Smart Battery Charger BC-210 and Battery Pack BP-15 User Instructions IMPORTANT: Keep these User Instructions for reference This product is part of a respiratory protection system that helps protect against certain airborne contaminants. Misuse may result in sickness or death. For proper use, see supervisor, or User Instructions, or call 3M in U.S.A., 1-800-243-4630. In Canada, call Technical Service at 1-800-267-4414 IMPORTANT SAFETY INSTRUCTIONS When using electrical products, basic precautions should always be practiced including the following: 1. READ AND FOLLOW ALL SAFETY INSTRUCTIONS. 2. Read and follow all instructions that are on the product or provided with the product. 3. For a cord-connected or direct plug-in power unit, do not use an extension cord. 4. For a cord-connected or direct plug-in power unit, do not install or use within 10 feet of a swimming pool. 5. For a cord-connected or direct plug-in unit, do not use in a bathroom. SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions for power units. 1
Intended Use The 3M Smart Battery Charger BC-210 is intended to charge the 3M Battery Pack BP-15 for use with the 3M Breathe Easy Belt-Mounted Turbo or 3M GVP PAPR Unit. List of Warnings and Cautions within these User Instructions This product is part of a respiratory protection system that helps protect against certain airborne contaminants. Misuse may result in sickness or death. For proper use, see supervisor, or User Instructions, or call 3M in U.S.A., 1-800-243-4630. In Canada, call Technical Service at 1-800-267-4414 Not for use in environments requiring intrinsic safety. If the red light on the 3M Battery Pack BP-15 comes on, immediately leave the work area and recharge the battery. Charge battery only in clean, well-ventilated, non-hazardous locations. Charge 3M Battery Pack BP-15 only with 3M Smart Battery Charger BC-210. Battery should be connected to the 3M Smart Battery Charger BC-210 when not in use. For infrequently used batteries, or batteries for long-term storage (longer than 3 months), the recommended method of storage is to leave the battery connected to the charger. If stored off the charger, fully charge battery prior to storing and recharge once every three months if not used sooner. Battery should not be left in a discharged state. Recharge battery immediately after use. Do not allow water to enter battery case. Sealed unit-do not disassemble. Must be recycled or disposed of properly. Do not incinerate. Do not open or permit water to enter this case. No field serviceable parts inside case. Charge battery only in clean, well-ventilated, non-hazardous locations. For indoor use only. Replace defective cords immediately. There are no field-serviceable parts inside the smart battery charger. Do not attempt to open the charger case or expose the charger to moisture. Doing so may result in serious bodily injury or death due to electrical shock. Failure to follow these user instructions may cause electric shock, fire or explosion and result in injury or death. Do not couple more than 10 charger units at one time. Do not clean with solvents. Cleaning with solvents may degrade some components and reduce effectiveness. Inspect all components before each use to ensure proper operating conditions. Failure to do so may result in sickness or death. Failure to conduct an inspection and complete all necessary repairs before use may adversely affect performance and result in sickness or death. Failure to comply with the above instructions may cause electric shock, fire or explosion or could adversely affect respirator performance and result in personal injury, sickness or death. 2
Important Before use, the wearer must read and understand these User Instructions, the User Instructions for the intended Powered Air Purifying Respirator (PAPR) and the User Instructions for the intended headgear. Keep these User Instructions for reference. Definitions of Product Icons - Attention, consult ACCOMPANYING DOCUMENTS - Dangerous voltage Attention, consult ACCOMPANYING DOCUMENTS. -On symbol Turn system ON - Standby symbol Place system in Standby Charge Status of Battery - Do not throw in trash. Dispose of product as directed by local, regional and national waste regulations. Specifications Weight BC-210 Smart Battery Charger (BC-100 and BC-210A CAM Module: Approximately 1.7 lb (771 g)) Battery pack (NiMH): Approximately 1.8 lb (830 g) Battery Charging Temperature 50 F to 90 F (10C to 32 C) Storage Temperatures Battery Pack The recommended dry storage conditions (less than 85% relative humidity) for the battery is -4 F to 115 F (-20 C to 45 C). Storage of the battery outside this range will shorten the usable life of the battery. Avoid prolonged storage at temperatures above 120 F (49 C). 3
