Analytic Systems BCA1000V User manual

INSTALLATION &
OPERATION MANUAL
BCA1000V
AC Source
Battery Charger
An ISO9001 and AS9100 Registered Company Battery Chargers •Inverters •Power Supplies •Voltage Converters

Copyright (2005-2016) Analytic Systems Ware (1993) Ltd.
Revised - May 18, 2016

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IMPORTANT & SAFETY INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS — This manual contains important safety and operating
instructions for battery charger
2. Do not expose battery charger to rain or snow.
3. Use of an attachment not recommended or sold by the battery charger manufacturer may
result in a risk of re, electric shock, or injury to persons.
4. Do not disassemble battery charger; take it to a qualied serviceman when service or
repair is required. Incorrect reassembly may result in a risk of electric shock or re.
5. To reduce risk of electric shock, unplug battery charger from outlet before attempting any
maintenance or cleaning. Turning off controls will not reduce this risk.
6. Never place battery charger directly above battery; gases from battery will corrode and
damage battery charger.
7. Never allow battery acid to drip on battery charger when reading gravity or lling battery.
8. O/P CONNECTION PRECAUTIONS
Connect and disconnect DC output connections only after setting the I/P power switch to
the off position.
ALL BATTERY CHARGERS
1. WARNING — RISK OF EXPLOSIVE GASES.
i. WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES
GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS
REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE SERVICING
EQUIPMENT IN THE VICINITY OF THE BATTERY, YOU READ THIS MANUAL AND
FOLLOW THE INSTRUCTIONS EXACTLY.
ii. To reduce risk of battery explosion, follow these instructions and those published
by battery manufacturer and manufacturer of any equipment you intend to use in
vicinity of battery. Review cautionary marking on these products and on engine.
2. PERSONAL PRECAUTIONS
i. Someone should be within range of your voice or close enough to come to your aid
when you work near a lead-acid battery.
ii. Have plenty of fresh water and soap nearby in case battery acid contacts skin,
clothing, or eyes.
iii. Wear complete eye protection and clothing protection. Avoid touching eyes while
working near battery.
iv. If battery acid contacts skin or clothing, wash immediately with soap and water.
If acid enters eye, immediately ood eye with running cold water for at least 10
minutes and get medical attention immediately.

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v. NEVER smoke or allow a spark or ame in vicinity of battery or engine.
vi. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark
or short-circuit battery or other electrical part that may cause explosion.
vii. 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.
viii. NEVER charge a frozen battery.
ix. If necessary to remove battery from service, always remove grounded terminal from
battery rst. Make sure all accessories in the vessels are off, so as not to cause an
arc.
x. Be sure area around battery is well ventilated.
xi. Clean battery terminals. Be careful to keep corrosion from coming in contact with
eyes.
xii. Study all battery manufacturer’s specic precautions such as removing or not
removing cell caps while charging and recommended rates of charge.
xiii. Add distilled water in each cell until battery acid reaches level specied by battery
manufacturer. This helps purge excessive gas from cells. Do not overll. For a
battery without cell caps, carefully follow manufacturer’s recharging instructions.
GROUNDING AND AC POWER CORD CONNECTION INSTRUCTIONS
The plug must be plugged into an outlet that is properly installed and grounded in accordance
with al local codes and ordinances.
DANGER Never alter AC cord or plug provided — if it will not t outlet, have proper cord
installed by a qualied electrician. Improper connection can result in a risk of an electric
shock.
Analytic Systems does not recommend the use of the BCA1000 Series Battery Chargers in life
support applications where failure or malfunction of this product can be reasonably expected
to cause failure of the life support device or to signicantly affect its safety or effectiveness.
Analytic Systems does not recommend the use of any of its products in direct patient care.
Examples of devices considered to be life support devices are neonatal oxygen analyzers,
nerve stimulators (whether used for anesthesia, pain relief, or other purposes), autotransfusion
devices, blood pumps, debrillators, arrhythmia detectors and alarms, pacemakers,
hemodialysis systems, peritoneal dialysis systems, neonatal ventilator incubators, ventilators
for both adults and infants, anesthesia ventilators, and infusion pumps as well as any other
devices designated as “critical” by the U.S. FDA.

