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

9.5 APPLICABLE 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.

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• 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.

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• 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.

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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.

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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.

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• 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!

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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.

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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.

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To maximize the accuracy and measurement repeatability, make sure that all clamps have a good
connection to the test object and avoid any crossing between the measuring cables.

CAUTION

• For safety reasons, a connection between the device and a test object(s)
should be always established as described in this Manual.

• The measuring cables should not be connected / reconnected after the start of
the charging process.

• The measuring cables should not be disconnected before the charging
process is over.

• It is important to organize working area in order to avoid damaging cables. It
may cause life threatening situations.

3.2 Setting Test Parameters

After the BAC25A device is switched on, the initial message informing the user about name of the
device and installed firmware version is displayed, Figure 3-2.

Figure 3-2: The initial screen

After the initial screen is being displayed for several seconds, the BAC25A changes the display to
the main menu and the green LED lights up.

The BAC25A keeps the user’s settings and offers them as default. What charging menu will be
displayed depends on user settings in the previous test. In case there are no saved test results, or
after the firmware upgrade, the IU charging menu (Figure 3-3) will be displayed.

Figure 3-3: The IU menu

The BAC25A device can perform charging in two modes:

- Mode IU (Float charging) is a constant-current charging mode of a battery string,

- Mode UU (Boost charging) is a constant-voltage charging mode of a battery string.

Besides the stated charging modes, the device can also be used as a power supply unit.

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The requested charging / supplying mode can be selected in the MODE menu. The MODE button,
placed on the front panel of the instrument, should be pressed to enter the MODE menu.

3.2.1 Mode menu

After the MODE button is pressed, the display switches to the MODE menu, presented in Figure 3-

4.

Figure 3-4: The Mode menu

The MODE menu enables the user to select the appropriate charging menu: IU (by selecting Mode
IU) or UU (by selecting Mode UU).

The UP / DOWN buttons are used for navigation and ENTER for entering the chosen submenu.
The STOP button should be press to exit the Mode menu.

3.2.1.1 Mode IU

If the IU charging menu (Figure 3-5) is not displayed, the user can open the menu by selecting the
Mode IU in the Mode menu.

Figure 3-5: The IU menu

VOLTAGE parameter (Figure 3-5) represents the real-time voltage value of the connected battery.
The parameter is not user-changeable – value is detected automatically once the test cables are
connected to the test object.

The following parameters need to be set before charging is started:

• Charge U. Maximum charge voltage. Maximum value to be set is 300 V DC.

• Charge I. Value of the constant charging current. The maximum current value depends on a

selected charging voltage, but it does not exceed 25 A.

The BAC25A sets automatically the value of Charge U and Charge I parameters depending on the
battery voltage being measured. The Charge I current is set as maximum respecting the battery
voltage level. If the device is / remains connected to the battery charged in the previous test, the
same value of Charge U parameter as in the previous test will be set. However, if the BAC is
connected to a battery string of different nominal voltage comparing to the previous charging,

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Charge U parameter will be set on the value approximately 2% higher than the battery voltage
being measured.
The automatically set values are not obligatory for the charging and can be changed by the user.

NOTE:

In case of a mains power supply interruption, the charging will be postponed until
the supply is restored. As the power supply is restored, the charging continues with
the same parameters as defined by the user before the interruption.

Charging in the IU mode, known as Float charging, is a 2-step process. First step is charging the
battery with the constant, user-selectable, current. The process continues until the battery voltage
reaches the predefined Charge U voltage (or Float voltage). After the Charge U voltage is reached,
charging continues with constant voltage which equals to the Charge U voltage.

As soon as the battery reaches the Charge U voltage, the device switches to the constant voltage
charging and the charging current begins to decrease. Charging current decreases continuously
during the constant voltage (float voltage) charging. Charging is stopped when a preset minimum
current value, which indicates a full charge, has been reached.

Values of both parameters are set by pressing the UP / DOWN buttons. Pressing the RIGHT
button enables the user to navigate through the menu and to set values for each digit separately.
Once the parameters are selected, ENTER should be pressed to confirm the selection.

