Analytic Systems BCA1505U-24DW User manual

INSTALLATION &
OPERATION MANUAL
BCA1505 SERIES
BATTERY CHARGER

2
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 minutes and
get medical attention immediately
AC SOURCE BATTERY CHARGER
IMPORTANT SAFETY INSTRUCTIONS

32
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.

4
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

54
Introduction
The BCA1505 AC source battery charger provides up to 1500 watts of precision charging
power to charge your one or two bank battery system from a 110 or 220 VAC source. The
batteries must share a common ground.
The recently-updated single board design incorporates time-tested switch-mode technology
for unmatched efciency and ultra-quiet operation. Multiple stages of ltering reduce radiated
and conducted noise to MIL461 levels. In the absence of a battery, the BCA1505 can also be
used as a power supply up to its continuous current rating.
This unit features output voltage adjustment and user-selectable charging proles to ne-
tune its charging capabilities in order to suit your specic needs. The voltage temperature
compensation and equalize cycle functionalities help maintain and protect your expensive
battery bank systems, maximizing their lifespan.
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.
Box Contents
The box you have received should contain the following:
• One BCA1505 battery charger
• This manual
• One Warranty Card
If anything is missing or damaged please contact your dealer or Analytic Systems for a replacement

76
3
4
2
1 1
Rear Panel
Main Parts
1. 2 Stage / 3 Stage Select Switch
(locking toggle switch)
2. Battery Negative Output Connection
3. Battery Positive Output Connection
4. LED Indicators
5. Power Button
6. Equalize Start Push button
(recessed)
7. AC Power Cord
8. AC Input Fuse
9. Output Voltage Adjust
3
2
1
4
6
5
7
8
9
Front Panel
1. Thermostatically-controlled
Cooling Fans
2. Battery Temperature
Sensor Connection
3. Dry Contact Output Fail Relay
Connection
4. Remote Control Connection

76
Operation
This unit is designed for simple and intuitive operation. Before operating, make sure that this
unit is properly installed and connected. See Installation for more information.
TO CHARGE A BATTERY
1. Choose which type of charging prole will be used during charging by moving the Stage
Select switch. See Charging Proles for more information.
2. Move the Power Switch to ON. The alarm buzzer will sound and the LOW VOLTAGE
OUTPUT LED will glow red briey, then the POWER LED will glow green. This is normal.
3. The CHARGING LED will start glowing green indicating normal operation. The unit will
automatically charge the battery until it is fully charged. This may take several hours.
4. Once the battery is fully charged, the CHARGING LED will turn off. The unit will maintain
the battery at full charge for as long as it is connected.
TO ADJUST THE CHARGING (FLOAT) VOLTAGE
1. Press the Power Button. The alarm buzzer will sound and the LOW VOLTAGE OUTPUT LED
will glow red briey, then the POWER LED will glow green. This is normal.
2. Disconnect the battery temperature sensor(s) from the unit, if connected.
3. Rotate the Output Voltage Adjust potentiometer on the front panel to adjust the output
voltage.
4. The charging (oat) voltage can be adjusted over a range of ±1.0 volts. Rotate the
potentiometer clockwise to increase the voltage; counterclockwise to decrease the voltage.
5. Using a digital voltmeter, check the charging voltage at the battery terminal. Rotate the
potentiometer until you are satised with the new voltage reading.
6. Reconnect the battery temperature sensor(s) if necessary.
TO END OPERATION
1. Press the Power Button.
2. Wait for all the LEDs stop glowing.
3. Once all of the LEDs are off, it is safe to disconnect the unit from the power source and
battery. The unit is now ready for storage or service.

98
Installation
MOUNTING
Mount the unit in a DRY and WELL
VENTILATED location with at least 4 inches
of clearance all around it.
There is 1500 volts of isolation between
the input and output, and the input and
case. There is 500 volts (1500V for 48V
output units) of isolation between the
output and case. Therefore, the unit may
be mounted on any surface without fear of
electrolysis or ground fault
CAUTION: The power switch must be in the OFF position before making connections.
When connecting the battery to the unit a small arc can form between the connectors. To ensure
spark-free connections, make connections only when the power switch is in the OFF position.
All connections should be made inside of an appropriate junction box with appropriately rated
circuit breakers used in the circuit panel to feed power to the BCA1505. See Specications for
the maximum input current and recommended fuses.
AC INPUT CONNECTION
This unit is equipped with a 5-foot (2.5m) power cable terminating in a NEMA 5-20 Connector
(for North American models) or a CEE7/7 Connector (for European models) to serve as an AC
Input Connection.
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 colors are as follows.
0.25
12.00
2.39
3.76
16.80
North American Plug
Black - AC Hot
White - AC Neutral
Green - Ground
European Plug
Brown - AC Hot / Phase 1
Blue - AC Neutral / Phase 2
Green/Yellow - Ground

