Lamar Technologies CA 1550 User Manual
INSTRUCTION MANUAL
CA-1550 – CML
BATTERY CHARGER / ANALYZER
Rev. C
Lamar Technologies LLC
14900 40th Ave. N.E., Marysville, WA 98271
Tel: (360) 651-8869 • Fax: (360) 651-6677
www.lamartech.com/power-products
TABLE OF CONTENTS
1
SYSTEM OVERVIEW ... ............................................................
1.1 SYSTEM OVERVIEW... .............................................................. .1
1.2 DISPLAYS AND CONTROLS... .................................................. .2
.1
2 INSTALLATION........................................................................
2.1 LINE VOLTAGE ..........................................................................
2.2 TERMINALS ... ..........................................................................
2.3 SPACE REQUIREMENTS... .....................................................
3 OPERATING GUIDE - CHARGING ... ...................................
3.1 CHARGE CHARACTERISTICS ... ............................................
3.2 CHARGING METHODS ... ........................................................
3.3 PREPARATION FOR CHARGING ... .........................................
3.4 CHARGE TIME ..........................................................................
3.5 SETTING CHARGE VOLTAGE AND CURRENT.........................
4 OPERATING GUIDE - DISCHARGING .................................
4.1 DISCHARGE CHARACTERISTICS ..........................................
4.2 DISCHARGE CAPACITY TESTING ............................................
4.3 PREPARATION FOR TESTING ..................................................
4.4 DISCHARGE TIME ..................................................................
4.5 CUTOFF VOLTAGE .................................................................
4.6 SETTING DISCHARGE CURRENT ..........................................
4.7 TEST COMPLETION AND ANALYSIS... ..................................
...18
...22
.3
.3
...4
...4
...5
...5
...6
..7
..9
.9
.13
.13
.15
.16
.18
.21
5
CALIBRATION AND MAINTENANCE ... ...............................
5.1 OVERVIEW OF CALIBRATION ... ............................................
5.2 VOLTMETER CALIBRATION .....................................................
5.3 AMMETER CALIBRATION ......................................................
5.4 SHUNT VERIFICATION ...........................................................
5.5 DISCHARGE CURRENT OPERATING RANGE .......................
5.6 MAINTENANCE... ......................................................................32
6
TROUBLE-SHOOTING ... .......................................................
7
SPECIFICATIONS ...................................................................
...24
WARRANTY ... ...............................................................................
CERTIFICATION OF CALIBRATION... .......................................
.24
..24
...28
.31
...32
..34
.36
.37
..38
1. SYSTEM OVERVIEW
1 SYSTEM OVERVIEW
1.1 SYSTEM OVERVIEW
The CA-1550 Charger/Analyzer is a self-contained unit for charging and discharge
capacity testing of rechargeable batteries. It has been designed to accurately test,
charge and indicate the emergency capacity of sealed or vented lead-acid or nickelcadmium batteries. Emergency capacity is especially important for aircraft batteries.
The unit comes in a convenient protective carrying case. It is very easy to move
around to accommodate flexibility in the work environment, whether used portable or
in the hangar or battery shop. The flexibility of charge and discharge parameters of
the CA-1550 makes it usable for a wide variety of batteries and voltages. The unit
accurately charges and tests lead-acid batteries of 12 or 24 volts, as well as nickelcadmium batteries of a single cell to 24 volts.
The charge unit of the CA-1550 allows charging at both constant potential and
constant current to give maximum flexibility in selection of charge method. The
charger has an adjustable charge current from 0 to 25 amperes, and an automatic
timer for charge time selection.
The discharge unit of the CA-1550 enables battery capacity testing with a constant
current of 0 to 50 amperes (usually set to 80-100% of the battery's capacity rating) for
a preset time. The unit automatically analyzes the discharge characteristics and
passes or fails the battery depending on the battery’s ability to maintain the
specified minimum voltage for the duration of the test.
1.2 DISPLAYS AND CONTROLS
The CA-1550 has been designed to have very simple and easy to understand
controls and displays.
Two digital panel meters allow viewing of charge and discharge current and
voltage. A digital electronic timer displays elapsed time and can be set to any fixed
duration period. Light indicators display if the unit is in charge or discharge mode and
also indicate battery pass or reject status after a discharge test (see Figure 1-
1).