This charging mode is usually used for nickel-cadmium and nickel-metal hydride cells or batteries.

3.2.1.2 Mode UU

If a battery requires Boost charging, or constant voltage charging, Mode UU (Figure 3-6) should be
selected in the Mode menu.

Figure 3-6: The UU menu

VOLTAGE parameter (Figure 3-6) represents the real-time voltage value of the connected battery.
The parameter is not user-changeable – value is detected automatically once the test cables are
connected to the test object.

The following parameters need to be set before charging is started:

• Boost U. Boost charging is when the charger voltage level is raised to a level somewhat

higher than the float charge voltage in order to “equalize” the voltage levels of the individual

cells or achieve a quicker recharge.

• Float U. Float charging is the normal charging method where the battery is recharged and
maintained in a fully charged condition by “floating” the battery at a voltage level that will keep

the battery charged.

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• Boost I. Boost current represents the maximum current (current limit) value at which the

BAC25A will boost (equalize) the battery.

The BAC25A sets automatically the value of Boost U and Float U parameters depending on the
battery voltage being measured. If the device is / remains connected to the battery charged in the
previous test, same values of Boost U and Float U parameters as in the previous test will be set.
However, if the BAC is connected to a battery string of different nominal voltage comparing to the
previous charging, Boost U and Float U will be set on the value approximately 2% higher than the
battery voltage being measured.
The automatically set values are not obligatory for the charging and can be changed by the user.

NOTE:

In case of a mains power supply interruption, the charging will be postponed until
the supply is restored. As the power supply is restored, the charging continues with
the same parameters as defined by the user before the interruption.

Charging in the UU mode, known as Boost charging, is a 2-step process. The first step is constant
voltage charging until the battery reaches the preselected Boost U voltage. Maximum charging
current that can be generated during the boost charging is user-defined (Boost I) which protects
battery of being damaged of high current. Charging will not terminate if Boost I value is reached – it
will be continued with current not higher than Boost I, until Boost U voltage is reached. Once this
voltage is reached, the charger will source enough current to hold the voltage of the battery at this
constant voltage (hence, the reason it is called constant voltage charging). Otherwise, if the battery
current doesn’t reach the current limit, the charger will charge at the selected boost voltage and the
current will decrease over time.

3.2.2 Limits menu

Limits settings is displayed by pressing the LIMITS button on the device. After pressing the LIMITS
button the device switches to the following screen:

Figure 3-8: The Limits menu

It is not necessary to enable any limit for conducting a charging / supply test. However, defining
test limits make the charging more customized, helping to adjust the parameters to the object that
needs to be charged / supplied. The following parameters can be enabled in the LIMITS menu:

• Boost T. Total boost charging time when the BOOST charging process ends. The device
switches to the float charging mode as this time is reached. This limit is active only for
charging in the UU mode.

• STOP U: Battery voltage value which ends the charging process.

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• STOP I: The value of charging current which ends the charging process.

• STOP T: The period after the charging ends automatically.

The RIGHT button is used for navigation, and UP / DOWN buttons to set desired values.

NOTE:

Whether a limit is active during the charging test depends on a selected charging
mode. All four limits can be active only in UU mode, while the Boost T limit is not
active in the IU mode.

In order to activate the limits of BOOST T, STOP U, STOP I and/or STOP T (YES or NO) the

RIGHT button should be used to move the cursor to the position of the limit status, and using UP /
DOWN buttons to select YES or NO option (Figure 3-8).

The charging process will stop automatically if any of the following parameters reaches its pre-set
value: STOP U, STOP I and STOP T (Figure 3-9). However, when Boost T parameter is reached in
UU mode, the BAC25A will switch to Float charging without interrupting the test.

Figure 3-9: STOP messages

The ENTER button is used to confirm limit values after the parameters are enabled and set. After
pressing the ENTER button, the display switches to the main charging / supply menu (Figure 3-3,
3-5 or 3-7, depending on the previously selected mode).

