Analytic Systems BCA1505 SERIES User manual

INSTALLATION &
OPERATION MANUAL
BCA1505 SERIES BATTERY CHARGER

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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
attempting 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
v. minutes and get medical attention immediately.

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vi. NEVER smoke or allow a spark or ame in the vicinity of a battery.
vii. 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.
viii. 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.
ix. NEVER charge a frozen battery.
x. 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.
xi. Be sure area around battery is well ventilated.
xii. Clean the battery terminals. Be careful to keep corrosion from coming in contact with
eyes.
xiii. 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.
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.
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.

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TABLE OF CONTENTS
• Front Cover, Product Photo and Title
• Product warnings and advisories
• Table of Contents
• Description/Overview of product
• Main Parts
• Operation instructions
• Mounting Instructions
• Connection instructions
• Conguration instructions
• Options
• Faults
• Specications,
• Warranty
Revised - August 8, 2016
Copyright (2005-2016) Analytic Systems Ware (1993) Ltd.

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Introduction
The BCA1505 battery charger provides up to 1500 watts to charge a one or two bank battery
system (single bank only for 12 volts) from a 110 or 220 VAC source. The batteries must share
a common ground.
The recently updated single board design incorporates state of the art switch- mode
technology for unmatched efciency and ultra-quiet operation. Multiple stages of ltering
reduce radiated and conducted noise to MIL461 levels. The BCA1505 does not need to be
connected to a battery to function, so it can also be used as a power supply if desired up
to the continuous current rating of the unit. Only a PWS1505 can deliver more than the
continuous power rating for extra short term output.
Safety features include both charger and battery over-temperature shutdown, current limiting,
short circuit protection with automatic recovery, input under voltage shutdown, output over-
voltage protection and battery reverse connection protection. Extra features include visual
indicators for low input voltage, charging and overtemperature, dry contact output fail output
and remote control connection.
Main Parts
Front Panel
1. Battery Negative Connection x 2
2. Battery Positive Connections x 2
3. Output Voltage Adjust
4. 2 Stage / 3 Stage Select
(locking toggle switch)
5. Equalize Start Push button (recessed)
6. AC Power Cord
7. AC Input Fuse
8. Power On / Off Push button
1
2
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5
8
6
7

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3
4
2
1 1
Rear Panel
1. Thermostatically controlled cooling fans x 2
2. Battery Temperature Sensor Connection x 2
3. Dry Contact Output Fail Relay Connection
4. Remote Control Connection
Top of Chassis (not shown)
1. Carrying Handle (Optional)
2. Digital Voltage Current Display (Optional, not shown). Adds three inches to chassis length

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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
change the prole, simply pull up on the toggle switch and place it in the correct position. To
turn the unit on, simply press the Power push button. 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 the oat voltage listed in the specications, which is
generally recommended for lead-acid batteries. If you wish to adjust the charging voltage, rst
temporarily disconnect the battery temperature sensors and then rotate the potentiometer
with a at blade screwdriver. Clockwise increases the output voltage, and counter clockwise
decreases it. When you are satised with the adjustment, reconnect the battery temperature
sensors.
An Equalize cycle can be initiated at any time by simply pressing the equalize start button.
This button is deliberately recessed to prevent accidental operation. It is most easily pressed
by using a ballpoint pen. If the charger is in the middle of charging the battery (the Charging
LED is on), the Equalize LED will ash. Once the main charging cycle is complete, the Equalize
cycle will begin and the Equalize LED will stay on all the time. If the Charging LED is off when
the button is pressed, the Equalize cycle will begin immediately.
NOTE: The charger can be used to recharge Lithium Ion batteries differ from lead acid
batteries in that they have four 3.6 volt cells instead of six 2.0 volt cells. To recharge a Lithium
Ion battery, follow these steps:
1. Select the 2 stage charge mode
2. Do not use a battery temperature sensor
3. Increase the output voltage adjust to maximum to obtain a charging voltage of 14.4
volts for a 12 volt LI battery. Similarly for other battery voltages, multiply the nominal
voltage by 1.2 to obtain the correct charging voltage or follow the battery manufacturers
recommendation for voltage.

