Analytic Systems BCA610V Series User manual

INSTALLATION &
OPERATION MANUAL
BCA610 SERIES
AC Battery Charger

3
IMPORTANT & SAFETY INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS — This manual contains important safety and operating
instructions for battery charger
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, unplug battery charger from outlet before attempting any
maintenance or cleaning. Turning off controls will not reduce this risk.
6. Never place battery charger directly above battery; gases from battery will corrode and
damage battery charger.
7. Never allow battery acid to drip on battery charger when reading gravity or lling battery.
8. O/P CONNECTION PRECAUTIONS
Connect and disconnect DC output connections only after setting the I/P power switch to
the off position.
ALL 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.

4
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 in the vessels are off, so as not to cause an
arc.
x. Be sure area around battery is well ventilated.
xi. lean 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.
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 AC cord or plug provided — if it will not t outlet, have 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 BCA610 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.
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.

5
Introduction
The model BCA610 Battery Charger charges 12, 24, 32 or 48 batteries from a 110 or 220 VAC
power source. The all new Current Mode switching design offers increased power and reliabil-
ity in a compact package. Extra input and output ltering reduce EMI to extremely low levels.
Reliability features include an input fuse, thermal shutdown, current limiting, reverse battery
hookup protection and output short circuit shutdown with automatic recovery. The output
voltage is easily adjusted 1.0 volts above or below the standard output voltage to accommo-
date special charging requirements. High quality digital meters can be added (factory option)
to allow monitoring of charging current and charging voltage.
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.
Specications
Input Voltages
Nominal (ip) 110 220
Actual (Vac) 90 – 130 180 - 260
Frequency (Hz) 45 - 65
Input Amps (max) 9.3 4.7
Input Fuse MDA-12 MDA-6

6
* Specications subjects to change without notice.
* This is Analytic Systems’ suggested range. Please consult your battery manufacturer for their recommendations.
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 40 22 16.5 11
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
Output Crowbar 16.0 ± 0.5 V 32.0 ± 1.0 V 42.7 ± 1.3 V 63.9 ± 2.0 V
Equalize Voltage (Vdc) 15.5 31 41.3 62
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
General
Battery Banks 1 or 2
Stages 2 or 3
Noise on Input < 50 milli-volts
Noise on Output < 50 milli-volts
Transient Resp. < 2V for 10A Surge
Efciency > 75 % @ maximum output
Temp. Range -25 to +40o C @ maximum output
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

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Mounting
Mount the unit in a DRY location. Allow at least 4 inches of clearance around the heat sink
ns for adequate cooling.
Power Connection
The unit is supplied with a power cable 5 feet long. 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 conduc-
tor grounded type extension cable. For hard wiring to a source of power, cut off the plug, and
strip the wires as necessary. The wire colours are:
Installation
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
All connections should be made inside an appropriate junction box. The maximum current
draw from a 110 VAC source is 7.6 amps, so a 10 amp circuit breaker should be used in the
circuit panel. For a 220 VAC source, 3.8 amps is the maximum current draw, so a 5 amp circuit
breaker should be used in the circuit panel to feed power to the BCA 610.
OUTPUT CONNECTIONS
Two Positive output terminals and two Negative output terminals are provided. Connect only
one wire to each terminal. Ensure that the total average load connected to the batteries does
not exceed the continuous current rating of the unit.
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 or 2 battery banks depending on the model. 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!
OUTPUT 1 OUTPUT 1
OUTPUT 2 OUTPUT 2
BATTERY
BANK #1
BATTERY
BANK #1
BATTERY
BANK #2

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Operation
Meters
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 posi-
tion. To access the switch, remove the cover plate (secured by 2 screws). Set the switch to
the correct position as shown on the label. When you are done, replace the cover plate and
securely tighten the screws.
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 batter-
ies 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 15% 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, 36.3 or 54.4
VDC, which is generally recommended for lead-acid batteries. If you wish to adjust this
voltage, remove the cover plate (secured by 2 screws) to expose the Output Adjust potenti-
ometer. 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. When you are done,
replace the cover plate and securely tighten the screws. It is advisable to check with the
battery manufacturer before changing the oat voltage.
High quality digital meters can be added to the charger (factory installed only). Both outputs
can be monitored for current and voltage

9
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 left to 3 stage or right 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 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.
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

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Troubleshooting
This unit provides LED indicators and a buzzer to help diagnose any problems. The unit should
sound the buzzer to alert you prior to shutting itself down. You should immediately check the
indicators to determine the cause of the shutdown.
LOW OUTPUT Indicates that the output voltage is below normal because:
The current demanded by the devices connected to the unit exceeds the
maximum output current rating, causing the output voltage to drop to
maintain the current at the maximum level,
The input voltage is not high enough for unit to operate,
LOW INPUT Indicates that the input voltage is below normal because:
The input voltage is not in the correct range for proper operation of the unit.
OVERTEMP Indicates that the Battery Charger is running too hot because:
Too much power is being drawn, turn off or unplug some devices.
The Battery Charger is located in a poorly ventilated area.
CHARGING Indicates that the battery charger is charging the batteries:
If the LED is not on, the batteries may be fully charged and the charger is
supplying a oat voltage to the batteries to keep them fully charged.
If the load exceeds the continuous rating for too long a period, the temperature sensor inside
the unit will turn off the outputs. After the unit cools sufciently, it will automatically come
back on. If this happens frequently, remount the unit for increased airow so it cools better.

