Analytic Systems BCA1050 User manual

INSTALLATION &
OPERATION MANUAL
101-8128 River Way, Delta B.C. V4G 1K5 Canada T. 604.946.9981 F. 604.946.9983 TF. 800.668.3884 (US/CANADA)
www.AnalyticSystems.com
An ISO9001 Registered Company Battery Chargers •Inverters •Power Supplies •Voltage Converters
ANALYTIC SYSTEMS
Power Conversion Solutions
BCA1050/1550
BATTERY CHARGERS
PWS1050/1550
POWER SUPPLIES

Copyright (2005-2020) Analytic Systems Ware (1993) Ltd.
Revised - May 11, 2020

BCA/PWS/1050/1550
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS — This manual contains important safety and operating
instructions for the battery charger.
GENERAL PRECAUTIONS
1. Do not expose the unit to rain or snow unless it is a sealed model.
2. Use of an attachment not recommended or sold by the 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 at-
tempting any maintenance or cleaning. Turning off controls will not reduce this risk.
5. Never place battery charger directly above battery; gases from battery will corrode and
damage battery charger.
6. Never allow battery acid to drip on the battery charger.
BATTERY SAFETY
1. WARNING — RISK OF EXPLOSIVE GASES
i. WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES
GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS
REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE SERVICING
EQUIPMENT IN THE VICINITY OF THE BATTERY, YOU READ THIS USER GUIDE AND
FOLLOW THE INSTRUCTIONS EXACTLY.
ii. To reduce risk of battery explosion, follow these instructions and those published by
the battery manufacturer and manufacturer of any equipment you intend to use in
vicinity of battery. Review the cautionary marking on these products.
2. PERSONAL PRECAUTIONS
i. Someone should be within range of your voice or close enough to come to your aid
when you work near a battery.
ii. Have plenty of fresh water and soap nearby in case battery acid contacts skin,
clothing, or eyes.
iii. Wear complete eye protection and clothing protection. Avoid touching eyes while
working near battery.
iv. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid
enters eye, immediately ood eye with running cold water for at least 10 minutes and
get medical attention immediately

54
MEDICAL EQUIPMENT NOTICE
Analytic Systems does not recommend the use of their products in life support
applications where failure or malfunction of this product can be reasonably
expected to cause failure of the life support device or to signicantly affect its
safety or effectiveness. Analytic Systems does not recommend the use of any
of its products in direct patient care. Examples of devices considered to be life
support devices are neonatal oxygen analyzers, nerve stimulators (whether used
for anesthesia, pain relief, or other purposes), auto-transfusion devices, blood
pumps, debrillators, arrhythmia detectors and alarms, pacemakers, hemodialysis
systems, peritoneal dialysis systems, neonatal ventilator incubators, ventilators
for both adults and infants, anesthesia ventilators, and infusion pumps as well as
any other devices designated as “critical” by the U.S. FDA.
DANGER: Never alter the AC power cord or plug provided. If it will not t the
output, use an approved adapter or have the proper AC power cord installed by a
qualied electrician. Improper connection can result in the risk of electric shock.
v. NEVER smoke or allow a spark or ame in the vicinity of a battery.
vi. 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.
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 current
high enough to melt metal, causing a severe burn.
viii.NEVER charge a frozen battery.
ix. 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.
x. Be sure area around battery is well ventilated.
xi. Clean the battery terminals. Be careful to keep corrosion from coming in contact with eyes.
xii. 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.

54
TABLE OF CONTENTS
• Front Cover, Product Photo and Title
• Product Warning and Advisories
• Table of Contents
• Introduction
• Front Panel Congurations
• Battery Charger Operation
• Power Supply Operation
• Installation
• AC Input Connection
• DC Output Connection
• Battery Temperature Sensors
• Equalize Cycle
• Product Options
• Troubleshooting
• Specications
• Warranty
ANALYTIC SYSTEMS
Power Conversion Solutions
Revised - June 4, 2020
Copyright Analytic Systems Ware (2020) Ltd.

