Analytic Systems BCA310 Series User manual

INSTALLATION &
OPERATION MANUAL
BCA310 SERIES
AC SOURCE
BATTERY CHARGER

3
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
AC SOURCE BATTERY CHARGER
IMPORTANT SAFETY INSTRUCTIONS

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

TABLE OF CONTENTS
• Front Cover, Product Photo and Title
• Product Warnings and Advisories
• Table of Contents
• Introduction / Box Contents
• Main Parts
• Charging Proles
• Operation
• Installation
• Product Options
• Battery Temperature Sensor
• Equalize Cycle
• Specications
• Troubleshooting
• Warranty
Revised - April 10, 2020

Introduction
The BCA310 AC source battery charger provides up to 300 watts of precision charging power
to charge your one or two bank battery system. The batteries must share a common ground.
This unit can be built to operate from any conventional AC mains power of 110 or 220 VAC .In
the absence of a battery, the BCA310 can also function as a power supply up to its continuous
current rating. See Specications for the output current rating of your unit.
This unit can be congured all your battery charging needs. The charger can deliver output
voltages of 12, 24, 32,48 or 72 VDC for battery capacities of all types. An output voltage
adjust, user-selected charging proles, and temperature compensation allow for precise and
gentle charging of your expensive battery banks. The user-initiated equalize cycle function can
help maintain your battery banks, prolonging their lifespan.
Internally, the recently updated single board design incorporates time-tested switch mode
technology for unmatched efciency and ultra-quiet operation. Additional stages of lter on
the outputs reduce conducted and radiated noise to very low levels.
Designed with safety in mind, this unit features reverse input connection, over temperature
shutdown, short circuit protection, input/output under voltage shutdown, reverse battery
connection and output overvoltage crowbar.
The box you’ve received should contain the following:
• One BCA310 Battery Charger
• One Battery Temperature Sensor (B-Temp)
• 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

1. Output Voltage Adjust
2. Equalize Start Button
3. Stage Select Switch
4. DC Output Connection: Molex
BEAU 4-pin Terminal Strip
5. Output Fuse: AGC-25
6. Indicator LEDs
7. Battery Temperature Sensor Port
8. Power Switch
9. Remote Control Port
10. Chassis Grounding Screw
11. AC Input Connection: 5-foot (2.5m)
power cable ending in a NEMA 5-20
Connector
12. Input Fuse: AGC-7
Main Parts
Front Panel
4
5
10
1
8
7
11
2
9
12
6
3

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• 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 dimin-
ishes 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.
Charging Proles
This unit has both two-stage and three-stage charging capability. You can choose which charg-
ing 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 dimin-
ishes 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.
TWO-STAGE CHARGING
THREE-STAGE CHARGING

Operation
The BCA310 is designed for simple and intuitive operation. Before operating, make sure this
unit is properly installed and connected. See Installation for more information.
TO CHARGE A LEAD-ACID BATTERY
1. Select a two-stage or three-stage charging prole by moving the Stage Select switch to
the correct position. See Charging Proles for more information.
2. Move the Power Switch to the ON position. The alarm buzzer will sound and the UNDER-
VOLTAGE OUTPUT LED will glow red briey, then the POWER LED will glow green.
3. The CHARGING LED will glow green and the unit will charge the battery.
4. Once the battery is fully charged, the CHARGING LED will turn off. The unit will maintain
the battery at the oat voltage for as long as it is connected.
TO ADJUST THE CHARGING VOLTAGE
1. Disconnect the waterproof battery temperature sensor from the unit, if it is connected.
2. Move the Power Switch to the ON position to turn on the charger.
3. Using an appropriately sized at-blade screwdriver, rotate the Output Voltage Adjustment
Potentiometer. The charging voltage can be adjusted over a range of ±10%.
4. Rotating the potentiometer clockwise increases the output voltage; rotating it counter-
clockwise decreases the output voltage.
5. Check the charging voltage using a voltmeter or multimeter at the battery terminal.
6. Reconnect the waterproof battery temperature sensor when satised with the voltage.
TO CHARGE A LITHIUM-ION BATTERY
1. Select a two-stage charging prole by moving the Stage Select switch to the correct
position.
2. Move the Power Switch to the ON position. The alarm buzzer will sound and the UNDER-
VOLTAGE OUTPUT LED will glow red briey, then the POWER LED will glow green.
3. Use the procedure above to adjust the charging voltage to a suitable voltage. Consult the
Li-On battery manufacturer for the recommended charging voltage.
4. The CHARGING LED will glow green and the unit will charge the Li-On battery.
5. Once the battery is fully charged, the CHARGING LED will turn off. The unit will maintain
the battery at the oat voltage for as long as it is connected.

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MOUNTING
Mount the unit in a DRY and WELL
VENTILATED location with at least 1 inch of
clearance all around it. The ideal mount-
ing conguration is to mount the unit on
a vertical surface oriented as shown. #10
screws are recommended for attaching the
unit to the surface.
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.
Installation
INPUT
FUSE
TO
REMOTE
OUTPUT TERMINAL
ON/OFF
INPUT POWER
OUTPUT
FUSE
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.
European Plug
Brown - AC Hot / Phase 1
Blue - AC Neutral / Phase 2
Green/Yellow - Ground
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 BCA310. 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:
North American Plug
Black - AC Hot
White - AC Neutral
Green - Ground

DC OUTPUT CONNECTION
This unit is equipped with a Molex
4-pin BEAU Terminal Strip to serve
as a DC Output Connection. The
connection can support up to 3
battery banks.
Remember, If you are charging
multiple battery banks that they
MUST share a common ground! If
you are charging 3 battery banks,
hook them up as is shown to the
right.
OUTPUT 1
OUTPUT 2
OUTPUT 3
BATT
BANK #2
BATT
BANK #1
BATT
BANK #3
Pins Polarity
1 Battery 1 Positive Output
2 Battery 2 Positive Output
3 Battery 3 Positive Output
4 Common Battery Negative
The wiring of this connection can be found on the unit’s front panel label and is as follows:
IMPORTANT: ENSURE THAT THE TOTAL LOAD DOES NOT EXCEED THE BATTERY
CHARGER’S CONTINUOUS CURRENT RATING. See Specications for more details.
CAUTION: DO NOT CONNECT THE BATTERY IN THE REVERSE POLARITY!
This will activate the reverse connection protection which will blow the output fuses inside the unit
in order to protect the device. The unit will be inoperable until these fuses have been replaced.