DV Power BAC25A User manual

Battery Charger BAC25A
M-B025CN-300-EN 1
BATTERY CHARGER BAC25A
Manual
Manual Version: M-B025CN-300-EN
This Manual refers to the firmware version 2.xx
Publishing date: 2016-03-22

Battery Charger BAC25A
M-B025CN-300-EN 2
Contents
1. Introduction.................................................................................................................................3
1.1 SAFETY INSTRUCTIONS ...............................................................................................................................3
1.1.1 Safety terms and symbols ..........................................................................................................3
1.1.2 Terms of Use ..............................................................................................................................3
1.1.3 Orderly Practices and Procedures..............................................................................................4
1.1.4 Device Maintenance ...................................................................................................................4
1.1.5 Operator Qualifications...............................................................................................................4
1.1.6 Safe Operating Procedures ........................................................................................................4
1.2 POWER SUPPLY....................................................................................................................................5
1.3 INTENDED USE......................................................................................................................................6
2 Description..............................................................................................................................7
2.1 FRONT PANEL COMPONENTS.................................................................................................................7
2.2. MAINS POWER AND PROTECTIVE EARTH CONNECTORS ..........................................................................9
3 Getting Started......................................................................................................................10
3.1 CONNECTING BAC25A TO TEST OBJECT.............................................................................................10
3.2 SETTING TEST PARAMETERS...............................................................................................................11
3.2.1 Mode menu...............................................................................................................................12
3.2.2 Limits menu...............................................................................................................................14
3.2.3 Set menu...................................................................................................................................15
3.3 CHARGING..........................................................................................................................................17
3.3.1 IU mode ....................................................................................................................................17
3.3.2 UU mode...................................................................................................................................20
3.3.3 Charging Parameters................................................................................................................22
3.3.4 Charging Rates.........................................................................................................................23
4. External Alarm Function............................................................................................................24
5 Alarm Messages........................................................................................................................25
5.1 ALARM MESSAGE "OVERVOLTAGE"......................................................................................................25
5.2 ALARM MESSAGE "UNDERVOLTAGE"....................................................................................................25
6 Error Messages.....................................................................................................................26
6.1 ERROR MESSAGE "VS POLARITY"........................................................................................................26
6.2 ERROR MESSAGE "POLARITY"..............................................................................................................26
6.3 ERROR MESSAGE "OVERCURRENT"......................................................................................................26
6.4 ERROR MESSAGE "OVERHEAT"............................................................................................................27
6.5 ERROR MESSAGE "MALFUNCTION".......................................................................................................27
6.6 ERROR MESSAGE "MAINS VOLTAGE <90V"..........................................................................................27
7 Customer Service.................................................................................................................. 28
8 Packing the Instrument for Shipment.....................................................................................29
9 Technical Data......................................................................................................................30
9.1 MAINS POWER SUPPLY .......................................................................................................................30
9.2 OUTPUT DATA.....................................................................................................................................30
9.3 ENVIRONMENTAL CONDITIONS.............................................................................................................30
9.4 DIMENSIONS AND WEIGHT...................................................................................................................30
9.5APPLICABLE STANDARDS.....................................................................................................................30
10 Accessories...........................................................................................................................31
Manufacturer Contact Information................................................................................................. 32

Battery Charger BAC25A
M-B025CN-300-EN 3
1. Introduction
The purpose of this Manual is to provide helpful instructions on how to use the BAC25A instrument
safely, properly and efficiently.
The following instructions will help the user to avoid unsafe situations, reduce maintenance costs
and will ensure the reliability and durability of the BAC25A instrument.
The BAC25A must be used in observance of all existing safety requirements and regulations
based on national / local standards for accident prevention and environmental protection. In
addition, the relevant international standards are listed in the “Technical Data” section of this
document.
1.1 Safety Instructions
Safety is the responsibility of the user. Before operating the BAC25A, please read the following
safety instructions carefully.
It is not recommended that the BAC25A is used (or even turned on) without careful observation of
the instructions listed in this Manual. The BAC25A should only be operated by trained and
authorized personnel.
1.1.1 Safety terms and symbols
Terms in the Manual. The following terms may appear in this Manual:
WARNING: Warning statements identify conditions or practices that could result in injury or loss
of life.
CAUTION: Caution statements identify conditions or practices that could result in damage to
this product or to other property.
Terms on the Device. The following warning terms used in this document may appear on the
device:
WARNING: indicates that potential hazard may occur.
CAUTION: indicates that potential damage may occur to the instrument or to the test object
connected to the instrument.
Symbol on the Product. The following symbol may appear on the device:
Refer to Protective
Manual Earth Terminal
1.1.2 Terms of Use
•The BAC25A shall be used only if it is in good technical condition. Its use shall be in
accordance to local safety and industrial regulations. Adequate precautions must be taken to
avoid any risks related to high voltages associated with this equipment and nearby objects.