76
Introduction
The 1050/1550 family of COTS AC-source battery chargers (BCA) and power supplies (PWS)
are designed to supply a DC load or charge a battery at 12, 24, 32, 36, 48 or 72 (Rail) VDC. The
1050 family provides up to 1000 watts of precision power, while the 1550 family can supply
up to 1550 watts. These 1050 and 1550 families are identical to their previous models (1005
and 1505, respectively) in form, t, and function and is a direct drop in replacement for their
predecessors.
Internally, the recently updated design incorporates a brand new Power Factor Corrected (PFC)
Input Stage. The PFC input stage increases the efciency over the previous auto-switching
technology and eliminates the dead spot between 110 and 220 VAC input allowing the power
supply to run continuously from 90 – 265 VAC In at 45 – 65 Hz. Additionally, heavy input and
output ltering reduce EMI to extremely low levels to prevent radio interference.
These units are constructed from heavy-duty anodized extruded and billet machined aluminum
and all stainless steel fasteners for rugged duty. These units feature a variety of optional
environmental upgrades including IP66 rated construction for service in marine environments
(IP67-rated construction with certication and testing also available). Additionally military
ruggedization upgrades are also available including MIL-spec connectors, expanded operating
temperature and shock and vibration protection.
Reliability features include an LED status indicator panel, input circuit breaker, thermal
shutdown, current limiting, reverse polarity connection protection and output short circuit
shutdown with automatic recovery.

76
Front Panel Congurations
BCA1050/1550
BCA1050W/1550W
5. Stage Select Switch
6. Power Switch
7. AC Input Connection: 3 m / 9.8ft
3xAWG14 power cord with NEMA 5-15 or
CEE 7/VII plug
8. Input Fuse
9. Equalize Start button
1. Indicator LEDs
2. Battery Temperature Sensor
Connection: 2x RJ45 ‘telephone jack’
connector
3. DC Output Connection: 2x Color-
coded Phoenix VDFK6 terminal blocks
4. Output Voltage Adjust
1
2
3
4
5
6
8
9
7
1
2
3
4
5
7
8
6
4. Output Voltage Adjust
5. Stage Select Switch
6. Power Switch
7. AC Input Connection: 3 m / 9.8ft
3xAWG14 power cord with NEMA 5-15 or
CEE 7/VII plug
8. Equalize Start button
1. Indicator LEDs
2. Battery Temperature Sensor
Connection: 4-pin socket panel
mount, ConXall Micro-Con-X, 17882-
4SG-300 connector
3. DC Output Connection: 4x color-
coded ying input leads encased in a
watertight Sealcon gland

98
1
2
3
4
5
7
8
6
BCA1050M/1550M
BCA1050MW/1550MW
1
2
3
4
5
7
8
6
5. Stage Select Switch
6. Power Switch
7. AC Input Connection: Amphenol 3-pin
Circular MIL-spec GTS02R16-10P con-
nector
8. Equalize Start button
1. Indicator LEDs
2. Battery Temperature Sensor
Connection: Amphenol 4-hole Circu-
lar MIL-Spec PT02A-8-4S
3. DC Output Connection: Amphenol
GTC02R22-22S-RDS 4-hole MIL-Spec
connector
4. Output Voltage Adjust
4. Output Voltage Adjust
5. Stage Select Switch
6. Power Switch
7. AC Input Connection: Amphenol 3-pin
Circular MIL-spec GTS02R16-10P con-
nector
8. Equalize Start button
1. Indicator LEDs
2. Battery Temperature Sensor
Connection: Amphenol 4-hole Circu-
lar MIL-Spec PT02A-8-4S
3. DC Output Connection: Amphenol
GTC02R22-22S-RDS 4-hole MIL-Spec
connectors
Front Panel Congurations

98
PWS1050/1550
PWS1050W/1550W
4. AC Input Connection: 3 m / 9.8ft
3xAWG14 power cord with NEMA 5-15 or
CEE 7/VII plug
5. Power Switch
6. Input Fuse
1. Indicator LEDs
2. DC Output Connection: Color-coded
Phoenix VDFK6 terminal blocks
3. Output Voltage Adjust
1
2
3
4
6
5
1
2
3
5
4
4. AC Input Connection: 3 m / 9.8ft
3xAWG14 power cord with NEMA 5-15 or
CEE 7/VII plug
5. Power Switch
1. Indicator LEDs
2. DC Output Connection: 4x color-cod-
ed 8AWG ying input leads encased in
a watertight Sealcon gland
3. Output Voltage Adjust