Not for use in environments requiring intrinsic safety. If the red light on the 3M Battery Pack BP-15 comes on, immediately leave the work area and recharge the battery. Charge battery only in clean, well-ventilated, non-hazardous locations. Charge 3M Battery Pack BP-15 only with 3M Smart Battery Charger BC-210. Battery should be connected to the BC-210 charger when not in use. For infrequently used batteries, or batteries for long-term storage (longer than 3 months), the recommended method of storage is to leave the battery connected to the charger. If stored off the charger, fully charge battery prior to storing and recharge once every 3 months if not used sooner. Battery should not be left in a discharged state. Recharge battery immediately after use. Do not allow water to enter battery case. Sealed unit-do not disassemble. Must be recycled or disposed of properly. Do not incinerate. Failure to comply with the above instructions may cause fire or explosion or could adversely affect respirator performance and result in personal injury, sickness or death. Use of the Battery Pack: The 3M Battery Pack BP-15 should be placed on the 3M Smart Battery Charger BC-210, and fully charged immediately upon receipt. It may take up to 3 charge/discharge cycles for new batteries to reach full capacity. The battery can be discharged by connecting to the motor-blower and running until air flow starts to diminish. Do not short circuit the battery to discharge it. The 3M Battery Pack BP-15 has a red indicator light, located on the top of the battery by the switch. The red light indicates that the battery has reached a point that it must be recharged. The battery has a low-voltage detection circuit that will engage shortly after the red light comes on. When it engages, the battery will shut down and the turbo will stop running. Therefore, when the red light comes on, immediately leave the work area and recharge the battery. Note: If the battery has been run down enough to engage the low voltage detection circuit, the red light will no longer function until the battery has been recharged. Charge the 3M Battery Pack BP-15 only with the 3M Smart Battery Charger BC-210. Operational time of battery will be reduced as the operating temperature goes down. To properly dispose of the 3M Battery Pack BP-15, follow local solid waste disposal regulations or call the RBRC Battery Recycling Information Help line at 1-800-8-BATTERY (1-800-822-8837). Charging the Battery Pack 4
Fig. 1 3M Smart Battery Charger BC-210 Do not open or permit water to enter this case. No field serviceable parts inside case. Charge battery only in clean, well-ventilated, non-hazardous locations. For indoor use only. Replace defective cords immediately. Failure to comply with the above instructions may cause electric shock, fire or explosion and result in sickness or death. Before use of a new 3M Smart Battery Charger BC-210, the plastic protective cover must be removed from between the power base and the adapter module. Verify that the smart battery charger is unplugged from any wall outlet. Remove the plastic protective cover by pulling the adapter module straight up out of the power base and removing the plastic protective cover. Replace the adapter module in the power base by pushing it straight down into the power base, aligning the guide slots. The adapter module should not be routinely removed. Repeated removal may damage the electrical contacts in the power base. Plug the receptacle end of the charger power cord into the side of the 3M Smart Battery Charger BC- 210 and the prong end of the power cord into an appropriate electrical outlet (Fig. 1). The charger will automatically detect and self-adjust to input voltages of 100 to 240 volts and frequencies of 50 to 60 Hz. Check the LED on the power base (on the left) to determine the status of the charger. See the Troubleshooting section. Power Base Status Power is ok, ready to start charging Excess current, not ready to charge Too hot LED Status Steady green Steady yellow Steady red 5