Battery Charger BAC25A
M-B025CN-300-EN 4
•The BAC25A is intended exclusively for the application purposes specified in the ”Intended
Use” section of this Manual. The manufacturer and distributors are not liable for any damage
resulting from wrong usage.
•The user bears responsibility in case of not following the instructions defined in this document.
•Do not remove protective casing of the BAC25A.
•All service and maintenance work must be performed by qualified personnel only.
1.1.3 Orderly Practices and Procedures
•The Manual shall always be available on the site where the BAC25A is used.
•Before using the BAC25A, all personnel (even personnel who only occasionally, or less
frequently, work with the BAC25A) assigned to operate the BAC25A should read this Manual.
•Do not make any modifications, extensions, or adaptations to the BAC25A.
•Use the BAC25A only with the original accessories provided by its manufacturer.
•Use the BAC25A and its original accessories for the device’s intended use only.
1.1.4 Device Maintenance
The device should be kept clean in order to prevent excessive cases of dust or other contaminants
affecting its operation. It should be cleaned with water/isopropyl alcohol after any dirt/contaminants
are noticed on its surfaces.
1.1.5 Operator Qualifications
•Testing with the BAC25A should only be carried out by authorized and qualified personnel.
•Personnel receiving training, instruction or education on the BAC25A should remain under the
constant supervision of an experienced operator while working with the test set and the test
object.
1.1.6 Safe Operating Procedures
•Hazardous voltages of up to 300V can occur inside the BAC25A. Therefore, it is not permitted
to remove the protective casing of the BAC25A.
•Hazardous voltages exist on the terminals of the BAC25A. Switch off and unplug the BAC25A
before touching the connections, particularly if a fault is suspected.
•Before putting the BAC25A into operation, check the test set for any visible damage.
•Do not operate the BAC25A under wet or moist conditions (condensation).
•Do not operate the BAC25A if explosive gas or vapors are present.
•When setting up the BAC25A, make sure that the air slots of the test set remain unobstructed.
•Removing the BAC25A protective casing will void the warranty. Any work inside the instrument
without prior authorization from DV Power will also void the warranty.

Battery Charger BAC25A
M-B025CN-300-EN 5
•If the BAC25A seems to be malfunctioning, please contact the DV Power Support Team (refer
to the "Manufacturer Contact Information” section) after previously checking the “Error
Messages” section.
•First connect cables to the device and then to the test object, after the test is completed
disconnect the cables from the test object first and then from the device.
•Prior to connecting the BAC25A, ensure that the battery (object) to be tested is completely
disconnected and isolated from the line. Every terminal should be checked and verified before
connecting the BAC25A.
•Do not use the BAC25A without the extra protective ground cables supplied with the BAC25A.
It must never be operated in a non-grounded configuration as this may result in an electric
shock to the user or damage to the device. Always establish this connection first before
establishing any other connections and remove this connection last.
CAUTION
Never open the measuring circuit while the test is in progress as dangerous high
voltage may occur.
Never disconnect cables from the battery while the test is in progress. This can
cause excessive DC arc flash on external terminals.
1.2 Power Supply
•Supply the BAC25A from a power outlet which is equipped with protective ground.
•Besides supplying the BAC25A from phase –neutral (L1-N, A-N), it may also be supplied
phase to phase (e.g. L1-L2; A-B). However, the voltage must not exceed 264 V AC. Please
refer to the “Technical Data” section.
•The BAC25A should be positioned in such a way that it is possible to disconnect it from the
power supply safely at any moment.
WARNING / AVERTISSEMENT
This is a class A product. In a domestic environment this product may cause radio interference
in which case the user may be required to take adequate measures.
Il s'agit d'un produit de classe A. Dans un environnement domestique, ce produit peut
provoquer des interférences radio, auquel casl'utilisateur peut être amené à prendre des
mesures adéquates.