CA-1550 CHARGER / ANALYZER - OPERATING MANUAL V1.2 Page 1
1. SYSTEM OVERVIEW
Figure 1-1. Controls and displays of CA-1550
CA-1550 CHARGER / ANALYZER - OPERATING MANUAL V1.2 Page 2
2. INSTALLATION
2 INSTALLATION
2.1 LINE VOLTAGE
The CA-1550 can operate on either 115 or 230 volts AC. The desired line voltage
can be changed by opening the unit and modifying the voltage-set jumper(s). The
unit is factory-preset at 115 volts AC.
WARNING: Ensure that the unit is turned off and that no
battery is connected before attempting to open the cover.
CAUTION: Ensure that the unit is set for the appropriate
line voltage before operation.
A. Turn off the unit and remove any battery
B. Open the cover by first unscrewing the two screws on the far right of the
front cover.
C. Locate the four position terminal strip with jumper(s). Note: There is a red
stripe on top of each jumper. Remove the clear plastic cover.
D. Two jumpers are used for 115VAC input and one jumper (across the middle
two screws) is used for 230VAC input. See Figures below.
115 volt AC setting 230 volt AC setting
E. For 230 VAC operation, the 115 VAC plug must be replaced with one for
230 VAC in required configuration.
NOTE: If the plug has to be changed make sure to connect
the green AC line wire to ground.
CA-1550 CHARGER / ANALYZER - OPERATING MANUAL V1.2 Page 3
2. INSTALLATION
Connect the unit to a wall outlet with a 15-20 ampere capacity. Sharing of the line
with other equipment may result in erratic operation if other equipment draws high
pulse or surge currents.
NOTE: The CA-1550 will maintain its operational integrity
with line fluctuation less than ± 10%.
2.2 TERMINALS
Two important points about the DC battery cable and connector are:
A. If the aircraft battery quick disconnect connector is removed, the ring
terminals can be used to connect to a post terminal battery.
WARNING: Correct polarity must be observed.
B. If the cable is extended or repaired during maintenance, the sensing leads
which run with the heavy DC cable must be connected to the new terminal
(see section 5.6).
2.3 SPACE REQUIREMENTS
The CA-1550 system comes in a sturdy transit case. It occupies 17" x 20" (432 mm x
508 mm) of table top space. Place the unit on a sturdy workbench in a wellventilated area with the battery adjacent to it.
The top of the unit has air flow from hot resistors. Always leave the cover open and
the resistor vent uncovered when in operation, to maintain proper air flow.
NOTE: In non air-conditioned rooms it is recommended
that circulating or extracting fans be used to aid in the
removal of heated air.
NOTE: Operation in dusty or otherwise dirty air
environments will severely reduce the cooling capacity of
the fans and can lead to premature failure.
CA-1550 CHARGER / ANALYZER - OPERATING MANUAL V1.2 Page 4
3. OPERATING GUIDE - CHARGING
3 OPERATING GUIDE - CHARGING
3.1 CHARGE CHARACTERISTICS
The constant current charge characteristics of a lead-acid cell with respect to cell
voltage, ampere-hours input, specific gravity and rate of gassing at constant
current can be seen in Figure 3-1.
Figure 3-1. Charge characteristics of a lead-acid cell
As shown by the curve in Figure 3-1 the cell voltage of a discharged battery rises
rapidly when the battery is first placed on charge. The extent of the initial rise
depends on the charging rate. As the charge continues, the voltage rises at a
slower rate and eventually levels off when a full state-of-charge is reached. It can
be seen that the specific gravity reading lags behind the rate of ampere-hour return
during most of the charging cycle. Consequently, the specific gravity is not
indicative of the available ampere-hour capacity until the cell approaches a fullcharge state.
When a battery reaches a full state-of-charge the voltage of the battery will
stabilize and remain constant or decrease. The charging should discontinue at this
stage. A minimum of 100% of previous discharge should be placed in the battery.
