Analytic Systems BCA610 Series User manual

INSTALLATION &
OPERATION MANUAL
BCA610 SERIES
AC SOURCE
BATTERY CHARGER

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 autho-
rized 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
iii. Someone should be within range of your voice or close enough to come to your aid
when you work near a battery.
iv. Have plenty of fresh water and soap nearby in case battery acid contacts skin,
clothing, or eyes.
v. Wear complete eye protection and clothing protection. Avoid touching eyes while
working near battery.
vi. 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.
vii. NEVER smoke or allow a spark or ame in the vicinity of a battery.
viii. 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.
ix. 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.
x. NEVER charge a frozen battery.
xi. 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.
xii. Be sure area around battery is well ventilated.
xiii. Clean the battery terminals. Be careful to keep corrosion from coming in contact
with eyes.
xiv. 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.

Introduction
The BCA610 AC source battery charger provides up to 600 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 BCA610 can also function as a power supply up to its continuous
current rating. See Specications for the output current rating of your unit.
Suitable for all your battery charging needs, this unit can be congured to charge a 12, 24, 32,
or 48 volt battery bank. With the output voltage adjust and user-selectable charging proles,
you have optimal control in how you charge your batteries. Additionally, voltage temperature
compensation protects your expensive battery banks from overly harsh charging, 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 ltering on the input
and output reduce conducted and radiated EMI noise to very low levels.
Designed with safety in mind, this unit’s safety features include reverse input connection,
input fuse, over temperature shutdown, short circuit protection, input/output under voltage
shutdown, reverse battery connection and output overvoltage crowbar.

General
Battery Banks 1 or 2
Stages 2 or 3
Transient Resp. < 2V for 10A Surge
Efciency > 75 % @ maximum output
Temp. Range
-25°C to +40°C: Continuous Operation
+40°C to +85°C: Intermittent Operation
Isolation Input-Output & Input-Case: 1500 VDC
Output-Case 500 VDC (1500Vdc @ 48 V Out)
Length 14.5 in / 36.8 cm
Width 9.9 in / 25.1 cm
Height 3.0 in / 14.0 cm
Clearance 1 Inch (2.5 cm) all around
Material Marine Grade Aluminum
Finish Black Anodize / Black Powder Epoxy
Fastenings 18-8 Stainless
Weight 7.2 lb / 3.3 kg
* Specications subjects to change without notice.
* This is Analytic Systems’ suggested range. Please consult your battery manufacturer for their recommendations.
Output
Nominal Voltage 12 VDC 24 VDC 32 VDC 48 VDC
Float Voltage 13.6 ± 0.05 VDC 27.2 ± 0.05 VDC 36.3 ± 0.05 VDC 54.4 ± 0.05 VDC
Absorption Voltage 14.4 VDC VDC 28.8 VDC 38.4 VDC 57.6 VDC
Charging Amps 40 A 22 A 16.5 A 11 A
Absorption to Float 6.0 Amps 3.3 Amps 2.48 Amps 1.65 Amps
Battery Size (Amp Hours)* 160 – 240 88 – 132 66 – 99 44 - 66
Output Adjust ± 1.0 Volts
Noise on Output < 50 mV
Output Crowbar 16.0 ± 0.5 V 32.0 ± 1.0 V 42.7 ± 1.3 V 63.9 ± 2.0 V
Equalize Voltage 15.5 VDC 31 VDC 41.3 VDC 62 VDC
Temperature Compensation Coefcient -30mV / oC -60mV / oC -80mV / oC -120mV / oC
Output Fuses ATC-40 x 2 ATC-30 x 2 ATC-20 x 2 ATC-15 x 2
Specications
Input
Nominal Voltage 110 VAC 220 VAC
Actual Voltage 90 – 133 VAC 180 - 265 VAC
Frequency 45 - 65 Hz
Noise on Input < 50 mV
Input Amps (max) 9.3 A 4.7 A
Input Fuse MDA-12 MDA-6

Mounting
Mount the unit in a DRY and WELL VENTI-
LATED location with at least 4 inches of
clearance all around it. The ideal mount-
ing conguration is to mount the unit at
on a horizontal surface. #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
All connections should be made inside an appropriate junction box with appropriately rated
circuit breakers used in the circuit panel to feed power to the BCA 610. See Specications for
the maximum input current and recommended fuses.
AC Input Connection
The unit is equipped with a 5-foot long power cable terminating in either a North American
outlet compatible NEMA 5-15 plug or European outlet compatible CEE-7/7 plug 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:
110 VAC
Brown - AC Hot
Blue - AC Neutral
Green - Ground
220 VAC
Brown - AC Hot / Phase 1
Blue - AC Neutral / Phase 2
Green/Yellow - Ground
DC Output Connection
This unit is equipped with a Molex 4-pin BEAU Terminal Strip to serve as a DC Output Connec-
tion. This connector has two positive output terminals and two negative output terminals. See
the unit’s label for the wiring of this connection.

