Analytic Systems BCA150 User manual

INSTALLATION &
OPERATION MANUAL
8128 River Way, Delta B.C. V4G 1K5 Canada T. 604.946.9981 F. 604.946.9983 TF. 800.668.3884 (US/CANADA)
www.analyticsystems.com
An ISO9001 Registered Company Battery Chargers •Inverters •Power Supplies •Voltage Converters
BCA150
AC SOURCE
BATTERY CHARGER

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AC SOURCE BATTERY CHARGER
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS — This manual contains important safety and operating
instructions for the battery charger.
BATTERY CHARGER PRECAUTIONS
1. Do not expose the battery charger to rain or snow unless it is a sealed model.
2. 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.
3. Do not disassemble the battery charger; return it to the manufacturer or an authorized
service center when service or repair is required. Incorrect reassembly may result in a
risk of electric shock or re. Voltages in excess of 350 volts are present inside the charger
anytime it is plugged into an AC outlet, even if it is switched off.
4. To reduce risk of electric shock, unplug the battery charger from the AC outlet before at-
tempting any maintenance or cleaning. Turning off controls will not reduce this risk.
5. Never place battery charger directly above battery; gases from battery will corrode and
damage battery charger.
6. Never allow battery acid to drip on the battery charger.
BATTERY SAFETY
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 USER GUIDE AND
FOLLOW THE INSTRUCTIONS EXACTLY.
ii. To reduce risk of battery explosion, follow these instructions and those published by
the battery manufacturer and manufacturer of any equipment you intend to use in
vicinity of battery. Review the cautionary marking on these products.
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 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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Medical Equipment Notice
Analytic Systems does not recommend the use of their products 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), auto-transfusion 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.
DANGER Never alter the AC power cord or plug provided. If it will not t the
output, use an approved adapter or have the proper AC power cord installed by a
qualied electrician. Improper connection can result in the risk of electric shock.
i. NEVER smoke or allow a spark or ame in the vicinity of a battery.
ii. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or
short-circuit the battery or other electrical part that may cause a re or explosion.
iii. 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 melt metal, causing a severe burn.
iv. NEVER charge a frozen battery.
v. If it is necessary to remove a battery from service, always remove grounded terminal from
battery rst. Make sure all accessories connected to the battery are off, to prevent an arc
when reconnecting the new battery.
vi. Be sure area around battery is well ventilated.
vii. Clean the battery terminals. Be careful to keep corrosion from coming in contact with eyes.
viii. Study all the battery manufacturer’s specic precautions such as removing or not
removing cell caps while charging and recommended rates of charge
GROUNDING AND AC POWER CORD CONNECTION INSTRUCTIONS
The plug must be plugged into an outlet that is properly installed and grounded in accordance
with all local codes and ordinances.

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TABLE OF CONTENTS
• Front Cover
• Product Warnings and Advisories
• Table of Contents
• Introduction
• Box Contents
• Main Parts
• Operation
• Two-Stage Charging
• Installation
• Troubleshooting
• Specications
• Warranty
Revised - April 11, 2018
Copyright (2005-2017) Analytic Systems Ware (1993) Ltd.

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The BCA150 AC-source battery charger provides up to 150 watts of precision charging power
to charge your one or two bank battery system. The batteries must share a common ground.
This unit features advanced Power Factor Correction circuitry on the AC input to use the
electricity in the most effective and efcient way possible and will work from any standard
AC voltage worldwide (85-265 VAC). The recently updated single board design incorporates
modern switch-mode technology for unmatched efciency and ultra-quiet operation. In the
absence of a battery, the BCA150 can also function as a power supply up to its continuous
current rating.
Designed for maximum safety, unit’s reliability features include spark-free battery connections
reverse battery connection protection, over temperature shutdown with automatic recover and
both input and output fuses Additional features include a drip shield for wall mounting and
visual indicators for the presence of AC power as well as charging progress.
Introduction
The box you’ve received should contain the following:
• One BCA150 battery charger
• One IEC320 AC cable
• This manual
• One warranty card
If anything is damaged or missing from your box, please contact your dealer or Analytic Systems for a
replacement.
Box Contents