NOTE:

The LIMITS button is active during the charging process. The user can change any
of the displayed parameters (Figure 3-8) without interrupting the test. To do so, the
LIMITS button should be pressed in order the LIMITS menu to be displayed. After
pressing the ENTER button, all modifications are accepted in real time and the test
continuous with respect to the new parameters.

3.2.3 Set menu

Pressing the SET button on the device the following screen appears on the display:

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Figure 3-10: The Settings menu

The UP and DOWN buttons are used for navigation and ENTER for entering the chosen submenu.
Alarm values are the first parameters to be set. After entering the SET ALARM submenu, the
instrument switches to the following screen:

Figure 3-11: The Alarm menu

There are two alarm parameters which values can be set by using the UP/DOWN buttons:
Overvoltage (indicating that the battery voltage is overcharged) and Undervoltage (indicating low
battery charge level).

The RIGHT button is used for navigation, and enables the user to set the value for each digit
separately. After setting the alarm values, it is necessary to set the status of ALARM (YES or NO).

Using the RIGHT button the cursor can be moved to the position of ALARM status, and using the
UP/DOWN buttons can be selected NO (as in Figure 3-11) or YES option.

All changes are accepted by pressing ENTER which switches the display to the main menu (Figure
3-3, 3-5 or 3-7, depending on the previously selected charging / supply mode).

NOTE:

The values of 145,0 V for Overvoltage and 125,0 V for Undervoltage limit are saved
as default. If the user changes the values of the default limits, the new limits will be
saved as default and be set automatically in the ALARM menu.
Limits will be restored to default ones in case of a firmware upgrade.

NOTE:

The ALARM menu is active during the charging process. The user can change any
of the alarms without interrupting the test. To do so, the SET button should be
pressed in order to be entered into the ALARM menu. After pressing the ENTER
button, all modifications are accepted and the test continuous with respect to the
new limit settings.

After entering the TIME & DATE submenu the instrument the following screen will be displayed:

Manual BAC25A

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Figure 3-12: The Time and Date menu

The RIGHT button is used for navigation, and UP / DOWN buttons to set desired values of time
and date.

Date format can be changed by pressing UP / DOWN buttons when cursor is placed on the
FORMAT parameter. One of three date formats can be selected:

1. YYYY-MM-DD

2. DD-MM-YYYY

3. MM-DD-YYYY

All changes are accepted by pressing the ENTER button which switches the display to the main
menu (Figure 3-3, 3-5 or 3-7, depending on the previously selected charging / supply mode).

After entering the SET LANGUAGE submenu the following screen is displayed:

Figure 3-13: The Language menu

The active language can be changed by using UP / DOWN buttons. Pressing the ENTER button
the language change is confirmed and the display switches to the main menu (Figure 3-3, 3-5 or 3­7, depending on the previously selected charging / supply mode).

3.3 Charging

After the charging / supply mode is selected and requested limits / alarms are set, the user can
start the charging / supply.

3.3.1 IU mode

Once the parameters are set in the main manu, ENTER should be pressed to confirm the selection
and Ready to charge screen will be displayed (Figure 3-14).

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Figure 3-14: The Ready to charge screen

Up to two enabled limits can be displayed on the Ready to charge screen for final, pre-test
verification. If the user needs to modify any limit settings before the charging is started, STOP
button should be pressed to exit the Ready to charge screen (which will enable the LIMITS button).

In case limit settings are satisfactory, charging can be initiated by pressing the START button.

Figure 3-15: The Charging screen

The Charging screen provides information on charging voltage, charging current and duration.
Green and red LEDs flash alternately during the charging process.

If the user decides to change the charging voltage value during the charging process, it can be
achieved by pressing the MODE button (Figure 3-16).

Figure 3-16: The Charging screen

Once the parameter is reset, the ENTER button should be pressed to display the Charging menu
(Figure 3-15).

Besides charging voltages, limit and alarm settings can be reset during the test. By pressing Limits
button, the Limits menu is displayed (Figure 3-17) enabling limit parameters reset. Changes are
confirmed by pressing ENTER and the display switches back to the Charging screen.