1110
1
2
3
5
4
PWS1050M/1550M
PWS1050MW/1550MW
1
2
3
5
4
4. AC Input Connection: Amphenol 3-pin
Circular MIL-spec GTS02R16-10P con-
nector
5. Power Switch
1. Indicator LEDs
2. DC Output Connection: Amphenol
GTC02R22-22S-RDS 4-hole MIL-Spec
connector
3. Output Voltage Adjust
4. AC Input Connection: Amphenol 3-pin
Circular MIL-spec GTS02R16-10P con-
nector
5. Power Switch
1. Indicator LEDs
2. DC Output Connection: Amphenol
4-hole Circular MIL-spec GTC02R22-22S-
RDS connectors
3. Output Voltage Adjust

1110
Battery Charger Operation (BCA)
The BCA1050/BCA1550 series battery chargers are designed for simple and intuitive
operation. Before operating, make sure this unit is properly installed and connected. See
Installation for more information.
TO CHARGE A BATTERY
1. Select the type of charging prole using the Stage Select switch on the front panel.
See Charging Proles for more information.
2. Move the Power Switch to ON. The alarm buzzer will sound and the LOW VOLTAGE
OUTPUT LED will glow red briey, then the POWER LED will glow green.
3. The CHARGING LED will glow green and the unit will charge the battery at the voltage
and current listed on the label.
4. Once the battery is fully charged, the CHARGING LED will turn off. The unit will maintain
the battery at full charge for as long as it is connected.
TO ADJUST THE CHARGING (FLOAT) VOLTAGE
The Output Voltage Adjust can be use to adjust the charging (oat) voltage ±1.0V from the
unit’s rated output voltage in order to ne-tune its charging capabilities.
1. On W-series and Y-series models the Output Voltage Adjustis protected by an O-ring
sealed hexagonal plug. This plug can be removed using a 5/8ths inch or 16mm wrench.
2. Move the Power Switch to ON.
3. Rotate the output voltage adjustment potentiometer on the front panel.
4. Rotating the potentiometer clockwise increases the output voltage; counterclockwise
descreases it.
5. Using a voltmeter or multimeter, check the charging voltage at the Output Connection.
Adjust until the voltage reading is suitable. If the unit has the optional digital meter, that
can be used to read the output voltage instead.
6. Replace the hexagonal plug to return the unit to water resistant condition.
TO END OPERATION
1. Move the Power Switch to OFF.
2. Wait for all the LEDs stop glowing.
3. Once all of the LEDs are off, it is safe to disconnect the unit from the power source and
battery. The unit is now ready for storage or service.

1312
Power Supply Operation (PWS)
The PWS1050/PWS1550 series power supplies are designed for simple and intuitve operation.
Before operating the unit, it must be properly installed and connected. See Installation for
more information.
TO POWER A LOAD
1. Move the Power Switch to ON. The alarm buzzer will sound and the LOW VOLTAGE
OUTPUT LED will glow red briey, then the POWER LED will glow green.
2. The POWER LED will glow green and the unit will charge the battery at the voltage and
current listed on the label.
TO ADJUST THE OUTPUT VOLTAGE
The Output Voltage Adjust can be use to adjust the charging (oat) voltage ±1.0V from the
unit’s rated output voltage in order to ne-tune its charging capabilities.
1. On W-series and Y-series models the Output Voltage Adjustis protected by an O-ring
sealed hexagonal plug. This plug can be removed using a 5/8ths inch or 16mm wrench.
2. Move the Power Switch to ON.
3. Rotate the output voltage adjustment potentiometer on the front panel.
4. Rotating the potentiometer clockwise increases the output voltage; counterclockwise
descreases it.
5. Using a voltmeter or multimeter, check the voltage at the Output Connection. Adjust until
the voltage reading is suitable. If the unit has the optional digital meter, that can be used
to read the output voltage instead.
6. Replace the hexagonal plug to return the unit to water resistant condition.
TO END OPERATION
1. Move the Power Switch to OFF.
2. Wait for all the LEDs stop glowing.
3. Once all of the LEDs are off, it is safe to disconnect the unit from the power source and
battery. The unit is now ready for storage or service.

