Analytic Systems BCA310MS User manual

INSTALLATION &
OPERATION MANUAL
BCA310MS
Battery Charger
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 and AS9100 Registered Company Battery Chargers •Inverters •Power Supplies •Voltage Converters

Copyright (2005-2014) Analytic Systems Ware (1993) Ltd.

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IMPORTANT & SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS — This manual contains important safety and operating instruc-
tions for the battery charger.
ALL BATTERY CHARGERS
1. CAUTION — To reduce risk of injury, charge only lead acid or sealed gel cell type
rechargeable batteries. Other types of batteries may burst causing personal injury and
damage.
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, disconnect battery charger from batteries and AC supply
before attempting any maintenance or cleaning. Turning off controls will not reduce this
risk.
AC 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 FOL-
LOW 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 vicin-
ity 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, cloth-
ing, 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 cur-
rent 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 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 remov-
ing 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.
3. BATTERY CHARGER LOCATION
i. Never place battery charger directly above battery; gases from battery will corrode
and damage converter.
ii. Never allow battery acid to drip on battery charger when reading gravity or lling
battery.
4. O/P CONNECTION PRECAUTIONS
i. Connect and disconnect DC output connections only after setting battery charger
switch to off position.
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 the AC cord or plug provided. If it will not t the outlet, have the
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 BCA310 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.

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Introduction
This all new single board design incorporates state of the art switchmode technology for
unmatched efciency and ultra-quite operation. Multiple stages of ltering reduce radiated or
conducted noise to very low levels. Extra features include adjustable output voltage, audible
and visual indicators for low input voltage, low output voltage and over temperature. Safety
features include reverse input protection, over-temperature shutdown, current limiting, and
short circuit protection with automatic recovery, input undervoltage shutdown, reverse battery
protection and output overvoltage crowbar. Optional features include a dry contact alarm relay
output, and remote panel monitoring with On/Off control.
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.
Examples of devices considered to be life support devices are neonatal oxygen analyzers,
nerve stimulators (whether used for anesthesia, pain relief, or other purposes), autotransfu-
sion 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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Specications
Input Voltages
Nominal (ip) 110 220
Actual (Vac) 90 - 130 180 - 260
Frequency (Hz) 45 - 65
Input Amps (max) 5.2 2.6
Input Fuse (slow blow) MDA-7 MDA-4
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 20 10 7.5 5A
Absorption to Float 3.0 Amps 1.5 Amps 1.13 Amps 0.75A
Battery Banks 1, 2 or 3
Battery Size (Amp Hours)* 80 – 120 40 - 60 30 – 45 20-35
Output Adjust ± 1.0 Volts
Output Fuses AGC 25 AGC 15 AGC 10 AGC10
Output Crowbar 16.0 ± 0.5 V 32.0 ± 1.0 V 42.7 ± 1.3 V 63.5 ± 0.5V
Temperature Compensation Coefcient -30mV / o C -60mV / o C -80mV / o C -120mV / o C
General
Efciency > 75 % @ maximum output
Stages 2 or 3
Temp. Range -40°C to +50°C @ maximum output
Isolation Input-Case & Input-Output 1500 VDC, Output-Case 500 VDC
Length 9.6 in / 24.4 cm
Width 8.2 in / 20.8 cm
Height 3.5 in / 6.4 cm
Clearance 1 Inch (2.5 cm) all around
Material Marine Grade Aluminum
Finish Black Powder Epoxy
Fastenings 18-8 Stainless
Weight 7.0 lb / 3.2 kg
Safety ABS 11-HS794404A-PDA
* Specications subject to change without notice.
* This is Analytic Systems’ suggested range. Please consult your battery manufacturer for their recommendations.