Figure 3-17: The Limits menu

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The alarm settings can be reset by pressing the SET button during the charging, which displays
the ALARM menu (Figure 3-18).

Figure 3-18: The Alarm menu

Changes are confirmed by pressing ENTER and the display switches back to the Charging screen.
If Overvoltage or Undervoltage value is reached, the buzzer is on and the appropriate message is

displayed (Figure 3-19). The charging is not interrupted in case alarm messages are displayed.

Figure 3-19: The alarm messages

The charging can be terminated in several ways:

- If a preselected limit is reached (STOP U, STOP I or STOP T),

- If the user presses the STOP button.

If a STOP U, STOP I or STOP T limit is reached and the charging is stopped, the corresponding
message is displayed while the buzzer is on. In case the user manually stop the test by pressing
the STOP button, the message Charging stopped is displayed and the buzzer is on (Figure 3-20).
In both cases, the user should press the STOP button to turn off the buzzer while the display will
switch to the main IU screen (Figure 3-3).

Figure 3-20: STOP messages

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3.3.2 UU mode

Once the parameters are set in the main manu, ENTER should be pressed to confirm the selection
and Ready to charge screen will be displayed (Figure 3-21).

Figure 3-21: The Ready to charge screen

Up to two enabled limits can be displayed on the Ready to charge screen for final, pre-test
verification. If the user needs to modify any limit settings before the charging is started, STOP
button should be pressed to exit the Ready to charge screen (which will enable the LIMITS button).

In case limits settings are satisfactory, charging can be initiated by pressing the START button.

Figure 3-22: The Charging screen

The Charging screen provides information on charging voltage, charging current and duration.
Green and red LEDs flash alternately during the charging process.

If the user decides to change a charge voltage during the charging process, it can be achieved by
pressing the MODE button (Figure 3-23).

Figure 3-23

Once Boost U and / or Float U parameter is reset, the ENTER button should be pressed to display
the Charging menu (Figure 3-22).

Besides charging voltages, limit and alarm settings can be also reset during the charging. By
pressing Limits button, the Limits menu is displayed (Figure 3-24) enabling limit parameters reset.
Changes are confirmed by pressing ENTER and the display switches back to the Charging screen.

Manual BAC25A

M-B025CN-300-EN 21

Figure 3-24: The Limits menu

The alarm settings can be reset by pressing the SET button during the charging. The ALARM
menu is displayed (Figure 3-25).

Figure 3-25: The Alarm menu

Changes are confirmed by pressing ENTER and the display switches back to the Charging screen.
If Overvoltage or Undervoltage value is reached, the buzzer is on and the appropriate message is

displayed (Figure 3-26). The charging is not interrupted in case alarm messages are displayed.

Figure 3-26: The alarm messages

The charging can be terminated in several ways:

- If a preselected limit is reached (STOP U, STOP I or STOP T),

- If the user presses the STOP button.

If a STOP U, STOP I or STOP T limit is reached and the charging is stopped, the corresponding
message is displayed while the buzzer is on (Figure 3-27). In case the user manually stop the test
by pressing the STOP button, the message Charging stopped is displayed and the buzzer is on. In
both cases, the user should press the STOP button to turn off the buzzer while the display will
switch to the main UU screen (Figure 3-6).

Manual BAC25A

M-B025CN-300-EN 22

Figure 3-27: STOP messages

The charging will not be terminated in case Boost T parameter is reached. The BAC25A will switch
to the Float charging while corresponding message is displayed.

Figure 3-28: The Float charging message

3.3.3 Charging Parameters

The maximum charging current for a certain battery voltage range, with the minimum achievable
cell voltage of 1,75 V is shown in the Table 3.1. The highest resolution of the reading is always
displayed.