1312
BCA ONLY LEDS
EQUALIZE [1]
THE BATTERY TEMPERATURE SENSOR MUST BE INSTALLED TO USE THIS FUNCTION
This LED glows red when the unit is performing an Equalize cycle. This LED blinks red when
the unit is waiting for a battery to nish charging before performing an Equalize cycle.
BATTERY OVER TEMP [2]
THE BATTERY TEMPERATURE SENSOR MUST BE INSTALLED TO USE THIS FUNCTION.
This LED glows red when the battery’s temperature is above the safe limit, the unit will then
turn OFF its outputs as precaution. Once the battery temperature is within the safe operating
range, the unit will automatically resume operation
Operational Indicators
This unit features seven indicator LEDs on its front panel to display the unit’s operating
condition. The meanings of these LEDs are detailed below. For more information on the LEDs
relating to alarm conditions, see Troubleshooting.
STANDARD LEDS
POWER ON [3]
This LED glows green when the unit is connected to an AC power source and turned ON.
CHARGING[4]
This LED glows green when the unit is currently charging a battery. This LED turns off when
the connected battery is fully charged. The charger will maintain the battery at the oat volt-
age for as long as it is connected.
OVERTEMP [5]
This LED glows red when the unit’s internal temperature is above the safe limit, the unit will
then turn OFF its outputs as a precaution. Once the internal temperature is within the safe
operating range, the unit will automatically resume operation.
LOW VOLTAGE OUTPUT [6]
This LED glows red when the output voltage is too low to properly charge the battery, the unit
will then turn OFF its outputs as a precaution. Once the unit detects the output voltage is
within the normal operating range, it will automatically resume operation.
LOW VOLTAGE INPUT [7]
This LED glows red when the input voltage is too low for proper operation, the unit will then
turn OFF its outputs as a precaution. Once the unit detects the input voltage is within the
normal operating range, it will automatically resume operation.

1514
Installation
MOUNTING
All 1050 and 1550 units weigh approximately
20lbs (9.1 kg) and can be safely mounted on
either a horizontal or vertical surface. Mount
the unit in a dry and well ventilated location at
least 1 inch (2.54 cm) surrounding clearance.
The W-series models are designed to meet
IP66 rating, and is resistant to water spray
from any direction. These units can be
mounted in wet locations but are not suitable
for submersion. The Y-series models are
designed and certied to meet IP67 rating.
These units are resistant to water immersion of a depth up to 1 meter for 30 minutes and suit-
able for mounting in locations such as a vehicle fording a river.
CAUTION: NEVER CONNECT OR DISCONNECT ANYTHING TO THE UNIT’S INPUT OR
OUTPUT WHILE IT IS ON!
To prevent the risk of high voltage electric shock, never connect or disconnect anything to/from the
unit’s input or output connections while the power switch is ON.
GROUNDING
The unit case is connected to AC Ground and AC Neutral in order to meet regulatory
requirements and reduce the possibility of it generating any radio frequency interference.
The unit case must be bonded appropriately to the grounding system of the vehicle or marine
vessel. On a vehicle, bond the case to the vehicle’s frame. On a marine vessel, bond the case
to the vessel’s hull. A grounding stud is provided on the front panel for this purpose.
To ensure proper grounding, check the connection with an ohmmeter. The case is isolated from
the DC input, so the DC power can be connected to a different ground from the AC output.
DISCONNECTING
If you need to disconnect the unit for service or storage:
1. Move the power switch to OFF and disconnect the power source and load
2. With power disconnected, move the power switch to ON.
3. Leave the switch in this position for one minute to discharge the storage capacitors.
4. Return the power switch to the OFF position.
5. The power supply or battery charger is ready for service or storage.

