Analytic Systems BCA1505 SERIES Bedienungsanleitung

INSTALLATION &

OPERATION MANUAL

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 Registered Company Battery Chargers •Inverters •Power Supplies •Voltage Converters

BCA1505 SERIES

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 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

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

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.

i. NEVER smoke or allow a spark or ame in the vicinity of a battery.

ii. 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.

iii. 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.

iv. NEVER charge a frozen battery.

v. 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.

vi. Be sure area around battery is well ventilated.

vii.Clean the battery terminals. Be careful to keep corrosion from coming in contact with eyes.

viii. 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

• Description/Overview of product

• Main Parts

• Operation instructions

• Mounting Instructions

• Connection instructions

• Conguration instructions

• Options

• Faults

• Specications

• Warranty

Revised - June 12, 2019

Introduction

The BCA1505 AC source battery charger provides up to 1500 watts of precision charging

power to charge your one or two bank battery system from a 110 or 220 VAC source. The

batteries must share a common ground.

The recently-updated single board design incorporates time-tested switch-mode technology

for unmatched efciency and ultra-quiet operation. Multiple stages of ltering reduce radiated

and conducted noise to MIL461 levels. In the absence of a battery, the BCA1505 can also be

used as a power supply up to its continuous current rating.

This unit features output voltage adjustment and user-selectable charging proles to ne-

tune its charging capabilities in order to suit your specic needs. The voltage temperature

compensation and equalize cycle functionalities help maintain and protect your expensive

battery bank systems, maximizing their lifespan.

Safety features include both charger and battery over-temperature shutdown, current limiting,

short circuit protection with automatic recovery, input under voltage shutdown, output over-

voltage protection and battery reverse connection protection.

Box Contents

The box you have received should contain the following:

• One BCA1505 battery charger

• This manual

• One Warranty Card

If anything is missing or damaged please contact your dealer or Analytic Systems for a replacement

1 1

Rear Panel

Main Parts

1. 2 Stage / 3 Stage Select Switch

(locking toggle switch)

2. Battery Negative Output Connection

3. Battery Positive Output Connection

4. LED Indicators

5. Power Button

6. Equalize Start Push button

(recessed)

7. AC Power Cord

8. AC Input Fuse

9. Output Voltage Adjust

Front Panel

1. Thermostatically-controlled

Cooling Fans

2. Battery Temperature

Sensor Connection

3. Dry Contact Output Fail Relay

Connection

4. Remote Control Connection

Operation

This unit is designed for simple and intuitive operation. Before operating, make sure that this

unit is properly installed and connected. See Installation for more information.

TO CHARGE A BATTERY

1. Choose which type of charging prole will be used during charging by moving the Stage

Select switch. 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. This is normal.

3. The CHARGING LED will start glowing green indicating normal operation. The unit will

automatically charge the battery until it is fully charged. This may take several hours.

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 (FLOAT) VOLTAGE

1. Press the Power Button. The alarm buzzer will sound and the LOW VOLTAGE OUTPUT LED

will glow red briey, then the POWER LED will glow green. This is normal.

2. Disconnect the battery temperature sensor(s) from the unit, if connected.

3. Rotate the Output Voltage Adjust potentiometer on the front panel to adjust the output

voltage.

4. The charging (oat) voltage can be adjusted over a range of ±1.0 volts. Rotate the

potentiometer clockwise to increase the voltage; counterclockwise to decrease the voltage.

5. Using a digital voltmeter, check the charging voltage at the battery terminal. Rotate the

potentiometer until you are satised with the new voltage reading.

6. Reconnect the battery temperature sensor(s) if necessary.

TO END OPERATION

1. Press the Power Button.

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.

Installation

MOUNTING

Mount the unit in a DRY and WELL

VENTILATED location with at least 4 inches

of clearance all around it.

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

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.

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 BCA1505. 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.

0.25

12.00

2.39

3.76

16.80

North American Plug

Black - AC Hot

White - AC Neutral

Green - Ground

European Plug

Brown - AC Hot / Phase 1

Blue - AC Neutral / Phase 2

Green/Yellow - Ground

DC OUTPUT CONNECTION

This unit is equipped with two pairs of Phoenix VDFK Through Panel connectors to serve

as Output Battery Connections. Use wires of an appropriate gauge for the expected output

current to make this connection. #6AWG wiring is the recommended size of wire to use for this

connection.

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. See Specications for more

details regarding these values.

The wiring of this connection can be found on the unit’s front panel label and is as follows:

OUTPUT 1 OUTPUT 1

OUTPUT 2 OUTPUT 2

BATTERY

BANK #1

BATTERY

BANK #1

BATTERY

BANK #2

Single Bank Connection Dual Bank Connection

NOTE: This Single Bank Connection wiring arrangement is mandatory

for charging a 12 volt battery bank.

Connector Colour Wiring

Black DC Negative

Red DC Positive

This connection can support charging up to two battery banks that share a common ground.

If you are only charging one battery bank, you may connect both of the BCA1505G’s positive

outputs in parallel to the battery’s positive terminal in order to reduce stress on each individual

output connection.

CAUTION: Do not reverse connect the battery in the reverse polarity!!

This will activate the battery reverse connection protection which will blow the output

fuses inside the unit in order to protect the battery. The unit will be inoperable until these

fuses have been replaced.

1110

• 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

diminishes 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.

100%

75%

50%

25%

Bulk

(Constant Current)

Absorption

(Constant Volts)

Float

(Constant Volts)

Time

Three Stage Charge

Volts

Amps

Charging Proles

This unit has both two-stage and three-stage charging capability. You can choose which

charging 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

diminishes 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.

100%

75%

50%

25%

Bulk

(Constant Current)

Float

(Constant Volts)

Time

Two Stage Charge

Volts

Amps

TWO-STAGE CHARGING

THREE-STAGE CHARGING

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