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Dry Contact Relay
To use your dry contact output fail relay you must connect a 9-pin D connector to the unit.
You must use pins one and six as is indicated on page 9 in the remote connector diagram.
The relay is factory preset to fail in the closed position when the low output LED and buzzer
come on. If you wish to have the relay fail in the open position when the low output LED and
buzzer come on, you must take the cover off the unit and move the jumper to the other posi-
tion on J22. J22 is located next to the relay.
To change the position of the jumper, rst turn the unit off and disconnect the unit from both
the power and batteries. Next, turn the unit on for 30 seconds to discharge the capacitors,
then turn it off again. Remove the eight screws holding on the cover. Turn the unit upside
down, remove the cover and locate J22. It will be next to the relay as is shown in the above
diagram. Simply move the jumper to the desired position as is shown in the above diagram.
Replace the cover and re-install the eight screws. Reconnect the unit to the power and batter-
ies.
BATTERY TEMPERATURE SENSORS
Up to 2 battery temperature sensors can be connected to the charger to allow temperature
compensation of the battery charging voltage (1 is supplied with the unit). If only the 1 sensor
is used, it MUST be plugged into the ‘BATT 1’ connection on the side of the unit. If no sensor
is used, the charger will default to standard output voltage.
For installation instructions of the temperature sensor, please see the section entitled
Remote Battery Temperature Sensor Installation.

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Remote Control Option
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.
IMPORTANT: This remote is to be used only on Battery Chargers
manufactured by Analytic Systems.
REMOTE CONNECTOR
This connector is located on the 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.
Equalize Option
The purpose of the Equalize Option 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 Option also includes a battery temperature sensor to compensate the
charging voltage for battery temperature, as well as to shut the charger down if the battery
should become overheated. A 2nd temperature sensor can be added to allow monitoring of
both batteries if the charger is connected to 2 banks of batteries.
An Equalize cycle can be initiated at any time by simply pressing the equalize start button
located next to the ON/OFF switch. 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

13
the time. If the Charging LED is off when the button is pressed, the Equalize cycle will begin
immediately.
The charger will charge the battery at approximately 10% its normal rate (i.e. 4 amps for a 40
amp charger) until the battery reaches equalize voltage and then the current reduces as neces-
sary 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. NOTE: 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 wiring to the telephone jack
marked “Batt 1” on the side of the unit. Note: If there is only one temperature sensor, it gets
plugged into “Batt 1”. If there is a second temperature sensor, it should be plugged into to the
phone jack labeled “Batt 2”.
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.
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.

Special Services & Options
A Line AC Detect & Autoswitch UPS
B Battery Backup (1A Chg InstAnt On BAttery BACkup fOr rACkmOunt pWs/VtC mOdels)
CCOTS |MIL461F, MIL810G (MIL Connectors) (VIBrAtIOn prOteCtIOn) (WIde temp {-40 tO +55oC})
(In-hOuse tested And repOrt fOr eACh unIt- AVAIlABle As Add On tO m OptIOn)
D Paralleling Diodes - Parallel Multiple PWS or VTC units
E European ROHS compliant (leAd free mAnufACtured)
F Electric Fork Lift (fIlterIng And surge suppressIOn)
G GMDSS (Charger c/w Digital Volt/Amp Meter & RCP1-BCA Remote Control)
H High Output (VTC120)
I MIL461F (In-hOuse tested And repOrt fOr eACh unIt- AVAIlABle As Add-On tO m OptIOn)
J MIL810G (In-hOuse tested And repOrt fOr eACh unIt- AVAIlABle As Add-On tO m OptIOn)
K Synchronized Inverters
L not assigned
M Military Rugged Package (MIL Connectors) (VIBrAtIOn prOteCtIOn) (WIde temp {-40 tO +55oC})
N Encapsulated
O Open Frame - No chassis just heat sink bars (nOt fOr All prOduCts)
P Portable (CArryIng hAndle, ruBBer feet)
Q 23” Rackmount Chassis c/w Digital Volt/Ammeter (fOr 610, 615, 1000, 1015 mOdels)
R 19” Rackmount Chassis c/w Digital Volt/Ammeter (fOr 610, 615, 1000, 1015 mOdels)
S not assigned
T not assigned
U Safety Special Inspection (CsA/ul)
V Integrated Digital Volt/Ammeter
W IP66 Water Resistant Chassis
X Heavy Duty Ruggedization (VIBrAtIOn prOteCtIOn) (WIde temp {-40 tO +55oC})
Y IP67 Water Tight Chassis (In-hOuse tested And repOrt fOr eACh unIt)
Z No Conformal Coating
On our website you can discover more about marine batteries & power.