Murphy Bceg 24 10 User Manual

Guardian Battery Charger Series  
Installation and Operations Manual  
00-02-0615  
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Section 75  
Table of Contents  
Safety Instructions.................................................................................................................. 1  
General Safety Instructions..........................................................................................1  
Personal Precautions...................................................................................................2  
Prior to Installation / Commissioning............................................................................2  
Charger Location and Connection................................................................................3  
General Product Information................................................................................................. 4  
Installation and Mounting Instructions................................................................................. 6  
Operating Instructions ........................................................................................................... 7  
Terminal Connection Information .................................................................................7  
Troubleshooting.................................................................................................................... 10  
Measuring Charging Voltage and Current..................................................................11  
Output Voltage ...........................................................................................................11  
Using Correct Size Battery Charger...........................................................................12  
Factors Contributing to Electrolyte Loss.....................................................................12  
Battery Life.................................................................................................................12  
Specifications........................................................................................................................ 14  
Power Supply.............................................................................................................14  
DC Charge Output .....................................................................................................14  
Charge Fail Output.....................................................................................................14  
General ......................................................................................................................14  
NOTES  
Safety Instructions  
This manual contains important safety and operating instructions for Guardian models BCEG-  
12-10, BCEG-24-10, and BCEG-24-20.  
General Safety Instructions  
For safe and correct use of the unit, follow the steps below. Should you have any problems  
and the unit does not function as expected, consult the “Troubleshooting Guidelines” section  
located at the end of these manual.  
Visually inspect unit for any signs of damage caused by transport or storage. Do  
not operate charger if it has been damaged or abused. Return to supplier in this  
event.  
Mount charger as outlined in “Charger Location and Connection”, paying  
attention to ambient temperature.  
Ensure that AC line voltage is disconnected. Make sure to only connect to the  
correct AC supply voltage.  
Ensure unit is properly grounded.  
Check batteries in accordance with manufacturer guidelines.  
Check charger is correct for battery type and voltage.  
Connect unit to batteries, observing correct polarity and ensuring a secure and  
tight connection.  
Switch on unit at electrical supply.  
Do not expose charger to rain or snow.  
Use of an attachment not recommended or sold by the battery charger  
manufacturer may result in risk of fire, electric shock, or injury to persons.  
Do not disassemble charger. Return to supplier when service or repair is  
required. Incorrect reassembly may result in a risk of electric shock or fire.  
WARNING – RISK OF EXPLOSIVE GASES  
WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS.  
BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL  
BATTERY OPERATION.  
To reduce the risk of battery explosion, follow these instructions  
and those published by battery manufacturers and manufacturer of  
any equipment you intend to use in vicinity of the battery. Review  
cautionary markings on these products and on any attached  
equipment.  
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Personal Precautions  
Someone should be within range of your voice or close enough to come to your  
aid when you work near a lead-acid battery.  
Have plenty of fresh water and soap nearby in case battery acid contacts skin,  
clothing or eyes.  
Wear complete eye protection and clothing protection. Avoid touching eyes while  
working near batteries.  
If battery acid contacts skin or clothing, wash immediately with soap and water.  
If acid enters eyes, immediately flood eyes with running cold water for at least 10  
minutes and get medical attention immediately.  
NEVER smoke or allow a spark or flame in vicinity of battery.  
Be extra cautious to reduce risk of dropping a metal tool onto battery. It may  
spark or short-circuit the battery or other electrical part that may cause explosion.  
Remove personal metal items such as rings, bracelets, necklaces, and watches  
when working with a lead-acid battery. A lead-acid battery can produce a short-  
circuit current high enough to weld a ring or the like to metal, causing a severe  
burn.  
Use charger only for charging batteries as marked on the charger. Do not use  
battery charger for charging dry-cell batteries that are commonly used with home  
appliances. These batteries may burst and cause injury to persons and damage  
to property.  
NEVER CHARGE A FROZEN BATTERY.  
Prior to Installation / Commissioning  
Clean battery terminals. Be sure to keep corrosion from coming in contact with  
eyes.  
Add distilled water in each cell until battery acid reaches level specified by  
battery manufacturer. This helps purge excessive gas from cells. Do not overfill.  
For a battery without cell caps, carefully follow manufacturer’s recharging  
instructions.  
Study all battery manufacturer’s specific precautions such as removing or not  
removing cell caps while charging and recommended rates of charge.  
Determine voltage of battery by referring to engine manual and ensure matches  
charger’s output voltage.  
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Charger Location and Connection  
The charger must be mounted inside. This device is not weather-proof. Free air  
flow is required from below and out the top of the unit.  