9
OUTPUT 1 OUTPUT 1
OUTPUT 2 OUTPUT 2
BATTERY
BANK #1
BATTERY
BANK #1
BATTERY
BANK #2
Battery Temperature Sensor Connection
This unit is equipped with a pair of RJ45 “telephone jack” connectors to serve as connections
for up to 2 Analytic Systems battery temperature sensors. If only 1 sensor is being used, it
must be plugged into ‘BATT 1” port. This sensor communicates the temperature of the battery
to the charger, and is required for the voltage temperature compensation function, over
temperature shutdown and user-initiated equalize cycle.
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.
Pictured: Analytic Systems Battery Temperature Sensor
Connect the battery bank(s) to the terminals using an appropriate gauge of wire for the charg-
ing amps. 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.
This connection can support up to 2 battery banks. Hook up the battery bank(s) as shown below.
If you are hooking up 2 battery banks keep in mind that they MUST share a common ground!
To install the sensor at the battery,
you may:
• Slide the sensor so it is ush
between the side of the battery and
battery platform.
• Place the battery 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.
Single Bank Connection Dual Bank Connection

8
Operation
The BCA610 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 battery
1. Select the type of charging prole using the Stage Select switch on the top panel.
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.
3. The CHARGING LED will glow green and the unit will charge the battery at the voltage
and current listed on the label.
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 voltage
1. Disconnect the battery temperature sensor(s) from the unit, if connected.
2. Move the Power Switch to ON.
3. Loosen the two screws and remove the cover plate on the top panel to access the output
voltage adjust potentiometer.
4. Using a small at-blade screwdriver, rotate the potentiometer.
5. The charging voltage can be adjusted over a range of ±10%. Rotate the potentiometer clock-
wise to increase the output voltage; counterclockwise to decrease the charging voltage.
6. Using a voltmeter or multimeter, check the charging voltage at the battery terminal.
7. When satised with the new voltage, return the cover plate to its original position, rein-
stall the screws and reconnect the battery temperature sensor(s)
To end operation
1. Move the Power Switch to OFF.
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.

11
This unit features two user-selectable charging proles. You can choose which type of charg-
ing prole, two stage or three stage, is used to charge your batteries using the Stage Select
switch on the front panel. Below are explanations of the two proles:
In two stage charging, the battery is
charged with a constant current until
the battery voltage reaches the “oat
voltage”. The current then diminishes as
necessary to maintain the battery at this
voltage. Once the current drops to 10%
of it’s initial value, the battery is then
held at the “oat voltage”
Two stage charging is recommended in most instances since it is gentler on the battery. The
battery is subjected to lower charging voltages, a reasonable load can be put on the battery
without altering the charger’s ability to keep the battery at optimal charge.
In three stage charging, the battery is
charged at a constant current until the
battery voltage reaches the “absorption
voltage”. The battery is maintained at
this voltage while the current diminishes.
Once the current drops to 10% of it’s
initial value, the battery is then held at
the “oat voltage”
Three stage charging is faster than two
stage. However, the battery is subjected to higher voltages. In addition, the charger cannot
differentiate between current going to a load on the battery and current being absorbed by
the battery, so it can overcharge a battery powering a load.
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
Charging Proles
Two Stage Charging
Three Stage Charging

This unit is tted with LED indicators and an alarm buzzer to display and diagnose any
problems in operation. In the event of a malfunction, the unit will sound the buzzer to alert
you prior to shutting itself down. You should immediately check which LEDs are glowing to
determine the cause of the alarm.
LED Indicator Meaning
BATTERY OVERTEMP The battery temperature is too high for safe charging.
Fix: The battery may be defective or there may not be adequate ventilation to
cool the battery.
Check that the battery is not defective. If it is working correctly, reposition
the battery for better air circulation.
OVERTEMP The unit’s internal temperature is too high for normal operation.
Fix: The internal cooling fan may have failed or there may not be adequate venti-
lation to cool the charger. Check that the cooling fan is still working; if it is
not then the unit must be returned to an authorized service center for repair.
If it is working correctly, remount the battery charger for better air circulation.
LOW INPUT The battery charger’s input voltage is too low for normal operation
Fix: Check that the power source is properly rated for the battery charger. Check
that the input cables and connection are free of damage and corrosion.
If all of the above are in proper working order, the cause is likely an internal
component failure and the unit must be returned to an authorized service
center for repair.
LOW OUTPUT The battery charger’s output voltage is too low for normal operation.
Fix: The charging current might be exceeding the unit’s maximum rating causing
the output voltage to drop to maintain the current at that level. Check
that the charging current is not over its limit, by using a multimeter at the
output terminals. If it is, reduce the load connected to the charger.
Check that the output cables and connections are free of damage and
corrosion.
If all of the above are in proper working order, the cause is likely an internal
component failure and the unit must be returned to an authorized service
center for repair.
Troubleshooting