Concorde BC-8000 Field Calibration Procedure

BC-8000 Field Calibration Procedure 55 AMP

CF1_FIELDCAL_BC8000 Revised 9/8/2012
Charger section can be used on a BC-9000 Version 1.00

INTRODUCTION:

The BC-8000 Battery Capacity Analyzer and Charger will perform capacity
testing of 12 and 24 volt lead-acid batteries and charge the batteries.
Capacity testing amperage setting resolution is 0.1A for tests in the range
of 0.5A to 15A and resolution of 1A for tests from 15A to 55A. The micro
processor controlled unit uses quartz crystal timing and will accurately
measure the capacity of a fully charged battery with a rating between 0.5
and 55 amp-hours. Amperage selection resolution is 0.1A for a load of

0.5 to 14.9 amps and 1A resolution for 15 to 55 amps. The BC-8000
saves the date, time, test parameters, and test results. It is equipped with
a USB interface. With the BC Report software the user can retrieve data
from the BC-8000 to create a printable report that includes test settings,
test results, time and date of test, and a battery discharge voltage graph.
The BC-8000 is line powered and easy to operate. The recommended
calibration interval is 1 year.

Battery charging amperage resolution is 0.01 amp from 0.050 to 2.50
amps and 0.1 amp from 2.6 to 25 amps. The battery charger voltage
range is 3.0V to 36.2V. When operating at 3.0V the maximum amperage
is 2 amps. The AC power input is universal 100V to 240V. The charger
can charge in 1 or 2 steps, maximum run time limit on each step, and
operate in constant voltage or constant current mode.

SCOPE:

This document provides instructions on how to perform the annual
calibration for the BC-8000. The calibration is broken down into the
following categories:

 Verify timing accuracy
 Calibrate Cutoff at 10.00 Volts
 Calibrate Cutoff at 20.00 Volts
 Calibrate 0.5A, 2.0A, 8.5A, 15A, and 55A calibration points
 Calibrate the Seiko clock chip (This is optional. The clock is calibrated

at the factory and requires adjustment if the time keeping accuracy is
unacceptable. The date and time are set to the current PC time by the
BC-8000 report utility every time test results are transferred from the
BC-8000 to the report utility)

 Calibrate the charger voltages and currents.

Page 1

TEST EQUPMENT REQUIRED:

1. CF1 test device (this is available from Concorde).

2. 12 Volt 55 Amp or greater fully charged battery used for 0.5A, 2.0A,

8.5A, 15A, and 55A calibration.

3. 24 Volt 1 Amp or greater fully charged battery or a 24 Volt 1 Amp
regulated power supply used to calibrate voltage and verify timing
accuracy.

4. Calibrated Fluke 87 DMM or equivalent. (for 450 Hz measurement)

5. Calibrated 5½ digit DMM Fluke 8840A or equivalent.

6. Calibrated Frequency counter with 1 second period measurement and
7 digit or more readout.

7. PC computer with BC Report utility software installed.

8. Anti-static wrist strap.

9. 24 Volt 25 Amp or greater battery to calibrate charger.

PROCEDURE:

INITIAL SETUP:

1. Photo copy the Calibration Work Sheet on page 8.

2. Attach anti static wrist strap to chrome fan guard and your wrist.

3. Remove the 8 lid screws. Remove the lid.

4. Connect CF1 test device ring terminals to the 24V power source. RED
lead to the positive terminal of the power source and the BLACK lead
to the negative terminal of the 24V power source.

5. Verify unit is OFF. Connect the BC-8000 to the VOLTAGE OUTPUT
CONNECTOR on the CF1 test device. It is the connector that has two
#16 AWG smaller wires.

6. Locate the display circuit board located on the inside of the front panel
and REMOVE the plastic jumper shunt across pins 1 & 3. See Figure
1 for the location of the jumper shunt.

VERIFY TIMING ACCURACY MEASUREMENT:

1. Set Fluke 87 DMM to measure frequency.

2. Use shielded test probe wires or twist non shielded probe wires
together to maximize measurement accuracy.

3. Connect DMM minus - to TP1 on the display circuit board. See figure
1 for the location of TP1 and TP2.

4. Connect DMM plus + to TP2 on the display circuit board.

5. Turn ON the BC-8000 power switch.

6. After the sign on message the unit will display “Code:“. The UP and
DOWN buttons will increase or decrease the digit's number value. The
NEXT button will advance to the next digit. Using the UP, DOWN, and
NEXT buttons, enter the code of “1234”. Press NEXT.

7. The unit will display “CAL VOLTS”. Press UP 2 times. The unit will
display “CHK 450Hz”. Press NEXT.

Page 2

8. Verify the Fluke 87 DMM frequency is 449.8 Hz to 450.2 Hz (450 Hz
±0.2 Hz).

9. Write the Frequency measurement reading into the calibration work
sheet. (450 Hz) If the frequency is not 449.8 Hz to 450.2 Hz, the unit
must be sent in for repair. The crystal oscillator should provide an
accurate time base for the entire life of the BC-8000. If the unit fails
this test, it is an indication that the crystal time base may have been
damaged.