Do not operate charger in a closed-in area or restrict ventilation in any way.  
Never place charger directly above battery being charged as gases from battery  
will corrode and damage charger.  
Never allow battery acid to drip on charger when reading specific gravity or filling  
battery.  
The battery charger should be connected to a grounded, metal, permanent wiring  
system.  
Connections to battery charger should comply with all local codes and  
ordinances.  
AC wiring should be run separately from the output of the charger and the alarm  
wiring. Use two runs of 12 gauge or heavier wire from the charger to the battery.  
Use 12 gauge or larger wire for input and ground connections.  
NOTE: Follow all national and local wiring codes and best practices.  
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General Product Information  
Please read the following information before installing. A visual inspection of this product for  
damage during shipping is recommended before installation. It is your responsibility to ensure  
that qualified mechanical and electrical technicians install this product.  
The Guardian charger provides automatic, current limited and voltage controlled charging of  
vented lead acid batteries. It may be used in a wide range of industrial charging applications,  
including batteries for standby engines, pumps and generators.  
This charger is designed for connection to only one battery. Do not use more than one charger  
per battery, or more than one battery per charger.  
The charger is supplied in an enclosed stainless steel panel suitable for wall mounting.  
NOTE: In event of no AC supply to charger, the voltmeter will display the DC  
voltage of any connected DC equipment.  
Each unit consists of a transformer, rectifier and thyristor control circuit. The control circuit  
ensures that the charger maintains a battery voltage at the pre-calibrated float level, while  
supplying any additional load current up to the specified maximum.  
Auto Boost (Equalizing) Operation  
Auto boost operation provides an increased output voltage when batteries are below a preset  
point. Once the batteries have reached the boost voltage the charger reverts to its float  
voltage. This operation equalizes the batteries, maximizing battery life and capacity.  
Boost Initiate Operation  
The boost initiate switch forces the charger to enter an auto boost cycle even if battery voltage  
is above the preset point. Once this operation is completed the charger returns to it’s float  
voltage.  
Temperature Compensation  
The remote temperature compensation provides control of the output voltage based upon  
temperature. As temperature increases the charging voltage is decreased at a negative  
coefficient of 3mV/°F/Cell.  
Charge Fail and Alarms  
A self diagnosis ‘charge fail’ circuit and relay output is provided along with under and over  
voltage warnings. The dry contact relay outputs de-energize in the event of a charging fault or  
high/low battery state.  
Electrical connection of the AC supply and DC output and alarms are via spring-clamp  
terminals.  
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Current Limiting  
The Guardian battery charger is current limited and will only output the rated current of the  
charger.  
Guardian Current Ratings  
Model  
Rating  
10A  
10A  
BCEG-12-10  
BCEG-24-10  
BCEG-24-20  
20A  
Battery Charged Condition  
When charged, the battery will only accept a charge to replace the losses within the battery  
(approximately 1mA per AH of battery). If there is a standing load (the panel controller, etc.)  
the charger will output the standing load plus the losses to the battery. If a standing load of 1A  
is present with 50AH Vented Lead Acid batteries then the charger will supply 1.05 amps.  
A charged battery with open circuit terminals (no load connected) will always be higher than  
nominal battery voltage (12.6 on a 12V lead acid battery).  
Dimensions  
Model  
BCEG-12-10  
W
10.83”  
D
4.92”  
H
11”  
Weight  
22 lbs.  
(275mm) (125mm) (280mm)  
10.9” 4.7” 11”  
(278mm) (120mm) (280mm)  
13.19” 7.71” 12.20”  
(10.0Kg)  
22 lbs.  
(10.0Kg)  
38.5 lbs.  
(17.5Kg)  
BCEG-24-10  
BCEG-24-20  
(335mm) (145mm) (310mm)  
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Installation and Mounting Instructions  
Mounting hole dimensions:  
Width (between holes) – 6.77” (172mm)  
Height (between holes) – 10.04” (255mm)  
Mounting holes 0= 0.2” (6mm)  
The charger must be mounted as shown in the figure above.  
By unscrewing the mounting screws the faces can be opened on their hinges to  
allow access to the internal connections.  
Cable entry is via ½” conduit knock-outs on either side of the unit. These must  
be carefully removed from the enclosure sides.  
A suitable cable-gland (0.8” DIA/20mm) should be used to prevent damage to  
cables and stop unwanted entry into inner part of charger. See “Terminal  
Connection Information” section of the chapter on Operating Instructions for  
details of terminal connections.  
The lower face should be firmly screwed to the charger before use.  