98
DC OUTPUT CONNECTION
This unit is equipped with two pairs of Phoenix VDFK Through Panel connectors to serve
as Output Battery Connections. Use wires of an appropriate gauge for the expected output
current to make this connection. #6AWG wiring is the recommended size of wire to use for this
connection.
Ensure that the total average load connected to the batteries does not exceed the unit’s
charging amps. See Specications for this unit’s charging amps. See Specications for more
details regarding these values.
The wiring of this connection can be found on the unit’s front panel label and is as follows:
OUTPUT 1 OUTPUT 1
OUTPUT 2 OUTPUT 2
BATTERY
BANK #1
BATTERY
BANK #1
BATTERY
BANK #2
Single Bank Connection Dual Bank Connection
NOTE: This Single Bank Connection wiring arrangement is mandatory
for charging a 12 volt battery bank.
Connector Colour Wiring
Black DC Negative
Red DC Positive
This connection can support charging up to two battery banks that share a common ground.
If you are only charging one battery bank, you may connect both of the BCA1505G’s positive
outputs in parallel to the battery’s positive terminal in order to reduce stress on each individual
output connection.
CAUTION: Do not reverse connect the battery in the reverse polarity!!
This will activate the battery reverse connection protection which will blow the output
fuses inside the unit in order to protect the battery. The unit will be inoperable until these
fuses have been replaced.

1110
• The battery is charged at a constant
current (higher than in two-stage)
until the battery’s voltage reaches
the absorption voltage.
• Then the charging current
diminishes as necessary to
maintain the battery at that voltage.
• Once the current drops to 10%,
the charging cycle is complete.
The unit switches to keeping the
battery at the oat voltage and will maintain the battery at full charge until needed.
•Three-stage charging is faster than two-stage, however the battery is subjected to higher
voltages and currents. Three-stage charging is not recommended for charging loaded batteries
because the unit cannot differentiate between current going to a load connected to the battery
and current being absorbed by the battery; this can cause overcharging.
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Absorption
(Constant Volts)
Float
(Constant Volts)
Time
Three Stage Charge
Volts
Amps
Charging Proles
This unit has both two-stage and three-stage charging capability. You can choose which
charging prole is used during operation by using the Stage Select switch on the front panel.
Below are explanations of the two proles:
•The battery is charged at a constant
current until the battery’s voltage
reaches the oat voltage.
•Then the charging current
diminishes as necessary to
maintain the battery at that voltage.
• Once the current drops to 10%, the
charging cycle is complete. The
unit will maintain the battery at
full charge until needed.
•Two-stage charging is gentler on the battery since the battery is subjected to lower voltages
and currents than in three-stage. In addition, a reasonable load can be connected to the
battery without affecting the charger’s ability to keep the battery at full charge.
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Float
(Constant Volts)
Time
Two Stage Charge
Volts
Amps
TWO-STAGE CHARGING
THREE-STAGE CHARGING

1110
Remote Control Accessory
Pin Number Function
1 Dry Contact Relay (Closed for fault)
6 Dry Contact Relay (Closed for fault)
2 Remote Off (Short to 5 to turn unit OFF)
7 OverTemp (Low for fault)
3 UnderVolt In (Low for fault)
8 OverLoad (Low for fault)
4 UnderVolt Out (Low for fault)
9 +12 Volts
5 Common
The remote control panel and 9-pin D-connector are an optional feature for this product line.
The remote control panel allows the unit to be operated remotely and duplicates all the
diagnostic LED indicators with audible alarm. A built-in dimmer switch allows you to control
the brightness of the remote control LEDs.
IMPORTANT: This remote is to be used
only on Battery Chargers manufactured
by Analytic Systems.
CAUTION: Do not turn on the battery charger until the remote is connected!
To prevent the possibility of high voltage electrical shock, the charger must be OFF while
connecting the remote control. Do not remove the dust-cover on the remote control connector
if it is not being used.
CAUTION: Do not connect this port to a computer!
This will cause serious damage to the inverter and computer. This damage is not be covered
under warranty.
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.

12
Battery Temperature Sensor
This unit is supplied with one battery temperature sensor. This sensor communicates the
temperature of the battery to the charger and is required to access the charger’s voltage
temperature compensation, batttery over temperature alarm and equalize cycle functionality.
BATTERY TEMPERATURE SENSOR CONNECTION
This unit is equipped with an Amphenol MIL-Spec PT02A8-4S connector to connect to up to
two Analytic Systems waterproof battery temperature sensor(s). This connection’s wiring is
shown on the unit’s label.
There are multiple ways to install the sensor at the battery. Regardless of which method you
use, the sensor must be rmly secured to the battery. The sensor should not lose physical
contact with the battery at any point in the charging cycle.
TO INSTALL THE SENSOR AT THE BATTERY, YOU MAY:
• Slide the sensor between the side of the battery and wall of the battery platform so it
sits ush.
• Place the battery so it is sitting on top of the sensor to hold it in place.
• Apply a small amount of silicone RTV sealant to the sensor and stick it to the top of the
battery.
VOLTAGE TEMPERATURE COMPENSATION
Heat is a normal by-product of the charging cycle. However, excessive heat can cause
overcharging, damaging the battery. With a battery temperature sensor installed, your battery
charger will automatically reduce the charging voltage to compensate for rising temperature.
The ambient battery temperature is set to 77°F (25°C). For each degree above 77°F (25°C),
the charger will reduce the charging voltage by a small amount. See Specications for
the temperature compensation coefcient specic to your unit. You can adjust the voltage
temperature compensation and the temperature compensation range using Analytic System’s
free-to-download software PowerWizard.
Pictured: An Analytic Systems
Waterproof Battery Temperature Sensor
(B-TEMPW)