10.Turn OFF the BC-8000 power.

ADJUST 10.00 and 20.00 VOLT CUTOFF:

1. Set DMM to a voltage range of 0-200 Volts.

2. Connect DMM minus - to VOLT minus - test point on the CF1 test
device.

3. Connect DMM plus + to VOLT plus + test point on the CF1 test device.

4. Turn ON the BC-8000 power switch.

5. After the sign on message the unit will display “Code:“. The UP and
DOWN buttons will increase or decrease the digit's number value. The
NEXT button will advance to the next digit. Using the UP, DOWN, and
NEXT buttons, enter the code of “1234”. Press NEXT.

6. On the CF1 test device, select the 10 Volt range and turn the voltage
adjustment knob to obtain a voltage of 10 volts ±0.010 volts on your
DMM.

7. The unit will display: “CAL VOLTS”. Press NEXT. The unit will display
“CAL Volts? 10”, press NEXT. The unit will display the voltage on the
right and the word “ADJUST”.

8. Use the UP and DOWN buttons to make the display read “10.00”.
Press NEXT to save the calibration data. Wait for the word “SAVED”
to appear then disappear.

9. Write the DMM Voltage reading into the calibration work sheet. (10 volt
cutoff)

10.On the CF1, select the 20 Volt range and turn the voltage adjustment
knob to obtain a voltage of 20 volts ±0.010 volts on your DMM.

11.The unit will display: “CAL VOLTS”. Press NEXT. Press UP. The unit
will display “CAL Volts? 20”, press NEXT. The unit will display the
voltage on the right and the word “ADJUST”.

12.Use the UP and DOWN buttons to make the display read “20.00”.
Press NEXT to save the calibration data. Wait for the word “SAVED”
to appear then disappear.

13.Write the DMM Voltage reading into the calibration work sheet. (20 volt
cutoff)

14.Turn OFF the BC-8000 power.

15.Unplug the BC-8000 from the CF1 VOLTAGE OUTPUT
CONNECTOR.

16.Disconnect the CF1 test device ring terminals from the 24 volt power

Page 3

source.

CALIBRATE AMP SETUP:

1. Connect the CF1 test device ring terminals to a fully charged 12 Volt
55 Amp battery. RED lead to the positive terminal of the battery and
the black lead to the negative terminal of the battery.

2. Set DMM to a range of 0-200 mV.

3. Connect 5 ½ digit DMM minus - to the AMP minus - test point on the
CF1 test device. Use caution as the DMM meter leads will be
connected to a high amperage battery.

4. Connect 5 ½ digit DMM plus + to the AMP plus + test point on the CF1
test device.

5. Verify the BC-8000 is OFF.

6. Connect the BC-8000 to the HIGH AMPERAGE CONNECTOR on the
CF1 test device. It is the connector wired with two #6 heavy duty
wires.

7. The scale factor is 1 A/mV. Example: when the 5 ½ digit DMM reads

10.000 mV, it is indicating 10.000 Amps. 0.500 mV is indicating 0.500
Amps.

CALIBRATE 0.5A, 2.0A, 8.5A, 15A, and 55A

1. Keep hands, arms, test leads, and clothing away from the FAN
BLADE. The FAN BLADE will rotate rapidly during the amp
calibration.

2. Turn ON the BC-8000 power switch.

3. After the sign on message the unit will display “Code:“. The UP and
DOWN buttons will increase or decrease the digit's number value. The
NEXT button will advance to the next digit. Using the UP, DOWN, and
NEXT buttons, enter the code of “1234”. Press NEXT.

4. The unit will display: “CAL VOLTS”. Press the UP button until the LCD
screen displays “CAL AMP”. Press NEXT, the unit will display “Volts?
12”. Press NEXT, the unit will display “Amps: 0.5”.

5. Press NEXT to start the process. The FAN will start.

6. Press the UP or DOWN button to obtain a DMM reading of 0.497 to

0.503 mV (0.500 mV ±0.003 mV). Allow a few seconds for the
reading to settle. Repeat this step to get as close as possible to 0.500
mV. 0.500 mV is 0.5 Amps actual current flow out of the battery.

7. Write the mV reading into the calibration work sheet. ( 0.5 Amp
calibration)

8. Press NEXT to save the calibration data into memory. Wait for the
word “SAVED” to appear then disappear.

9. Press the UP button to select “Amps: 2.0”.

10.Press NEXT to start the process. The FAN will start.

11.Press the UP or DOWN button to obtain a DMM reading of 1.996 to

2.004 mV (2.000 mV ±0.004 mV). Allow a few seconds for the

Page 4