In general a vented battery may be charged at any rate that will not produce
excessive gassing or electrolyte temperatures above 115°F (46°C). Sealed lead-
CA-1550 CHARGER / ANALYZER - OPERATING MANUAL V1.2 Page 5
3. OPERATING GUIDE - CHARGING
acid batteries should never be charged in a constant-current mode with a current
greater than C1/10 (C1equals the rated capacity of the battery). During constant
current charging at a rate in excess of C /10, oxygen is produced at an excessive rate.
The resulting increasing pressure will cause the cell to vent. Venting of
gasses results in a depletion of electrolyte. As the electrolyte cannot be replaced in a
sealed battery, the cell will dry out resulting in a decrease in capacity and
eventually battery failure. Therefore constant-potential charging is the
recommended charge method for sealed batteries (SLAB).
3.2 CHARGING METHODS
There are two main methods of charging a battery: 1) constant current; and 2)
constant potential. In what follows both methods will be described in some detail.
3.2.1 CONSTANT-CURRENT CHARGE METHOD (CI)
In this method the current remains at a preset level while the voltage can reach a
high level, e.g. 34-37 volts.
An advantage of the constant-current charge method is that the ampere-hour input
into the battery can be determined precisely by multiplying the charging current
with the charge time in hours. However, it is necessary to ensure that the battery is
not charged at a high rate for an excessive period of time. Such overcharging can
result in overheating, excessive gassing, and possible damage to the battery.
3.2.2 CONSTANT-POTENTIAL CHARGE METHOD (CP)
A charge source applies a fixed (constant) voltage (potential) to the battery. The
current supplied by the charge source fluctuates (rises and falls) with the battery
voltage.
There are several advantages of the constant-potential charge method. First, there
is less danger of gassing at an excessive rate. Secondly, batteries of the same
nominal voltage but with different capacities can be connected in parallel directly to
the charging source. Thirdly, batteries are charged more rapidly and with less
attention.
3.2.3 LEAD-ACID BATTERIES
With the constant-current charge method the voltage can climb to 34-37 volts.
Therefore, this method should normally not be used to charge lead-acid batteries,
especially not the sealed type (SLAB). It is preferred to charge a sealed lead-acid
battery in constant-potential mode at a voltage of 28.6 ± 0.2 volts for four hours or
until the charge current drops below one ampere.
CA-1550 CHARGER / ANALYZER - OPERATING MANUAL V1.2 Page 6
3. OPERATING GUIDE - CHARGING
The constant-current charge method can however be used for reconditioning
SLAB’s. The current must be set low and the timer set to 12-18 hours. The battery
should be periodically monitored for overheat during reconditioning. When the battery
begins to accept charge current, it can be switched to constant-potential charging set
to 14.5 (12 volt battery) or 28.6 volts (24 volt battery).
3.2.4 NICKEL-CADMIUM BATTERIES
Nickel-cadmium batteries may be initially charged with constant potential set to
14.5 (12 volt battery) or 28.6 (24 volt battery). After the initial charge the batteries
could be topped with a low constant-current (usually C
1/10) charge to 1.55 volts
per cell.
The nickel-cadmium can also be completely charged in the constant-current mode.
The current would be adjusted to a lower rate for topping. A low constant current
applied during a long time can also be used to eliminate fading, previously called the
“memory effect”, from nickel-cadmium batteries.
Refer to your manufacturer’s maintenance manual for the recommended
discharge times.
3.3 PREPARATION FOR CHARGING
Before starting charging the battery, read the component maintenance manual
(CMM) or the operating and maintenance manual (OMM) for the specific battery.
Ensure that the charge time and current or voltage from the battery manufacturer
are followed.
It is recommended that a visual inspection of the battery is carried out in
conjunction with testing and charging batteries. The charging, unless otherwise
specified in the manufacturer's CMM/OMM, shall be conducted at room ambient
temperature of 70°F to 85°F (21°C to 29°C).
1.1.1 VERIFY END VOLTAGE
The end voltage (in all charge modes) can be verified by the following steps: 1)
turn unit power off; 2) disconnect any battery; 3) turn charge current to max; 4) turn
unit power on; and 5) verify the end voltages on the CA-1550 digital voltmeter (see
also Modify Constant Potential in section 3.5).