Four screws should be used to mount charger to panel. Ensure screws are  
tightened firmly as not to become loose during normal operation.  
Adequate consideration should be given to ventilation for proper heat dissipation.  
CAUTION: When handling chargers, do not do anything that will cause any  
stress on the internal devices or wiring. Nothing should be mounted or hung  
inside the enclosure. Only connect the appropriate wires inside the enclosure.  
Unit should be handled by steel enclosure.  
Guard against debris from mounting, wiring, or connection to conduit entering the  
enclosure. Do not allow metal cuttings or filings to enter the enclosure. Make  
sure no moisture or oil can drip inside the enclosure.  
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Operating Instructions  
Before operating the battery charger, ensure that the charger is assembled and installed as  
per the installation instructions.  
WARNING: DANGER OF INJURY OR DEATH  
Before connection, disconnection or handling of Guardian battery  
charger, be sure AC power supplies are off.  
NOTE: Connection to or disconnection from live wiring can also cause damage  
to internal components.  
Terminal Connection Information  
Output:  
Input:  
To battery  
CAUTION: Observe correct polarity  
AC supply  
CAUTION: Observe correct voltage as stated on unit.  
Alarm Indication  
Boost:  
Over voltage, under voltage and charge fail  
Boost initiate – Linking these two connectors will force the charger into a  
single boost cycle of operation. Once the charger has completed a single  
boost cycle the charger returns to its normal mode of operation.  
Stripped wire is introduced just before the clamping unit.  
The clamp spring is pressed down and wire is introduced into the  
clamping unit immediately.  
The clamp spring is released – the conductor is automatically clamped.  
NOTE: All connections, including AC input and DC output are made via spring-  
clamp connections as outlined above.  
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The BCEG-12-10 and BCEG-24-10 models are fitted with a self-resetting polyfuse on the DC  
output. If reverse polarity or short circuit faults occur, turn off AC power and disconnect the  
outputs. This will allow the polyfuse to reset. The charger can then be re-connected and  
switched back on. No replacement of output fuse should be necessary. If fuse fails to reset,  
the charger should be returned to supplier. BCEG-24-20 models are fitted with an automotive  
type blade fuse. Ensure correct rating when replacing fuses.  
Automatic Battery Charger  
The Guardian is an automatic battery charger. If battery voltage falls below a preset voltage  
(12.2V on a 12V lead-acid battery) the charger will automatically enter an increased charging  
voltage state (boost). Once the batteries have reached a charged state, the charger will switch  
to it’s normal “float” voltage. This prevents over-charge, which in turn prevents the battery  
from over-gassing and subsequently maximizes battery life.  
Connection to Power Supply  
Ensure supply is off before connection is made to charging unit. Ensure unit is properly  
grounded to the charger’s metal chassis.  
CAUTION: Ensure correct AC voltage is supplied to unit. Applying 240VAC on  
a 120VAC unit will destroy it and could cause serious personal injury.  
Connection to Batteries  
Ensure power supply is off before connecting charger to batteries. Ensure battery type and  
voltage are correct before connecting to batteries.  
WARNING: Charging either different voltage or type of batteries from stated  
type may result in damage to both the charging unit and/or batteries and could  
result in serious personal injury.  
Disconnection of Batteries  
Ensure power supply is off before disconnecting charger from batteries.  
WARNING: Disconnecting the batteries while power supply is connected to the  
charger could result in a spark at battery terminals, which could ignite the  
hydrogen given off from the batteries.  
Boost Initiate Connection  
The charger will be in it’s normal mode of operation while the boost link is broken. Upon  
connecting the two boost initiate terminals the charger will perform a single auto-boost cycle.  
While the charger outputs a higher voltage, once the battery voltage has reached this point,  
the charger returns to it’s normal float mode of operation.  
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Over Voltage, Under Voltage, and Charge Fail Connection  
In a de-energized state the COM – N/C contact is alarmed. The relay energizes on power up  
and changes state to COM – N/O. These contacts are volt-free contacts rated at 1A @  
30VDC.  
Fuses  
All Guardian models are fitted with fuses at the required ratings. Before replacing any fuses,  
ensure charger is off from power supply.  
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Troubleshooting  
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Measuring Charging Voltage and Current  
To check the charger is working, follow these steps then consult the expected conditions listed  
below.  
1. VOLTAGE – Place voltmeter across battery terminals (“V” in diagram).  
2. CURRENT – Turn off AC power supply before breaking into the line to measure DC  
Amps. Break the positive line to the battery and place an ammeter between positive  
from charger and positive of battery (“A” in diagram).  