Insert the charging lead into the charging socket on the top of the 3M Battery Pack BP-15. The LED indicator on the adapter module (on the right) shows the status of the charging process. Charger Status Power ON Standby; Waiting to charge Rapid charging Top-off charge Charge complete; Ready mode Battery fault LED Status Momentary (single) flash green Steady yellow Rapid flashing green Slow flashing green Steady green Steady red* * NOTE: If a charger indicates a battery fault error, unplug and wait 5 minutes before plugging the charger into another battery or the same battery. If error light remains on call 3M OH&ES Technical Service at 1-800-243-4630 for assistance. There are no field-serviceable parts inside the smart battery charger. Do not attempt to open the charger case or expose the charger to moisture. Doing so may result in serious bodily injury or death due to electrical shock. The 3M Smart Battery Charger BC-210 can be connected (up to ten chargers) to produce a multistation charger. To connect, first make sure that the charger power cord is unplugged from the electrical outlet. Remove the socket cover from the BC-210 and save for later use. From the bottom of the BC-210 in the semi-circle area remove the screw. Slide male connection on the left of the charger into the female connection on the right side of the other charger. Insert and tighten the screw in the hole from which it was removed. This should now make an assembly of the BC-210s. Add additional3m Smart Battery Charger BC-210 in the same manner up to a maximum of ten (10) chargers total. When ten (10) chargers are assembled the maximum rated current draw is 6.0 amps. The maximum current rating for a single charger is 0.60 amps. The 3M Smart Battery Charger BC-210 adapter module unit should not be regularly removed from the power base. Frequent removal of the adapter module may damage electrical contacts in the power base and cause the charger to malfunction. The 3M Smart Battery Charger BC-210 should be used in a clean atmosphere free of particulates or other contamination. Particles deposited in between the adapter module and the power base may interfere with proper function of the charger. If the adapter module is removed to clean the power base unit, only compressed air dusters should be used. Aggressive cleaning of the power base or adapter module may damage electrical contacts and cause the charger to malfunction. Failure to follow these user instructions may cause electric shock, fire or explosion and result in injury or death. Do not couple more than 10 charger units at one time. 3M Battery Pack BP-15 provides up to 400 charge/discharge cycles. However, the life of 3M batteries will be significantly reduced when they are exposed to high heat over an extended period of 6
time. At 5 charge/discharge cycles per week (1 per shift), this equals an estimated life expectancy of approximately two (2) years. Contact 3M Technical Service for additional guidance. To maximize battery life, these guidelines should be followed: 3M Battery Pack BP-15 may be charged any time during the discharge cycle. Battery memory (also known as voltage depression) is not a significant factor in PAPR applications. The 3M Battery Pack BP-15 may remain connected to the BC-210 charger for an extended period of time. The 3M Smart Battery Charger BC-210 will trickle charge the BP-15 battery to overcome normal charge loss. This is the recommended storage method for maximum battery performance. Do not allow water to enter the battery housing, as this will damage the battery assembly. Always charge 3M Battery Pack BP-15 at a temperature between 50 F (10ºC) and 90 F (32ºC). Beyond this range, the battery may not accept a full charge. If a battery feels hot, let it cool for 1/2 hour before charging. Do not stack batteries together or on top of charger during charging. Do not charge in an enclosed cabinet. Heat from chargers and batteries must be allowed to dissipate. If you try to charge a battery that is too hot, the charge adapter will indicate yellow and charging will not begin until the battery has cooled. 3M Battery Pack BP-15 stored at room temperature loses approximately 2% of its charge per day after charging. The rate of self-discharge will increase as storage temperature increases. For infrequently used batteries or batteries in storage, 3M recommends they be fully charged immediately upon receipt and then stored connected to the charger. Batteries stored off the charger should be fully charged, initially, then fully charged once every three months of non-use to maintain charge. Batteries should not be subjected to prolonged storage without regular charge/discharge cycling. Prolonged storage with out regular charge/discharge cycling may damage the battery cells. You can check battery capacity by running the PAPR motor/blower unit with the airflow indicator installed and recording the time until the airflow falls below six cfm. See the User Performance Check section in the appropriate 3M PAPR assembly User Instructions for details. Two or three charge/run-down cycles may restore battery capacity for batteries that have been in prolonged storage. Cleaning, Inspection, and Storage Follow the hygiene practices established by your employer for the specific contaminants to which you have been exposed. Do not clean with solvents. Cleaning with solvents may degrade some components and reduce effectiveness. Inspect all components before each use to ensure proper operating conditions. Failure to do so may result in sickness or death. Cleaning Solvents should not be used to clean the battery pack or smart battery charger. Liquid solvents may chemically weaken the plastic. Use the following suggested procedures for cleaning: 1. Wipe the battery pack and smart battery charger with a mild cleaning solution. 2. Do not immerse the battery pack or smart battery charger into any type of liquid. 7