WARNING: Always turn the AC power switch off before
connecting or disconnecting a battery
NOTE: Once set, all settings are maintained and need not be
reset for duplicate charging
CA-1550 CHARGER / ANALYZER - OPERATING MANUAL V1.2 Page 7
3. OPERATING GUIDE - CHARGING
A. SWITCH OFF MAINS POWER
Turn off the AC on-off/reset power switch.
B. TURN DOWN CHARGE CURRENT
Repeatedly turn the Ampere Adjust knob fully
counter-clockwise to set charge current to
zero.
CA-1550 CHARGER / ANALYZER - OPERATING MANUAL V1.2 Page 8
3. OPERATING GUIDE - CHARGING
3.4 CHARGE TIME
3.4.1 TIMER UNIT SETTING
The CA-1550 has a built in timer, allowing charge time settings from .1-999.9
minutes.
3.4.2 CHARGE TIME SETTING
The charge time will be set based on the state of charge of the battery and at
which rate the battery is being charged.
C. SET TIMER
Set the timer by pushing the up/down buttons
to the required charge time.
D. SELECT CHARGE MODE
Turn the Mode Select knob to the desired
charge mode: 1) Constant potential, CP; or 2)
Constant current, CI.
NOTE: The factory-presets are 14.5 and 28.6
volts in constant-potential mode can, if desired,
be modified in step E.
3.5 SETTING CHARGE VOLTAGE AND CURRENT
The CA-1550 provides maximum flexibility in setting charge parameters. Both the
current and the voltage can be modified to accommodate different battery voltages
and charge methods.
CA-1550 CHARGER / ANALYZER - OPERATING MANUAL V1.2 Page 9
3. OPERATING GUIDE - CHARGING
E. MODIFY CONSTANT POTENTIAL
If charging in constant-potential mode (CP),
the constant charging voltage can be
modified. This has to be done before
connecting the battery.
1. Turn on the AC on-off/reset power switch.
2. Turn the Constant Potential Adjust
Trimpot until the desired voltage is
obtained. The voltmeter will display the
voltage as it is being adjusted.
3. Turn off the AC on-off/reset power switch
when voltage has been adjusted.
CAUTION: Ensure the unit is turned off
before connecting the battery.
F. CONNECT BATTERY
Connect the battery DC cable to the battery.
Ensure the connectors are plugged in
completely.
NOTE: The factory-presets are 24.5 and 28.6
volts in constant-potential mode can, if desired,
be modified in step E.
G. SWITCH ON MAINS POWER
Turn on the AC on-off/reset power switch. The
voltmeter reads the battery terminal voltage,
the ammeter reads zero. The timer reads 0’s
and its red LED is off.
CA-1550 CHARGER / ANALYZER - OPERATING MANUAL V1.2 Page 10
H. SET CHARGE CURRENT
1. CONSTANT-CURRENT
CHARGING
Turn the Ampere Adjust knob until the
desired charge current has been reached.
The charge current is displayed on the
ammeter as the current is being adjusted.
2. CONSTANT-POTENTIAL
CHARGING
Turn the Ampere Adjust knob to max (fully
clockwise) or to the desired current limit. The
charge current is displayed on the ammeter as
the current is being adjusted.
NOTE: The CA-1550 has a current limit of 25
amperes.
3. OPERATING GUIDE - CHARGING
I. WAIT FOR CHARGE TO AUTOMATICALLY COMPLETE
During the charging of the battery the battery voltage, charge current, and
elapsed charge time are displayed.
1. CONSTANT-CURRENT CHARGING
The current remains constant while the voltage increases during the time of
charging.
2. CONSTANT-POTENTIAL CHARGING
The charger’s end voltage remains constant while the current starts at a
high value and gradually approaches zero as the battery approaches a full
charge.
The actual charge voltage in both modes is determined by the battery, until
the constant voltage is reached (28.6 volts or 35 volts in constant-current
mode).
The test completes when the set charge time has been reached. The Off
lamp illuminates.
For the constant-current method, if a second charging is desired (topping)
repeat steps C, H, and I, with the current adjusted to a lower value (usually
C1/ 10)
CA-1550 CHARGER / ANALYZER - OPERATING MANUAL V1.2 Page 11
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