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Installation
Allow at least 1 inch of clearance all around the case for cooling. The best mounting congu-
ration is to mount the unit on a vertical surface oriented as shown. Use #10 screws of the
appropriate type for the mounting surface to securely mount the unit.
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.
The unit is supplied with a 5 foot power cable. 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 colors are
All connections should be made inside an appropriate junction box. The maximum current
draw from the 110 VAC supply is 5.2 amps, so a 7 amp circuit breaker should be used in the
circuit panel. For a 220 VAC supply, 2.6 amps is the maximum current draw, so a 4 amp circuit
breaker should be used in the circuit panel to feed power to the BCA 310.
To reduce radio noise to the absolute minimum, it may be necessary to bond the case to
ground. To do this, remove one the screws that mount the output terminal strip to the chassis.
Then place a #6 ring terminal with a ground wire crimped to it under the screw head, and
replace the screw.
Designed and manufactured by: ANALYTIC SYSTEMS WARE (1993) LTD.
8128 River Way
Delta, BC V4G 1K5 Canada
p. 604.946.9981 f. 604.946.9983
tf. 800.668.3884 US/Canada
www.analyticsystems.com [email protected] Revised July 2014
INPUT
FUSE
TO
REMOTE
OUTPUT TERMINAL
ON/OFF
INPUT POWER
OUTPUT
FUSE
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

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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 unit may be hooked to 1, 2 or 3 battery banks. If you are hooking up 2 or 3 battery banks
keep in mind that they MUST share a common ground! If you are hooking up 3 battery banks,
hook them up as is shown below.
OUTPUT 1
OUTPUT 2
OUTPUT 3
BATT
BANK #2
BATT
BANK #1
BATT
BANK #3
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.
The switch is located to the right of the output terminal on the front panel. Set the switch to
the correct position as shown on the label.
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 maximum current and the
charging light will be on. After a period of time which may be minutes to hours, the batteries
will reach the absorption voltage (3-stage) or oat voltage (2-stage), and the charging current
will reduce as necessary to maintain the batteries at that voltage. Once the charging current
has dropped to a low level (about 10% of the charging current rating), the charging light will
go off, and if set to 3-stage charging the voltage will drop to the oat level. 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 for a oat voltage of 13.6, 27.2 or 36.3 VDC, which is generally
recommended for lead-acid batteries. The output adjust potentiometer is located to the right
of the 2 stage / 3 stage select switch. If you wish to adjust this voltage, reach in with a very
small at blade screwdriver to rotate the potentiometer. Please Note that this adjusts both the
oat and absorption voltages at the same time. Clockwise increases the output voltage, and
counter clockwise decreases it. It is advisable to check with the battery manufacturer before
changing the oat voltage.

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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 up to 3 stage or down for 2 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.
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 differenti-
ate 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.
2 or 3 Stage Charging
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Maintenance
(Constant Volts)
Time
Two Stage Charger
Volts
Amps
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Absorption
(Constant Volts)
Maintenance
(Constant Volts)
Time
Three Stage Charger
Volts
Amps

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Troubleshooting
If the red OVERTEMP LED and the audible alarm come on, the unit has overheated, and it will
shut down until it cools off sufciently. You may not have allowed sufcient space around the
unit for cooling, or there may be too many devices connected to the output of the unit. Either
reduce the number of devices connected to the unit, or reposition the unit for better cooling. If
necessary, direct a stream of moving air over the unit.
If the yellow LOW INPUT LED and the audible alarm comes on, the input voltage has dropped
to below a usable level.
If the LOW OUTPUT LED and the audible alarm come on, and the green OUTPUT ON LED is
completely off, the output of the unit has been shorted out, or there has been an internal
failure. Turn the unit off, disconnect all the loads connected to it, and turn it back on again. If
it comes on normally, turn it off again, reconnect one load, and turn it back on. Continue recon-
necting loads until the short circuit condition returns. Turn the unit off, disconnect the faulty
load, and reconnect it only after the fault is found and rectied. If the condition still exists
even after all the loads have been disconnected, the unit is defective, and must be returned to
the factory or an authorized service center for repair.
If the unit will not turn on at all, check the input fuse. To do this, rst turn off the unit and
disconnect the power cord. Next, remove the negative battery lead and cover the end with non
conductive material such as tape. Repeat this with the other battery lead. This will prevent an
accidental discharge from the battery. Remove the fuse and check it with an ohmmeter. If it is
blown, replace it with a new one. If that fuse blows as well or the unit still will not turn on, it
is defective, and must be returned to the factory or an authorized service center for repair.
If the batteries are hooked up backwards the output fuses will blow. To change them follow
the same procedure as for the input fuse.
If both the input and output fuses are good and the unit still does not function it must be
returned to the factory for servicing.
Meters
A high quality digital meter can be added to the voltage converter (factory installed only). The
meter shows simultaneous voltage and current on either of the two output terminals. A toggle
switch permits selection between the output terminals. The meter features bright red LED
readouts to permit easy monitoring from many feet or meters away.