1514
European Union Mains
Brown AC Hot / Phase 1
Blue AC Neutral / Phase 2
Green/Yellow Ground
NA Mains
Black AC Hot
White AC Neutral
Green Ground
1050/1550/1050W/1550W
Regular and W-series BCA and PWS units are equipped with a 1.0m/3.0ft power cord ending
in a NEMA 5-20 plug connector (for North American models) or a CEE7/7 plug connector (for
European models) to serve as an AC Input Connection.
To hard wire this connection a source of power, cut the plug off the wire, and strip the wires
inside as necessary. The wire colors are as follows:
Pin Polarity
Pin A AC Live/Hot
Pin B AC Neutral
Pin C AC Ground
1050M/1550M/1050MW/1550MW
M-series and MW-series BCA and PWS units are equipped with a 3-pin Amphenol circular
MIL-Spec connector to serve as an AC Input Connection. See Specications for more
information regarding suitable mating connectors. This connector’s wiring pin-out can be
found on the front panel label and is as follows:
AC Input Connection
The AC Input connection is intended for connection to the AC power source that is powering
the battery charger or power supply. All 1050 and 1550 units feature Power Factor Correction
technology on the input and can operate from any AC input voltage from 90-265 VAC.
Some units may require wiring to this connection. To determine suitable wiring, the rated
input voltage and current values can be found on the unit label located on the XXXX panel. For
more information, regarding input power specications, see the Specications section.

1716
DC Output Connection
The DC Output Connection is intended for connection to the batteries being charged or DC
load being powered by the battery charger or power supply, respectively. To ensure normal
operation, the total average connected load should not exceed the unit’s output amps rating.
Some units may require wiring to this connection. To determine suitable wiring, the rated
output voltage and current values can be found on the unit label located on the XXXX panel.
For more information, regarding output power specications, see the Specications section.
TIP: WHEN CHARGING MULTIPLE BATTERIES OR POWERING MULTIPLE LOADS,
THEY MUST SHARE A COMMON GROUND.
CAUTION: NEVER CONNECT THE LOAD OR BATTERY IN REVERSE POLARITY!!
This will activate the reverse polarity connection protection which will blow the internal
output fuses in order to protect the device. The unit will be inoperable until these fuses have
been replaced. See Output Fuse Replacement for more information.
CAUTION: NEVER USE A POWER SUPPLY UNIT TO CHARGE A BATTERY!!
PWS power supply units do not have the necessary circuitry on the output to prevent current
from back-feeding into the unit. Using a power supply to charge a battery will damage the unit
and is not covered under the Warranty.
Single Battery/Load
Connection
Dual Battery/Load
Connection
IMPORTANT: 12 VOLT OUTPUT BATTERY CHARGER AND POWER SUPPLY UNITS
WILL ONLY SUPPORT SINGLE BATTERY/LOAD CONNECTION.

1716
Connector Color Polarity
Black Negative
Red Output Positive
1050/1550
Base BCA and PWS units are equipped with two sets of Phoenix VDFK terminal block connec-
tors to serve as a DC Output Connection. This polarity of this connection can be found on the
front panel label and is also as follows:
1050W/1550W
W-series and Y-series BCA and PWS units are equipped with two sets color-coded ying
8AWG input leads encased in a watertight Sealcon gland to serve as a DC Output Connection.
This polarity of this connection can be found on the front panel label and is also as follows:
Wire Color Polarity
Black Negative
Red Output Positive
1050M/1550M/1050MW/1550MW
M-series and MW-series BCA and PWS units are equipped with a Amphenol GTC02R22-22S-
RDS 4-hole MIL-Spec connectors DC Output Connection. The wiring for this connection can be
found on the front panel label and is as follows:
Pin Polarity
Pin A Output Positive 1
Pin B Output Positive 2
Pin C Negative
Pin D Negative

1918
Battery Temperature Sensor (BCA Only)
This unit is supplied with one battery temperature sensor. The sensor communicates the
temperature of the battery to the battery charger and is necessary for the charger’s voltage
temperature compensation, battery over temperature shutdown and equalize cycle functions.
BATTERY TEMPERATURE SENSOR CONNECTION
This unit is equipped with an Amphenol MIL-Spec PT02A8-4S connector to connect to up to
two Analytic Systems waterproof battery temperature sensors. This connection’s pinout can
be found on the unit label.
TO INSTALL THE SENSOR AT THE BATTERY:
• Slide the sensor ush between the side of the battery and wall of the battery platform.
• Place the battery on top of the sensor to hold it in place.
• Apply a small amount of silicone RTV sealant to the sensor and stick it to the top of the
battery.
There are multiple ways to install the sensor at the battery. Regardless of which method you
use, the sensor must be rmly secured and should not lose physical contact with the battery at
any point in the charging cycle.
VOLTAGE TEMPERATURE COMPENSATION
Heat is a normal by-product of the charging cycle. However, excessive heat can cause
overcharging, damaging the battery. With a battery temperature sensor installed, the battery
charger will automatically reduce the charging voltage to compensate for rising temperature.
The ambient battery temperature is pre-set to 77°F (25°C). For each degree above 77°F (25°C),
the charger will reduce the charging voltage by a small amount. See Specications for more
information regarding, the default temperature compensation coefcient of your unit. You can
change the voltage temperature compensation coefcient and set its operating thresholds
using Analytic Systems’ free-to-download software PowerWizard.
Pictured: An Analytic Systems
waterproof battery temperature sensor
(Product:B-TEMPW)