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1. Output Voltage Adjust
2. AC Input Connection:
Bulgin IEC320 Flange Mount Inlet
6.3mm
3. DC Output Connections: 2 sets
Phoenix VDFK4 Terminal Blocks
(Red and Black)
4. Chassis Grounding Screw
24
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Main Parts
Front Panel
Top Panel
1. Lighted Power Switch
2. Power Indicator LED
3. Drip Shield
4. Integrated Digital Voltmeter
5. Load Indicator LEDs (Output 1&2)
2
1
3
5
1
4

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Operation
The BCA150 is designed for simple and intuitive operation. Before operating the charger,
it must be properly connected to a source of AC Power and to the batteries as shown in
Installation.
Charging a battery
1. Move the Power Switch to the ON position.
2. The Power LED will glow green indicating that the unit is powered ON. The Output LED(s)
will also glow corresponding to the charge of the battery. See LED Indicators.
3. Once the batteries are fully charged, the Output LED will glow green. The unit will
maintain the batteries at the oat voltage as long as they connected.
4. You can check the battery’s charge using a voltmeter or multimeter at the battery.
Adjusting the charging voltage
The charging voltage can be adjusted over a range of ±0.6V (±1.2V for the 24V model) to suit
your specic charging needs. To adjust the charging voltage:
1. Using a small at-blade screwdriver rotate the Output Voltage Adjust potentiometer.
Rotate clockwise to increase the output voltage.
2. Rotate it counterclockwise to decrease the output voltage.
3. You can check the charging voltage using the integrated digital voltmeter.
LED Indicators
The BCA150 features several indicator LEDs on its top panel to display the unit’s operating
condition. Their meanings are detailed below.
POWER:
This LED glows green when the unit is connected to an AC power source and energized.
OUTPUT 1 & OUTPUT 2:
These LEDs indicate what stage of charging that the connected battery is undergoing.
• If the LED is glowing red, the battery is in the Bulk stage of the charging cycle.
• If the LED is glowing yellow, the battery is in the Float stage of the charging cycle.
• If the LED is glowing green, the battery is completely charged. The unit will maintain
the battery in this state as long as it is connected, so it always ready for service.

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The BCA150 charges batteries using either a two-stage charging prole. A two-stage
charging prole occurs in two stages.
During the bulk stage, the battery draws a constant current (Output Current) from the charger.
This causes the battery’s voltage to rise until nally reaching a voltage slightly higher than the
battery’s rated capacity, the oat voltage. The oat voltage is higher than the rated voltage to
compensate for the characteristic discharge of idle batteries.
Then during the oat stage, the battery is held at the oat voltage the current reduces as
necessary to maintain it at this voltage. The battery can be left connected to the charger inde-
nitely, which will maintain it.
A two-stage charger is recommended in most instances (over a three-stage charger) since it is
the most versatile. The battery is also subjected to lower voltages than in three-stage charging
and therefore is less stressed. In addition, a reasonable load can be put on the battery without
altering its ability to keep the battery at full charge.
Two-Stage Charging
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Float
(Constant Volts)
Time
Two Stage Charge
Volts
Amps

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Mounting
Mount the unit in a WELL VENTILATED and DRY area with at least one inch (2.54 cm) of clear-
ance around the extruded vents. The unit should be mounted on a vertical surface with the
drip shield facing upward as shown below.
Installation
DC Output Connection
This unit is equipped with two sets of Phoenix VDFK block connectors to serve separate DC
output connections. Connect the batteries to this connection using an appropriate gauge of
wire for the current (see Specications for more information). These connections are wired as
follows:
RED: Positive Battery Terminal
BLACK: Negative Battery Terminal
These connections can be used to charge up to two battery banks simultaneously. If charging
a single battery, connect the positive terminal of that battery to both positive DC outputs, this
will reduce strain on the connection.
AC Input Connection
This unit is equipped with a 3-pin Bulgin AC Inlet (6.3mm) Tab Flange Mount to serve as an AC
input connection. Your unit is supplied with an IEC320 cable for connection to an AC power
source, if the supplied cable does not t your AC receptacle, any other IEC320 cable can be
used.