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Introduction
All new Current Mode switching design offers increased power and reliability in a compact
package. Extra input and output ltering reduce EMI to extremely low levels. Reliability
features include an input fuse, thermal shutdown, current limiting, reverse battery hookup
protection and output short circuit shutdown with automatic recovery. The output voltage
is easily adjusted 1.0 volts above or below the standard output voltage. The model
BCA1000 Battery Charger supplies either 12, 24, 32 or 48 VDC from a 110 or 220 VAC power
source. High quality digital meters can be added (factory option) to allow monitoring of
charging current and charging voltage. A remote control option or equalize & temperature
compensation (factory installed) option is available for this model.
Features
In a DC UPS ( Un-interruptible Power Supply ), the charger simultaneously powers the DC load
as well as the battery. As long as the AC power to the charger is available and the charger is
working normally, the charger will supply the DC load as well as charge / oat the battery. In
case the AC power fails or if the charger stops working, the battery will automatically power
the DC load. As soon as the AC power to the charger is restored, the DC load will once again
be fed by the charger and at the same time the battery will be recharged.
CAUTION! Please ensure that the sum of the current drawn by the DC load and the current
desired for charging the battery is less than the maximum current capacity of the charger. To
use as a DC UPS, rst switch off the DC load and connect it to the battery. Now connect the
battery. Switch on the charger and then switch on the DC load.
Specications
Input Voltages
Nominal (ip) 110 220
Actual (Vac) 90 – 130 180 - 260
Frequency (Hz) 45 - 65
Input Amps (max) 17 8.5
Input Fuse (Slow Blow) MDA-20 (12V) / MDA-25 all others MDA-10 (12V) / MDA-15 all others
Output Voltages
Nominal (op) 12 24 32 48
Float (Vdc) 13.6 ± 0.05 27.2 ± 0.05 36.3 ± 0.05 54.4 ± 0.05
Absorption Voltage (Vdc) 14.4 28.8 38.4 57.6
Charging Amps 60 40 30 20
Absorption to Float 9 Amps 6 Amps 4.5 Amps 3 Amps
Output Fuses (ATC) 40 x 2 40 x 2 40 x 2 25 x 2
Battery Banks 1 or 2 1 or 2 1 or 2 1 or 2
Output Adjust ± 1.0 Volts

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* This is Analytic Systems’ suggested range. Please consult your battery manufacturer for their
recommendations.
* Specications subjects to change without notice.
Battery Size (Amp Hours)* 240 – 360 160 – 240 120 – 180 80 - 120
Output Crowbar 16.0 ± 0.5 V 32 ± 1.0 V 42.7 ± 1.3 V 63.9 ± 2.0 V
Equalize Voltage (Vdc) 15.5 31 41.3 62
Temperature Compensation Coefcient -30mV / oC -60mV / oC -80mV / oC -120mV / oC
General
Stages 2 or 3
Noise on Input < 50 milli-volts
Noise on Output < 50 milli-volts
Transient Resp. < 2V for 10A Surge
Efciency > 75 % @ maximum output
Temp. Range -25 to +40o C @ maximum output
Isolation
Input-Output & Input-Case 1500 Vdc
Output-Case 500 VDC (1500Vdc @ 48 V Out)
Length 14.5 in / 36.8 cm
Width 9.9 in / 25.1 cm
Height 5.0 in / 12.7 cm
Clearance 1 Inch (2.5 cm) all around
Material Marine Grade Aluminum
Finish Black Anodize / Black Powder Epoxy
Fastenings 18-8 Stainless
Weight 12 lb / 5.5 kg

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Installation
MOUNTING
Mount the unit in a DRY location. Allow at least 4 inches of clearance around the heat sink
ns for adequate cooling.
POWER CONNECTION
The unit is supplied with a power cable 5 feet long. This should normally be adequate to
connect to a source of power. If you must extend the power cable be sure to use a 3 conductor
grounded type extension cable. For hard wiring to a source of power, cut off the plug, and strip
the wires as necessary. The wire colours are: to connect to a source of power. If you must
extend the power leads, be sure to use at least a good quality (typeTEW) AWG 8 gauge wire.
The wire colours are:
All connections should be made inside an appropriate junction box. The maximum current
draw from the 110 VAC supply is 13.8 amps, so a 15 amp circuit breaker should be used in the
circuit panel and for a 220 VAC supply, 6.9 amps is the maximum current draw, so a 10 amp
circuit breaker should be used in the circuit panel to feed power to the BCA1000.
OUTPUT CONNECTIONS
Two Positive output terminals and two Negative output terminals are provided. Connect only
one wire to each terminal. Ensure that the total average load connected does not exceed the
continuous current rating of the unit.
To ensure spark free connections the power switch must be in the OFF position prior to making
the connections to the battery bank(s).
The charger may be hooked to 1 or 2 battery banks. Hook up the battery bank(s) as shown
below. If you are hooking up 2 battery banks keep in mind that they MUST share a common
ground! If you are going to hook up one battery bank to the charger, you may hook up the
outputs in parallel to reduce stress on the output isolation diodes inside the charger.
110 VAC 220 VAC
Brown - AC Hot Brown - AC Hot / Phase 1
Blue - AC Neutral Blue - AC Neutral / Phase 2
Green - Ground Green/Yellow - Ground
OUTPUT 1 OUTPUT 1
OUTPUT 2 OUTPUT 2
BATTERY
BANK #1
BATTERY
BANK #1
BATTERY
BANK #2