Table 3.1: Maximum currents for various battery voltages at 220 V mains power supply

Battery
voltage

Min-Max

voltage

Max. charge

current

12 V
10,5 V

25 A

14,1 V

24 V
21,0 V

25 A

28,2 V

48 V
42,0 V

25 A

56,4 V

60 V
52,5 V

20 A

70,5 V

110/120 V

96,3 V

20 A

141,0 V

220/240 V

192,5 V

10 A

282,0 V

Manual BAC25A

M-B025CN-300-EN 23

Table 3.2: Maximum currents for various battery voltages at 110 V mains power supply

Battery
voltage

Min-Max

voltage

Max. charge

current

12 V
10,5 V

20 A

14,1 V

24 V
21,0 V

20 A

28,2 V

48 V
42,0 V

20 A

56,4 V

60 V
52,5 V

15 A

70,5 V

110/120 V

96,3 V

10 A

141,0 V

220/240 V

192,5 V

6 A

282,0 V

Table 3.3: Resolution and full scale for each charging range

Full scale

Resolution

Voltage

range

0 – 125 V

0,1 V

125 – 300 V

0,1 V

0 – 15 A

0,1 A

15 – 40 A

0,1 A

3.3.4 Charging Rates

Batteries can be charged at different rates depending on the requirement. Typical rates are shown
below:

• Slow Charge = Overnight or 14-16 hours charging at 0,1C rate

• Quick Charge = 3 to 6 Hours charging at 0,3C rate

• Fast Charge = Less than 1 hour charging at 1,0C rate

NOTE:
It is important to provide a good connection between the clamps and the

connecting point on the test object to achieve stable and accurate results.

Manual BAC25A

M-B025CN-300-EN 24

4. External Alarm Function

This function is provided and controlled by a relay connected to a connector called “UNDER V” and
“OVER V”(the figure below). This connector and the adequate cable are used for connecting to the

external alarm or battery control panel. The relay specifications are 8 A, 24 V.
The external alarm connector is illustrated in the Figure 4-1. The pins 1, 2 and 3 of the connector

are in use, where 4 pin is not used. Pin 1 corresponds to a common branch of the relay. Pin 3
corresponds to a steady state of the relay and pin 2 corresponds to an active mode. When the
relay closes the circuit between pins 3 and 1 the alarm is not activated, i.e. the alarm is in steady
mode. However, when relay closes the circuit between pins 2 and 1 the alarm is activated.

Figure 4-1: The external alarm connector

The cable, that is usually plugged in the above connector and connected to the external alarm, is
shown in the Figure 4-2.

Figure 4-2: The external alarm cable

Green cable corresponds to pin 2, which is connected to the active mode of the relay.
Brown cable corresponds to pin 3, which is connected to the steady state of the relay.
Yellow cable corresponds to pin 1, which is connected to the common branch of the relay.
The alarm is activated in the following scenarios:

• Alarm value of the string voltage is reached.

• The charge process is stopped because the string voltage limit value is reached.

• Power supply is suddenly interrupted and the device is turned off.

• Sudden connection failure between the device and the charger.

The alarm is acknowledged by pressing the STOP button.

Manual BAC25A

M-B025CN-300-EN 25

5 Alarm Messages

Any operational situation requiring additional attention is indicated by an external alarm or by an
alarm buzz. Furthermore, the display indicates a status message. Press STOP to end the external
alarm or the alarm buzz, or to remove the status message from the display. Press STOP again to
end the charging and to return to the starting menu, if desired so.

5.1 Alarm Message "Overvoltage"

This message appears on the display when the ALARM STATUS in the ALARM MENU is set as
ON and the selected value of the overvoltage is reached. The alarm is activated and the buzzer is
on. The buzzer can be stopped by pressing the STOP button.

Figure 5-1: Alarm message "Overvoltage"

5.2 Alarm Message "Undervoltage"

This message appears on the display when the ALARM STATUS in the ALARM MENU is set as
ON and the selected value of the undervoltage is reached. The alarm is activated with the
continuous sound. The sound can be stopped by pressing the STOP button.

Figure 5-2: Alarm message "Undervoltage"

Note:

If the external alarm for overvoltage and undervoltage is not used, the internal
BAC25A alarm buzzer will be activated the same way instead in all the above
scenarios.

Manual BAC25A

M-B025CN-300-EN 26

6 Error Messages

Any operational error is indicated by the red LED blinking and accompanied by an alarm buzz.
Furthermore, the display indicates an error status message. To stop the alarm buzz, the status
message should be removed from the display. Return to the starting menu by pressing STOP.