3. If the adapter module is removed to clean the power base unit, only compressed air dusters should be used. Aggressive cleaning of the power base or adapter module may damage electrical contacts and cause the charger to malfunction Inspection Failure to conduct an inspection and complete all necessary repairs before use may adversely affect performance and result in sickness or death. 1. Inspect the power base and adapter module for cracks or other damage. 2. Inspect the power cord and charging lead for frayed wires or other damage. Replace if necessary. 3. Inspect the 3 pins on the charging lead. The slot in each pin should be of uniform width from top to bottom. If the pin slots show signs of narrowing, unplug the charger from its power source. A small, thin tool such as a feeler gauge can be used to gently reopen the slots to a uniform width. Storage Store your batteries and chargers at room temperature in a dry area that is protected from exposure to hazardous contaminants. Fuse Replacement CAUTION FOR CONTINUED PROTECTION AGAINST RISK OF FIRE, REPLACE WITH THE SAME TYPE AND RATING OF FUSE, 250VAC, 8A, DISCONNECT POWER BEFORE REPLACING FUSE. To replace the fuse in the smart battery charger, disconnect any batteries attached to the charger and the power cord from the power base. Locate the fuse cover on the power base where the power cord is attached and pry the fuse cover out with a blunt object. Remove the fuse from the plastic clip and replace with the spare located in the cover. Snap the fuse cover back in place and reconnect the power cord. For additional replacement fuses, contact the 3M Service Center. NOTE: Because 3M Smart Battery Charger BC-210 may produce radio frequency energy, 3M is providing the following information pursuant to FCC regulations. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. 8
Troubleshooting Use the table below to help identify possible causes and corrective actions for problems you may experience. Problem Probable Cause Corrective Action Battery does not work after charging Low voltage detection circuit has not reset Recharge for short period of time BC-210 does not work, charge adapter indicator is steady yellow Battery is too hot or too cold for charging Incorrect battery is connected to the charger Allow battery and charger temperatures to moderate to between 50 F (10ºC) and 90 F (32ºC). Select the correct charger for the battery BC-210 does not work, power base indicator is steady yellow BC-210 does not work, no lights illuminated on power base or charge adapter BC-210 does not work, the charge adapter indicator is red or is not illuminated Too many chargers are chained together. The maximum number allowed is ten (10). Fuse on power base has blown Incorrect battery is connected to the charger. The BC-210 is only to be used with the BP-15 battery. Remove excess chargers Determine cause of the blown fuse and replace with like fuse Select the correct charger for the battery Intermittent operation of the PAPR Frequent incomplete charging or battery pack does not reach full charge (solid green light does not come on) Use of 520-01-61, 520-01-61SGL, 520-01-61FIV, 520-03-72, 520-03-73 or 521-01-43 battery charger does not work, but is not defective. Slots in charging lead pins have narrowed. Slots in pins on charging lead are narrowed Slots in pins on charging lead are narrowed Incorrect battery is connected to the charger. These chargers are to be used only with the 520-01-15, 520-01-17 and BP-17IS batteries. Use feeler gauge or similar flat, thin tool to gently respread pin slots. Gently reopen the slots with a feeler gauge or similar tool Gently reopen the slots with a feeler gauge or similar tool Select the correct charger for the battery For More Information In United States, contact: Website: www.3m.com/occsafety Technical Assistance: 1-800-243-4630 For other 3M products: 1-800-3M-HELPS or 1-651-737-6501 9
3M Occupational Health and Environmental Safety Division 3M Center, Building 0235-2W-70 St. Paul, MN 55144-1000 3M 2008 98-0060-0001-6/4 10