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Operation
Prior to turning on the unit, you must decide on which charging prole, 2 or 3 stage charging,
to use. To help you decide, please see the following section entitled 2 or 3 Stage Charging to
determine the charging prole.
Once you have decided on the charging prole you must set the switch to the correct
position. To access the switch remove the cover plate (secured by 2 screws). Set the switch
to the correct position as shown on the label. When you are done, replace the cover plate
and securely tighten the screws.
To turn the unit on, simply move the power switch to the ON position. The alarm buzzer will
sound and the Low Output LED will come on briey, and then the green OUTPUT ON LED will
illuminate.
When the unit is rst turned on, it will charge the batteries at a constant current and
the charging light will be on. After a period of time, which may be minutes to hours, the
batteries will reach the oat voltage at which time the charging light will go off, and the
charging current will reduce as necessary to maintain the batteries at that voltage. You
may check this voltage at the output terminals of the unit with a good digital voltmeter. As
shipped from the factory, the unit is preset to 13.6, 27.2, 36.3 or 54.4 VDC, which is generally
recommended for lead-acid batteries. If you wish to adjust the charging voltage, remove the
cover plate (secured by 2 screws) to expose the output adjust potentiometer. Reach in with a
very small at blade screwdriver to rotate the potentiometer. Clockwise increases the output
voltage, and counter clockwise decreases it. When you are done, replace the cover plate and
securely tighten the screws. It is advisable to check with the battery manufacturer before
changing the oat voltage.
High quality digital meters can be added to the charger (factory installed only). Both outputs
can be monitored for current and voltage
Meters

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Atwo-stage charger provides a constant current until the battery reaches its rated capacity
and then switches to a “oat” voltage. The current then reduces as necessary to maintain
the battery at the oat voltage. The charger can be connected to the battery indenitely and
will provide the appropriate prole. A two-stage charger is recommended in most instances
since it is the most versatile and can be permanently connected to attenuate the characteristic
discharge of unused batteries. A load can be put on the battery or batteries without altering
its ability to keep the battery at optimal charge.
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Absorption
(Constant Volts)
Maintenance
(Constant Volts)
Time
Three Stage Charger
Volts
Amps
A three-stage charger is the fastest charger. It charges the battery at a constant current
until the battery voltage reaches a slightly elevated level. The battery is maintained at
this voltage while the charging current diminishes to a low value, and then the battery is
switched to the oat voltage where it can be maintained indenitely. However, the charger
cannot differentiate between a current going to a load on the battery, or being absorbed by
the battery, so it can overcharge a battery supplying current to a load. A two-stage charger
is preferred for “loaded” batteries and a three-stage for idle or unloaded batteries during
recharging.
All of Analytic Systems’ chargers include adjustable output voltage for charging standard or
deep cycle lead-acid, VLRA or gel type batteries.
This charger features user selectable 2 or 3 stage charging. The charging prole is selected by
moving the slide switch on the front panel left to 3 stage or right for 2 stage charging.
2 or 3 Stage Charging
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Maintenance
(Constant Volts)
Time
Two Stage Charger
Volts
Amps

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Troubleshooting
This unit provides LED indicators and a buzzer to help diagnose any problems. The unit should
sound the buzzer to alert you prior to shutting itself down. You should immediately check the
indicators to determine the cause of the shutdown.
LOW OUTPUT Indicates that the output voltage is below normal because:
• The current demanded by the devices connected to the unit exceeds the maximum
output current rating, causing the output voltage to drop to maintain the current at
the maximum level
• The input voltage is not high enough for unit to operate,
LOW INPUT Indicates that the input voltage is below normal because:
• The input voltage is not in the correct range for proper operation of the unit.
OVERTEMP Indicates that the Battery Charger is running too hot because:
• Too much power is being drawn, turn off or unplug some devices.
• The Battery Charger is located in a poorly ventilated area.
• If the load exceeds the continuous rating for too long a period, the temperature
sensor inside the unit will turn off the outputs. After the unit cools sufciently, it
will automatically come back on. If this happens frequently, remount the unit for
increased airow so it cools better.
CHARGING Indicates that the battery charger is charging the batteries:
• If the LED is not on, the batteries may be fully charged and the charger is supplying a
oat voltage to the batteries to keep them fully charged.
If the load exceeds the continuous rating for too long a period, the temperature sensor inside
the unit will turn off the outputs. After the unit cools sufciently, it will automatically come
back on. If this happens frequently, remount the unit for increased airow so it cools better.
Dry Contact Relay
To use your dry contact output fail relay you must connect a 9-pin D connector to the unit.
You must use pins one and six as is indicated on page 9 in the remote connector diagram.
The relay is factory preset to fail in the closed position when the low output LED and buzzer
come on. If you wish to have the relay fail in the open position when the low output LED
and buzzer come on, you must take the cover off the unit and move the jumper to the other
position on J22. J22 is located next to the relay.