If abnormal operating conditions occur during the battery charging, the following error messages
will appear on the display.

6.1 Error message "VS Polarity"

This message is displayed in case the current cables are connected properly but the voltage sense
cables are connected in opposite polarity either on the side of a device or the side of a battery.

Figure 6-1: Error message "VS Polarity"

6.2 Error message "Polarity"

This message is displayed in case the current cables are connected in opposite polarity either on
the side of a device or the side of a battery.

Figure 6-2: Error message "Polarity"

In this case connect the current cables correctly and repeat the charging process.

6.3 Error message "Overcurrent"

This message is displayed if the charge current is higher than the set or maximum permissible
current values.

Figure 6-3: Error message "Overcurrent"

Manual BAC25A

M-B025CN-300-EN 27

6.4 Error message "Overheat"

This message is displayed when the BAC25A internal operating temperature rises too high. The
charging process will be stopped and the alarm activated. In this case, it is necessary to wait for
the test set to cool down and repeat the charging process.

Figure 6-4: Error message "Overheat"

6.5 Error message "Malfunction"

If this message is shown on the display, or if BAC25A cannot operate anymore at all, a serious
internal error occurred. Please do not open BAC25A without permission and instructions given by
IBEKO Power AB. Please refer to ”Manufacturer Contact Information” section for contact
information.

Figure 6-5: Error message "Malfunction"

6.6 Error message "Mains Voltage < 90V"

This message is displayed when the BAC25A mains voltage is below 90 V. The BAC25A must be
restarted to reset the status message.

Figure 6-6: Error message "Mains Voltage < 90V"

Manual BAC25A

M-B025CN-300-EN 28

7 Customer Service

Before calling or sending an e-mail to Customer Service for assistance, please take the following
steps:

• Check all cable connections.

• Try the test on another instrument, if available.

• Perform the troubleshoot procedure.

• Have the following information available: instrument serial numbers, hardware configuration,

and software revision.

• Exact description of the problem, including DUT (Device Under Test), error messages and the
sequence of events before it appeared.

• List of solutions that have been tried.

The Customer Support Department can be reached at:
Local support (Sweden): [phone]
International support: [phone]
E-mail: [email protected]

Note:

We prefer contact via e-mail. Then the case is documented and traceable. Also the
time zone problems and occupied telephones do not occur.

Manual BAC25A

M-B025CN-300-EN 29

8 Packing the Instrument for Shipment

If you need to send the instrument to DV Power for servicing, please contact the DV Power
Customer Service for return instructions at:

Local support (Sweden): [phone]
International support: [phone]
E-mail: [email protected]

Note:

DV Power is not responsible for shipping damage. Please protect each instrument
from shipping and handling hazards carefully. Please ensure protective covers are
securely in place. Instruments should be sent to DV Power freight pre-paid, unless
other arrangements have been authorized in advance by DV Power Customer
Service.

To prepare an instrument for shipment, please follow these instructions:

1. Disconnect and remove all external cables. Do not include manuals, cables, and transducer

connecting rods unless recommended by DV Power Customer Service.

2. Reuse the original packing material if it is available. If it is not, pack the instrument for shipment

according to the instructions for fragile electronic equipment. It is recommended use two-wall
minimum corrugated cardboard box with a minimum 5 cm (2 inch) thick poly foam padding, or a
wooden crate with minimum of 5 cm (2 inch) thick poly foam padding all around.

Manual BAC25A

M-B025CN-300-EN 30

9 Technical Data

9.1 Mains Power Supply

• Connection according to IEC/EN60320-1; C320

• Voltage 90 V – 264 V AC, 50 / 60 Hz, single-phase

• Power consumption up to 3 200 VA

• Fuse 20 A / 230 V, type F

9.2 Output Data

• Output current up to 25 A DC

• Voltage 10 - 300 V DC

• Typical voltage accuracy: ± (0,25 % rdg + 0,25 % FS)

9.3 Environmental Conditions

• Temperature -10 °C to +45 °C / 14 °F to +113 °F

• Maximum relative humidity 95 %

for temperatures up to 31 °C,
decreasing linearly to 40 %
relative humidity at 45 °C

• Pollution degree 2

9.4 Dimensions and Weight

- Dimensions 407 mm x 198 mm x 275 mm

16 in x 7.8 in x 10.8 in
(D x W x H) without handle

- Weight 10 kg / 22 lbs.

