Analytic Systems BCA1505 SERIES Bedienungsanleitung

INSTALLATION &

OPERATION MANUAL

BCA1505 SERIES BATTERY CHARGER

IMPORTANT & SAFETY INSTRUCTIONS

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

v. minutes and get medical attention immediately.

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

vii. 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.

viii. 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.

ix. NEVER charge a frozen battery.

x. 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.

xi. Be sure area around battery is well ventilated.

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

eyes.

xiii. 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.

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.

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.

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 - August 8, 2016

Introduction

The BCA1505 battery charger provides up to 1500 watts to charge a one or two bank battery

system (single bank only for 12 volts) from a 110 or 220 VAC source. The batteries must share

a common ground.

The recently updated single board design incorporates state of the art switch- mode

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

reduce radiated and conducted noise to MIL461 levels. The BCA1505 does not need to be

connected to a battery to function, so it can also be used as a power supply if desired up

to the continuous current rating of the unit. Only a PWS1505 can deliver more than the

continuous power rating for extra short term output.

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. Extra features include visual

indicators for low input voltage, charging and overtemperature, dry contact output fail output

and remote control connection.

Main Parts

Front Panel

1. Battery Negative Connection x 2

2. Battery Positive Connections x 2

3. Output Voltage Adjust

4. 2 Stage / 3 Stage Select

(locking toggle switch)

5. Equalize Start Push button (recessed)

6. AC Power Cord

7. AC Input Fuse

8. Power On / Off Push button

1 1

Rear Panel

1. Thermostatically controlled cooling fans x 2

2. Battery Temperature Sensor Connection x 2

3. Dry Contact Output Fail Relay Connection

4. Remote Control Connection

Top of Chassis (not shown)

1. Carrying Handle (Optional)

2. Digital Voltage Current Display (Optional, not shown). Adds three inches to chassis length

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

change the prole, simply pull up on the toggle switch and place it in the correct position. To

turn the unit on, simply press the Power push button. 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 a constant current and the

charging light will be on. After a period of time, which may be minutes to hours, the batteries

will reach the oat voltage at which time the charging light will go off, and the charging

current will reduce as necessary to maintain the batteries at that voltage. 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 to the oat voltage listed in the specications, which is

generally recommended for lead-acid batteries. If you wish to adjust the charging voltage, rst

temporarily disconnect the battery temperature sensors and then rotate the potentiometer

with a at blade screwdriver. Clockwise increases the output voltage, and counter clockwise

decreases it. When you are satised with the adjustment, reconnect the battery temperature

sensors.

An Equalize cycle can be initiated at any time by simply pressing the equalize start button.

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 the time. If the Charging LED is off when

the button is pressed, the Equalize cycle will begin immediately.

NOTE: The charger can be used to recharge Lithium Ion batteries differ from lead acid

batteries in that they have four 3.6 volt cells instead of six 2.0 volt cells. To recharge a Lithium

Ion battery, follow these steps:

1. Select the 2 stage charge mode

2. Do not use a battery temperature sensor

3. Increase the output voltage adjust to maximum to obtain a charging voltage of 14.4

volts for a 12 volt LI battery. Similarly for other battery voltages, multiply the nominal

voltage by 1.2 to obtain the correct charging voltage or follow the battery manufacturers

recommendation for voltage.

This charger features user selectable 2 or 3 stage charging. The charging prole is selected

by moving the locking toggle switch on the front panel down for 2 stage or up for 3 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.

100%

75%

50%

25%

Bulk

(Constant Current)

Float

(Constant Volts)

Time

Two Stage Charge

Volts

Amps

100%

75%

50%

25%

Bulk

(Constant Current)

Absorption

(Constant Volts)

Float

(Constant Volts)

Time

Three Stage Charge

Volts

Amps

2 or 3 Stage Charging

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.

Equalize

The purpose of the Equalize Mode 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 Mode requires the use of a battery temperature sensor (one

is included with the charger) to compensate the charging voltage for battery temperature,

as well as to shut the charger down if the battery should become overheated. A second

temperature sensor can be added to allow monitoring of both batteries if the charger is

connected to two banks of batteries.

The charger will charge the battery at approximately 10% of its normal rate (i.e. 6 amps for

a 60 amp charger) until the battery reaches equalize voltage and then the current reduces as

necessary 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.

CAUTION: 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 to either telephone jack on the

rear of the unit.

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.

NOTE: If there is a second temperature sensor (recommended for two bank charging), the

charger will use whichever temperature is higher to control the charging voltage.

Dry Contact Relay

The relay is factory preset to fail when the low output LED and buzzer come on. Both normally

open and normally closed contacts are available on the connector. If your system detects an

alarm condition when the charger is operating normally, simply move the wire connected to

Pin 1 of the dry contact terminal block to Pin 3, or vice versa as needed.

Remote Control Option

IMPORTANT: This remote is to be used only on

Battery Chargers manufactured by Analytic Systems.

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.

REMOTE CONNECTOR

This connector is located on the rear 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.

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 for different battery voltages.

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