Current Flow from Charger to Battery  
If voltage at terminals is less than nominal battery voltage then the maximum rated charger  
current should be present.  
NOTE: Once battery is fully charged, output current should be between 0.1%  
and 0.5% of batteries AH capacity plus any standing loads.  
Voltage Rise at Battery Terminals  
A gradual rise of voltage should be seen showing as float voltage is reached – batteries should  
not be boost charged continuously.  
NOTE: If the battery voltage increases rapidly during charge and no minimum  
current is measured then the battery may have become sulphated and will not  
hold charge and may be unrecoverable.  
Output Voltage  
12/v  
13.6V  
14.1  
24/v  
24.2  
28.2V  
LEAD  
ACID  
Float:  
Boost:  
Typical output with no battery or load  
connected. For all Guardian models the  
precalibrated float voltage should be present.  
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Using Correct Size Battery Charger  
The battery charger will need to provide both the standing load and minimum charge current.  
If a charging current of 2 amps is required, and the standing load is 1 amp, then the charger  
needs to be able to output a total of 3 amps.  
Refer to genset manual for sizing of battery chargers to generator set. If installing your own  
chargers, lead acid battery manufacturers recommend the following:  
Minimum charge current should be approximately 5% battery AH capacity.  
Maximum charge current to be equal to 25% battery AH capacity  
NOTE: When batteries are normally charged by a charging alternator, a float  
battery charger rated at lower than the minimum charge current is sufficient to  
keep batteries in fully charged state.  
Factors Contributing to Electrolyte Loss  
Physical damage to cells can cause electrolyte to leak or evaporate.  
High charging voltages will evaporate electrolyte.  
Check charging voltage against battery type and voltage.  
WARNING: If the batteries are being used at above 20° Celsius, the chargers  
output voltage should be temperature compensated at -3mV/°F/Cell.  
Battery Life  
Two possible methods can be used for determining battery life:  
Using Hydrometer  
Using a digital DC voltmeter  
Follow these steps to check battery life.  
1. Fully charge the batteries.  
2. Disconnect batteries and leads and leave for 24 hours.  
3. Measure either specific gravity (hydrometer) or terminal voltage (voltmeter) and  
compare with the table on the following page.  
4. If time is limited due to on-site testing, remove surface charge by either applying a 20  
amp load for 3 minutes or crank engine for 10 seconds, then disconnect batteries and  
leads and leave for minimum of 10 minutes.  
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NOTE: On this method, providing batteries have been sized correctly for engine  
and charged correctly, an open terminal voltage of 12.5V or greater should be  
present.  
The following table is for Lead Acid batteries with removable vent caps that can have  
electrolyte or distilled water added to them for routine maintenance.  
Voltage (DC) on  
a 12V battery  
12.8  
% Charge  
Specific Gravity  
100  
75  
50  
1.265  
1.225  
1.19  
12.5  
12.4  
25  
1.155  
1.12  
12.0  
11.5  
Discharged  
NOTE: If the voltage across the terminals shows around 10.5V, this may  
indicate a shorted cell is present.  
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Specifications  
Power Supply  
Nominal operating voltages – 120V Units  
Permissible voltage variation - ± 6% of nominal  
Nominal operating frequency – 50/60Hz  
DC Charge Output  
Maximum current ADC – 20  
Nominal voltage VDC – 12 or 24  
Float/boost voltages  
These are factory preset for specified batteries, typical settings are as follows:  
Vented lead acid – Float voltage – 12V / 13.6V and 24V / 27.2V  
Vented lead acid – Boost voltage – 12V / 14.1V and 24V / 28.2V  
Charge Fail Output  
Relay type – volt free SPDT contacts relay de-energized on fault.  
Contact rating – 1A @ 30VDC (resistive load)  
General  
Transformer – Single phase 50-60 Hz Class 155 (F)  
Operating temperature - +14°F to +131°F (-10°C to +55°C)  
Wall mounted enclosure models  
BCEG-12-10, BCEG-24-10 – dimensions 10.9”/278mm(W) x 4.7”/120mm(L) x  
11”/280mm(H); weight 22 pounds / 10.0Kg  
BCEG-24-20 – dimensions 11.8”/300mm(W) x 11.8”/300mm(L) x 8.3”/210mm(H), weight  
38.5 pounds / 17.5Kg  
EMC emission/immunity – EN58801-2 / EN50082-2  
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MURPHY and the Murphy logo, are registered and/or common law trademarks of Murphy Industries, Inc. This  
document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with all  
rights reserved. (c) 2007 Murphy Industries, Inc. Other third party product or trade names referenced herein are  
the property of their respective owners and are used for identification purposes only.  
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