9.5 Applicable Standards

• European standards EN 61010-1

LVD 2006/95/EC

• International standards IEC 61010-1

UL 61010-1

CAN/CSA-C22.2 No. 61010-1, 2nd edition,

including Amendment 1

Manual BAC25A

M-B025CN-300-EN 31

10 Accessories

Included

Article No

Mains Power cable

Ground (PE) cable

Recommended

Article No

Current cables 2 x 5 m 6 mm2 (16.4 ft, 9 AWG) with alligator clamps (A2)
isolated

C2-05-06LMA2

Device bag

DEVIC-BAG-00

Cable bag

CABLE-BAG-00

Optional

Article No

Current cables 2 x 10 m 6 mm2 (32.8 ft, 9 AWG) with alligator clamps (A2)
isolated

C2-10-06LMA2

Current cables 2 x 15 m 6 mm2 (49.2 ft, 9 AWG) with alligator clamps (A2)
isolated

C2-15-06LMA2

Current cables 2 x 20 m 6 mm2 (65.6 ft, 9 AWG) with alligator clamps (A2)
isolated

C2-20-06LMA2

Sense cables 2 x 5 m 2,5 mm2 (16.4 ft, 13 AWG) with banana plugs +
dolphin clip

S2-05-25BPDC

Sense cables 2 x 10 m 2,5 mm2 (32.8 ft, 13 AWG) with banana plugs +
dolphin clip

S2-10-25BPDC

Cable for external alarm 2 x 5 m (16.4 ft)

CA-EXABAC-05

Extension cable for external alarm 2 x 5 m (16.4 ft)

E1-EXABAC-05

PT100 temperature indicator

TI-000-PT100

Transport case

HARD-CASE-ME

Manual BAC25A

M-B025CN-300-EN 32

IBEKO Power AB 2016

This Manual is a publication of IBEKO Power AB, 181 50 Lidingö, Sweden. These documents are
protected by Swedish Copyright law and international contracts as intellectual property of the
IBEKO Power AB. The documents contain confidential information of IBEKO Power AB which is
protected by patent, copyright, trademarks or otherwise as inventions, trademarks or creations of
IBEKO Power AB. The reproduction, duplication, transmission or use of these documents or its
contents is not permitted without express prior written consent of the IBEKO Power AB.

IBEKO Power AB shall not be liable for any incidental or consequential damages resulting from the
performance or use of this document or its product. This document has undergone extensive
technical approval before being released. IBEKO Power AB reviews this document at regular
intervals, and includes appropriate amendments in subsequent issues. While every effort has been
made to keep the information herein as accurate and up to date as possible, IBEKO Power AB
assumes no responsibility for errors or omissions or for damages resulting from the use of the
information contained herein. IBEKO Power AB cannot take over liability resulting in any way from
the use of this document or parts thereof. The product information, pictures, drawings and all
technical data contained within this manual are not contractually binding and IBEKO POWER AB
reserves the right to make modifications at any time to the technology and/or configuration without
prior notice.

Insofar as any information, software or documentation is made available, any liability for defects as
to quality or title of the information, software and documentation especially in relation to the
correctness or absence of defects or the absence of claims or third party rights or in relation to
completeness and/or fitness for purpose are excluded except for cases involving willful misconduct
or fraud.

In case of a disagreement between the translation and the original English version of this Manual,
the original English version will prevail.

Manufacturer Contact Information

IBEKO Power AB

Box: 1346, 181 25 Lidingö, Sweden
Fax: [phone]
Local support (Sweden): [phone]
International support: [phone]
E-Mail: [email protected]
Website: http://www.dv-power.com