1312
Equalize Cycle
If a battery is left discharged for too long, sulfate crystals can form on its internal electrode
plates. This interferes with their conductance reducing battery’s capacity and charging speed.
Your battery charger can perform an Equalize Cycle to correct this condition. An Equalize Cycle
ensures all the cells of the battery are fully charged; deliberately overcharging the battery at
a low current (approximately 10% of its normal output) until it reaches the unit’s programmed
Equalize Voltage. The charger maintains the battery at that voltage for three hours after which
time the Equalize Cycle ends and the battery charger resumes normal operation; maintaining
the battery at the oat voltage.
DANGER: An Equalize Cycle can only be performed in a well ventilated area!
Hydrogen gas is a normal by-product of the Equalize Cycle and is explosive at concentrations
greater than 4% of the local atmosphere.
CAUTION: A battery temperature sensor must be installed and used!
Heat is a normal by-product of the Equalize Cycle and excessive heat will damage the battery
bank. The battery temperature sensor must be connected and installed to allow the unit to
monitor the temperature and ensure it is within safe operating limits.
TO PERFORM AN EQUALIZE CYCLE:
1. Connect and install the supplied Analytic Systems Battery Temperature Sensor. See
Installation for more information.
2. Push the Equalize Button on the front panel. On some units, this button is recessed to
prevent accidental operation; a ballpoint pen can be used to access it.
3. If the unit is not currently charging a battery, the EQUALIZE LED will glow red and the
Equalize Cycle will begin.
4. If the unit is currently charging a battery, the EQUALIZE LED will blink red. Once the
charging cycle ends, the CHARGING LED will shut off and the EQUALIZE LED will glow
red and the Equalize Cycle will begin.
5. Three hours later, the Equalize Cycle will end. The battery charger will automatically
resume normal operation maintaining the battery at the oat voltage.

Specications
Input Voltages
Input Volts Nominal 110 and 220 VAC (auto switching)
Input Volts Actual 90 - 140 and 180 - 260 VAC
Input Amps 16 maximum (at 90 VAC in)
Input Fuse 25 A Slow Blow Part # MDA25A
Input Frequency 45 - 405 Hz
Noise on Input < 50 mV
Output Voltages
Output Volts Nominal 12 VDC 24 VDC 32 VDC 48 VDC 72(rail) VDC
Absorption Voltage 14.4 VDC 28.8 VDC 38.4 VDC 57.6 VDC 76.8 VDC
Float Voltage 13.6 ± 0.05 27.2 ± 0.05 36.3 ± 0.15 54.4 ± 0.2 72.5 ± 0.3
Output Voltage Adjust +/- 0.5 V +/- 1.0 V +/- 1.5 V +/- 2.0 V +/- 3.0 V
Charging Amps 100 A 60 A 45 A 30 A 20 A
Battery Banks 1 1 or 2 1 or 2 1 or 2 1 or 2
Recommended Battery Capacity
(Amp Hrs.) 200 - 600 100 - 300 75 - 200 50 - 150 40 - 120
Output Overvoltage Protection
Crowbar 17.0 ± 0.05 V 34.0 ±1.0 V 45.0 ± 0.5 V 68.0 ± 2.0 V 90.0 ± 0.3 V
Temp. Compensation Coefcient -30 mV / °C -60 mV / °C -80 mV / °C -120 mV / °C -160 mV / °C
Duty Cycle Continuous
Efciency > 80% @ Maximum Output
Stages 2 or 3
Mechanical
Dimensions 17.4 in / 44.2 cm Long x 8.35 in/ 21.2 cm Wide x 4.0 in / 10.2 cm High
Clearance 1.0 in / 2.5 cm all around
Weight 18.0 lb / 8.2 kg
Material and Finish Marine Grade Black Anodized Aluminum with 18-8 Stainless Fasteners
Connections
AC Input - NEMA 5-20 plug with 2.5 m AWG14 cable (approx. length) (North
America) or CEE 7/7 2.5 m cable (Europe)
DC Output - Color coded Phoenix VDFK6 terminal blocks, 60 Amp rated
Environmental and Safety
Operating Temperature Range -25°C to +40°C @ maximum output. Derate Linearly 2.5% per °C from 40°C
(Optional -40°C extra wide temperature operation available)
Humidity 0 - 95% Relative Humidity (non-condensing) with standard conformal coating
Isolation Input-Case, Input-Output and Output-Case 1500 VDC
Audible Noise 40 dB when fans operating
Typical Service Life > 10 years (87,600 hrs)
Warranty Three years parts and labor
Safety Built to meet CSA 22.2.107.1 & UL458
Learn more about marine batteries & power we have.