Analytic Systems BCA310MS User manual

INSTALLATION &

OPERATION MANUAL

BCA310MS

Battery Charger

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 and AS9100 Registered Company Battery Chargers •Inverters •Power Supplies •Voltage Converters

IMPORTANT & SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS — This manual contains important safety and operating instruc-

tions for the battery charger.

ALL BATTERY CHARGERS

1. CAUTION — To reduce risk of injury, charge only lead acid or sealed gel cell type

rechargeable batteries. Other types of batteries may burst causing personal injury and

damage.

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, disconnect battery charger from batteries and AC supply

before attempting any maintenance or cleaning. Turning off controls will not reduce this

risk.

AC 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.

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 are off, so as not to cause an arc.

x. Be sure area around battery is well ventilated.

xi. Clean 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.

3. BATTERY CHARGER LOCATION

i. Never place battery charger directly above battery; gases from battery will corrode

and damage converter.

ii. Never allow battery acid to drip on battery charger when reading gravity or lling

battery.

4. O/P CONNECTION PRECAUTIONS

i. Connect and disconnect DC output connections only after setting battery charger

switch to off position.

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 the AC cord or plug provided. If it will not t the outlet, have the

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 BCA310 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.

Introduction

This all new single board design incorporates state of the art switchmode technology for

unmatched efciency and ultra-quite operation. Multiple stages of ltering reduce radiated or

conducted noise to very low levels. Extra features include adjustable output voltage, audible

and visual indicators for low input voltage, low output voltage and over temperature. Safety

features include reverse input protection, over-temperature shutdown, current limiting, and

short circuit protection with automatic recovery, input undervoltage shutdown, reverse battery

protection and output overvoltage crowbar. Optional features include a dry contact alarm relay

output, and remote panel monitoring with On/Off control.

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.

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.

Specications

Input Voltages

Nominal (ip) 110 220

Actual (Vac) 90 - 130 180 - 260

Frequency (Hz) 45 - 65

Input Amps (max) 5.2 2.6

Input Fuse (slow blow) MDA-7 MDA-4

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 20 10 7.5 5A

Absorption to Float 3.0 Amps 1.5 Amps 1.13 Amps 0.75A

Battery Banks 1, 2 or 3

Battery Size (Amp Hours)* 80 – 120 40 - 60 30 – 45 20-35

Output Adjust ± 1.0 Volts

Output Fuses AGC 25 AGC 15 AGC 10 AGC10

Output Crowbar 16.0 ± 0.5 V 32.0 ± 1.0 V 42.7 ± 1.3 V 63.5 ± 0.5V

Temperature Compensation Coefcient -30mV / o C -60mV / o C -80mV / o C -120mV / o C

General

Efciency > 75 % @ maximum output

Stages 2 or 3

Temp. Range -40°C to +50°C @ maximum output

Isolation Input-Case & Input-Output 1500 VDC, Output-Case 500 VDC

Length 9.6 in / 24.4 cm

Width 8.2 in / 20.8 cm

Height 3.5 in / 6.4 cm

Clearance 1 Inch (2.5 cm) all around

Material Marine Grade Aluminum

Finish Black Powder Epoxy

Fastenings 18-8 Stainless

Weight 7.0 lb / 3.2 kg

Safety ABS 11-HS794404A-PDA

* Specications subject to change without notice.

* This is Analytic Systems’ suggested range. Please consult your battery manufacturer for their recommendations.

Installation

Allow at least 1 inch of clearance all around the case for cooling. The best mounting congu-

ration is to mount the unit on a vertical surface oriented as shown. Use #10 screws of the

appropriate type for the mounting surface to securely mount the unit.

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.

The unit is supplied with a 5 foot power cable. 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 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

All connections should be made inside an appropriate junction box. The maximum current

draw from the 110 VAC supply is 5.2 amps, so a 7 amp circuit breaker should be used in the

circuit panel. For a 220 VAC supply, 2.6 amps is the maximum current draw, so a 4 amp circuit

breaker should be used in the circuit panel to feed power to the BCA 310.