1918
Equalize Cycle (BCA Only)
If a battery is left discharged for too long, sulfate crystals can form on its internal electrode
plates. This interferes with their conductance reducing battery’s capacity and charging speed.
Your battery charger can perform an Equalize Cycle to correct this condition. An Equalize Cycle
ensures all the cells of the battery are fully charged; deliberately overcharging the battery at
a low current (approximately 10% of its normal output) until it reaches the unit’s programmed
Equalize Voltage. The charger maintains the battery at that voltage for three hours after which
time the Equalize Cycle ends and the battery charger resumes normal operation; maintaining
the battery at the oat voltage.
DANGER: AN EQUALIZE CYCLE CAN ONLY BE PERFORMED IN A WELL VENTILATED
AREA!
Hydrogen gas is a normal by-product of the Equalize Cycle and is explosive at concentrations
greater than 4% of the local atmosphere.
CAUTION: A BATTERY TEMPERATURE SENSOR MUST BE INSTALLED AND USED!
Heat is a normal by-product of the Equalize Cycle and excessive heat will damage the battery
bank. The battery temperature sensor must be connected and installed to allow the unit to
monitor the temperature and ensure it is within safe operating limits.
TO PERFORM AN EQUALIZE CYCLE:
1. Connect and install the supplied Analytic Systems Battery Temperature Sensor. See
Installation for more information.
2. Push the Equalize Button on the front panel. On some units, this button is recessed to
prevent accidental operation; a ballpoint pen can be used to access it.
3. If the unit is not currently charging a battery, the EQUALIZE LED will glow red and the
Equalize Cycle will begin.
4. If the unit is currently charging a battery, the EQUALIZE LED will blink red. Once the
charging cycle ends, the CHARGING LED will shut off and the EQUALIZE LED will glow
red and the Equalize Cycle will begin.
5. Three hours later, the Equalize Cycle will end. The battery charger will automatically
resume normal operation maintaining the battery at the oat voltage.

2120
Output Fuse Replacement
This unit features output reverse polarity connection protection. If a load or battery is
connected to the output in reverse polarity, the output fuses will blow to protect the power
supply or battery charger.
The unit is inoperable until the fuses are replaced. See the specications section for rating
and make fuses. When replacing the fuses, ALL the fuses must be replaced as they operate in
parallel.
CAUTION: BEFORE REPLACING THE FUSES, DISCONNECT THE UNIT FROM THE
POWER SOURCE AND MAKE SURE THE POWER SWITCH IS OFF.
To prevent risk of high voltage electric shock, the unit must be fully disconnected from power
before attempting to replace the output fuses.
TO REPLACE THE FUSES:
1. Loosen and remove the ten screws holding the front panel to the chassis.
2. Gently pull the front panel free from the main circuit board. The output fuses are mounted
in fuse holders on the front panel circuit board. Their location is indicated below.
3. Replace the old fuses with new fuses. The new fuses must be the same type and rating
as the old ones. See Specications for more information regarding output fuses.
4. The main circuit board connects to the front panel, via the black square shaped
connectors above the fuses. Gently push the two together to seat them.
5. Make sure that any O-ring seals and gaskets are properly seated. This is very important
for the W/Y models in order to maintain a water-tight seal!
6. Re-insert all the front panel screws loosely, making sure none are cross-threaded. Once all
screws are started, tighten them in sequence. The screws are made from corrosion resistant
stainless steel which is softer that regular steel, so take care to not over-tighten.
7. Reconnect the unit to power and check that it turns ON. Turn the unit OFF and then,
making certain that the polarity is correct, reconnect the load or battery to the output.
Turning the unit ON, normal operation should resume immediately.
Pictured: Front panel circuit board. Output fuse location indicated by red circle.