 12V System : 9 Cell NiCad = 9 x 1.4 =12.6V or
i.e. 10 Cell NiCad =10 x 1.4 =14.0V & 20 Cell NiCad =20 x 1.4 =28.0V
& 18 Cell NiCad =18 x 1.4 =25.2V










3A, 5A
L
H
D
X
Y
10A
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E. & O. E. The Proven Solution to Power Controls DA07BCM-2


SPECIFICATION

Part Number Information unless specified otherwise
Model Number System
Voltage
Battery
Type
Number
of Cells
Float
Voltage
Boost
Voltage
BCM -- / 12 12V Lead Acid 6 13.7 15.0
BCM -- / 24 24V Lead Acid 12 27.4 30.0
BCM -- / 12 12V L.A. (Gell) 6 13.7 ---
BCM -- / 24 24V L.A. (Gell) 12 27.4 ---
BCM -- / 09C 12V Nicad 9 12.6 13.5
BCM -- / 10C 12V Nicad 10 14.0 15.0
BCM -- / 18C 24V Nicad 18 25.2 27.0
BCM -- / 20C 24V Nicad 20 28.0 30.0
BCM03 series ... current limited to 3A output (no thermal trip on heatsink)
BCM05 series ... current limited to 5A output (24V versions have thermal trip on heatsink)
BCM10 series ... current limited to 10A output (24V versions have thermal trip on each heatsink)
The above Float and Boost levels are only a guide. Where possible, always refer the the
battery manufacturers latest information.
Note: Boost Mode should not be used with Sealed Lead-Acid Batteries

Supply : connect for 115V or 230V operation at 50 / 60Hz
115V nominal =100 130V
230V nominal =210 250V

Note: Other voltages available, please contact the Sales Desk for price and availability.

Output Trim : see above and page 2.

Leakage Current : from battery into charger approx. 2 mA

Ambient Temperature : Operating : -10
0
C to +55
0
C
Storage : -25
0
C to +70
0
C

Construction : Mild steel (1mm) chassis, zinc plated and gold passivated, carrying: - frame
transformer, black anodised aluminium heatsink, bridge rectifier, printed circuit
board and insulated cover plate. The charger MUST be mounted with adequate
ventilation and so that the natural airflow rises vertically, through the fins of the
heat-sink.


CAPRICORN CONTROLS LIMITED
INDUSTRIAL ELECTRONIC ENGINEERS - Est.1988
SPECIALIST CONTROLS FOR ENGINE APPLICATIONS
Thorpe Close, Banbury, Oxon., OX16 4SW, England.
Tel: +44 (0) 1295 272360 Fax: +44 (0) 1295 264766
E-mail: sales@capricorn-controls.com Web: www.capricorn-controls.com
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