To reduce radio noise to the absolute minimum, it may be necessary to bond the case to

ground. To do this, remove one the screws that mount the output terminal strip to the chassis.

Then place a #6 ring terminal with a ground wire crimped to it under the screw head, and

replace the screw.

Designed and manufactured by: ANALYTIC SYSTEMS WARE (1993) LTD.

8128 River Way

Delta, BC V4G 1K5 Canada

p. 604.946.9981 f. 604.946.9983

tf. 800.668.3884 US/Canada

www.analyticsystems.com [email protected] Revised July 2014

INPUT

FUSE

REMOTE

OUTPUT TERMINAL

ON/OFF

INPUT POWER

OUTPUT

FUSE

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

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, 2 or 3 battery banks. If you are hooking up 2 or 3 battery banks

keep in mind that they MUST share a common ground! If you are hooking up 3 battery banks,

hook them up as is shown below.

OUTPUT 1

OUTPUT 2

OUTPUT 3

BATT

BANK #2

BATT

BANK #1

BATT

BANK #3

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

determine the charging prole.

Once you have decided on the charging prole you must set the switch to the correct position.

The switch is located to the right of the output terminal on the front panel. Set the switch to

the correct position as shown on the label.

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 batteries

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 10% 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 or 36.3 VDC, which is generally

recommended for lead-acid batteries. The output adjust potentiometer is located to the right

of the 2 stage / 3 stage select switch. If you wish to adjust this voltage, 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. It is advisable to check with the battery manufacturer before

changing the oat voltage.

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 up to 3 stage or down 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 differenti-

ate 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.

2 or 3 Stage Charging

100%

75%

50%

25%

Bulk

(Constant Current)

Maintenance

(Constant Volts)

Time

Two Stage Charger

Volts

Amps

100%

75%

50%

25%

Bulk

(Constant Current)

Absorption

(Constant Volts)

Maintenance

(Constant Volts)

Time

Three Stage Charger

Volts

Amps

Troubleshooting

If the red OVERTEMP LED and the audible alarm come on, the unit has overheated, and it will

shut down until it cools off sufciently. You may not have allowed sufcient space around the

unit for cooling, or there may be too many devices connected to the output of the unit. Either

reduce the number of devices connected to the unit, or reposition the unit for better cooling. If

necessary, direct a stream of moving air over the unit.

If the yellow LOW INPUT LED and the audible alarm comes on, the input voltage has dropped

to below a usable level.

If the LOW OUTPUT LED and the audible alarm come on, and the green OUTPUT ON LED is

completely off, the output of the unit has been shorted out, or there has been an internal

failure. Turn the unit off, disconnect all the loads connected to it, and turn it back on again. If

it comes on normally, turn it off again, reconnect one load, and turn it back on. Continue recon-

necting loads until the short circuit condition returns. Turn the unit off, disconnect the faulty

load, and reconnect it only after the fault is found and rectied. If the condition still exists

even after all the loads have been disconnected, the unit is defective, and must be returned to

the factory or an authorized service center for repair.

If the unit will not turn on at all, check the input fuse. To do this, rst turn off the unit and

disconnect the power cord. Next, remove the negative battery lead and cover the end with non

conductive material such as tape. Repeat this with the other battery lead. This will prevent an

accidental discharge from the battery. Remove the fuse and check it with an ohmmeter. If it is

blown, replace it with a new one. If that fuse blows as well or the unit still will not turn on, it

is defective, and must be returned to the factory or an authorized service center for repair.

If the batteries are hooked up backwards the output fuses will blow. To change them follow

the same procedure as for the input fuse.

If both the input and output fuses are good and the unit still does not function it must be

returned to the factory for servicing.

Meters

A high quality digital meter can be added to the voltage converter (factory installed only). The

meter shows simultaneous voltage and current on either of the two output terminals. A toggle

switch permits selection between the output terminals. The meter features bright red LED

readouts to permit easy monitoring from many feet or meters away.

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