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This charger features user selectable 2 or 3 stage charging. The charging prole is selected
by moving the locking toggle switch on the front panel down for 2 stage or up for 3 stage
charging.
A two-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)
Float
(Constant Volts)
Time
Two Stage Charge
Volts
Amps
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Absorption
(Constant Volts)
Float
(Constant Volts)
Time
Three Stage Charge
Volts
Amps
2 or 3 Stage Charging
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.

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Equalize
The purpose of the Equalize Mode is to deliberately overcharge the battery at a low rate
of current to ensure that all cells are fully charged and to reduce the chance of sulfation
of the battery. During the Equalize cycle, the cells, which are fully charged, will produce
Hydrogen gas, and the cells, which are undercharged, will be brought up to full charge. An
Equalize cycle should be done once every 2-3 months, or whenever battery capacity appears
to be diminished. The Equalize Mode requires the use of a battery temperature sensor (one
is included with the charger) to compensate the charging voltage for battery temperature,
as well as to shut the charger down if the battery should become overheated. A second
temperature sensor can be added to allow monitoring of both batteries if the charger is
connected to two banks of batteries.
The charger will charge the battery at approximately 10% of its normal rate (i.e. 6 amps for
a 60 amp charger) until the battery reaches equalize voltage and then the current reduces as
necessary to maintain the battery at that voltage. Three hours after the Equalize cycle begins,
the charger will return to the oat mode where the battery can be maintained indenitely. If
the battery temperature reaches 120 degrees F (50 degrees C) the equalize cycle will end and
the charger output reduced to a very low voltage until the battery cools, and then the charger
will return to the oat mode.
Remote Battery Temperature Sensor Installation
The remote battery temperature sensor allows the monitoring of the battery bank so that
the charging prole can be adjusted to optimally charge the battery bank depending on the
temperature of the battery bank.
CAUTION: The temperature sensor must be used during an equalize cycle or damage to the
battery may occur.
The battery temperature sensor may be installed in many different ways, so long as the
sensor stays in contact with the battery. The preferred method is as follows:
The batteries to be charged will be placed on a platform made of wood. Prior to placing the
batteries on the wooden platform a cavity is hollowed out such that the sensor will t inside
the cavity and be ush with the battery. Place the sensor inside the cavity facing the proper
way (this is shown on the sensor). Next connect the sensor to either telephone jack on the
rear of the unit.
If a battery blanket is used the sensor may be tucked inside the blanket with the proper side
of the sensor facing the battery. The sensor may be placed on top of the battery but it should
be secured to the battery so as to prevent it from losing contact with the battery.
NOTE: If there is a second temperature sensor (recommended for two bank charging), the
charger will use whichever temperature is higher to control the charging voltage.

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Dry Contact Relay
The relay is factory preset to fail when the low output LED and buzzer come on. Both normally
open and normally closed contacts are available on the connector. If your system detects an
alarm condition when the charger is operating normally, simply move the wire connected to
Pin 1 of the dry contact terminal block to Pin 3, or vice versa as needed.
Remote Control Option
IMPORTANT: This remote is to be used only on
Battery Chargers manufactured by Analytic Systems.
A remote control panel may be connected to the battery charger using a 9-pin D-connector,
which attaches to the side of the battery charger. The remote control panel and D connector
are part of the remote control option. The remote control panel allows the unit to be operated
remotely as well as duplicating all the diagnostic indicators and audible alarm.
REMOTE CONNECTOR
This connector is located on the rear side of the unit. Important: To prevent the possibility of
High
Voltage Electrical Shock, do not power up the battery charger unless all wiring from the unit to
the remote is securely connected. Do not remove the dust cover from the DB-9 connector if the
remote is not being used.
Battery Charger Temperature Compensation
The charger is calibrated with the sensor input preset to 77 degrees (25 degrees C). For
example, for a 12V battery, this voltage is 13.6 volts, and 27.2 volts for a 24V battery. See the
specications for the temperature compensation coefcient for different battery voltages.