Battery Charger BAC25A
M-B025CN-300-EN 6
1.3 Intended Use
The Battery charger Unit BAC25A is a stand-alone instrument designed for charging primarily
Lead-Acid and Ni-Cd batteries. BAC25A is intended to support the main charger in order to charge
battery much faster or to quickly recharge a battery following a discharge test. It is used for
charging batteries that serve as backup power supply in:
•Power plants
•Generator excitation systems
•Substations
•Protection and control systems
The BAC25A charges 10 –300 V battery systems using one single cable setup, with effective
currents of up to 25 A.

Manual BAC25A
M-B025CN-300-EN 7
2 Description
2.1 Front Panel Components
1. Display
Displays the settings during the device charging mode selection as well as the measured values
during and after charging operation.
2. Keyboard
Used to control the device.
•UP/DOWN buttons are used to navigate through the active menu and to set the charging
parameters.
•RIGHT button to navigate through the active menu.
•ENTER button to confirm selected charging parameters, language, time and date, as well as
to go to the next screen if no changes are needed in the active menu.
•STOP button to stop the charging process, to interrupt the alarm buzzer and to return to the
previous menu.

Manual BAC25A
M-B025CN-300-EN 8
•START button to start the charging process.
•SET button to enter the SETTINGS menu (alarm, language, and time & date settings).
•LIMITS button to go to LIMITS menu.
•MODE button to set the charging mode (MODE IU, MODE UU).
3. LED Indicators
Green LED
•Lights continuously when BAC25A is switched on.
•Flashes alternately with the red LED during the charging process.
Red LED
•Lights continuously (and the alarm buzzer is active) in case of an operational error.
•Lights continuously (and the alarm buzzer is active) when test is stopped.
•Flashes alternately with the green LED during the charging process.
4. Temperature Sensor
Temperature sensor channel provides the ambient temperature measurement and the float
charging voltage correction according to measured temperature values.
5. Interface
The USB PC interface enables firmware loading. A USB cable is provided as an accessory.
6. Alarm Overvoltage
Alarm overvoltage channel is used for connecting the BAC25A with an external ALARM buzzer. If
unexpected overvoltage occurs, the external alarm will be activated.
7. Alarm Undervoltage
Alarm under voltage channel provides connecting the BAC25A with an external ALARM buzzer. If
unexpected undervoltage occurs the external alarm will be activated.
8. Current and Voltage Terminals
The instrument is equipped with current and voltage test cable terminals.
CAUTION
Never open the charging circuit while the test is in progress as dangerous high
voltage may occur. Do not disconnect or make reconnection of any cables when
the test is in progress!

Manual BAC25A
M-B025CN-300-EN 9
2.2. Mains Power and Protective Earth Connectors
Ventilation
CAUTION
For safety reasons, connection to protective ground should be established as the
first one before any other connections and separated as the last one at the end of a
charging.
Protective earth connector
For protection against parasitic currents or voltages, the BAC25A
earth/ground connector should always be connected to protective
ground (PE). Only the originally provided cable should be used for
this purpose.
Mains power connector
Connects the BAC25A to the mains power supply with a power cord.
Power switch –Double pole switch
I- In this position, the BAC25A is connected to the mains power supply.
0 - In this position, the BAC25A is separated from the mains power supply.

Manual BAC25A
M-B025CN-300-EN 10
3 Getting Started
3.1 Connecting BAC25A to Test Object
Before the BAC25A has been connected to a test object (e.g. a battery), the following steps must
be taken:
•The battery should be examined for any visual damages or liquid leakage.
•The BAC25A itself should be properly grounded. The grounding screw, placed on the rear side
of the device, needs to be connected to the PE using a grounding cable.
NOTE:
Always connect current/sense cables to the BAC25A first and then to the battery
string / test object. When disconnecting, always disconnect the cables from the
battery string / test object first and then from the BAC25A.
The grounding wire PE should be disconnected last.
Not following these instructions may cause life-threatening situations.
Figure 3-1: Connecting the BAC25A to a test object
Thick red and black lines represent current cables which conducts charging energy. Current cables
are recommended and necessary accessory for conducting the charging test. Thinner lines
represent voltage sense (VS) cables. Voltage sense cables are optional accessory which provide
smoother voltage regulation during the charging process. By using the VS cables, the voltage drop
on current cables does not affect the voltage measurement accuracy during the test.
The red device terminal (red clamp) should be connected to the plus and the black terminal (black
clamp) to the minus battery terminal.
The current cables and voltage sense cables should be separated physically to minimize the
effects of any coupling between them. Any source of interference should be eliminated from the
working area if possible.