Analytic Systems BCA1550MW User manual

INSTALLATION &
OPERATION MANUAL
BCA1550MW
AC SOURCE
BATTERY CHARGER
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 ISO9001:2015 Registered Company Battery Chargers •Inverters •Power Supplies •Voltage Converters

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Copyright (2005-2023) Analytic Systems Ware (1993) Ltd.
Revised -Jan 31, 2023

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SAVE THESE INSTRUCTIONS — This manual contains important safety and operating
instructions for the battery charger.
BATTERY CHARGER PRECAUTIONS
1. Do not expose the battery charger to rain or snow unless it is a sealed model.
2. Use of an attachment not recommended or sold by the battery charger manufacturer may
result in a risk of re, electric shock, or injury to persons.
3. Do not disassemble the battery charger; return it to the manufacturer or an authorized
service center when service or repair is required. Incorrect reassembly may result in a
risk of electric shock or re. Voltages in excess of 350 volts are present inside the charger
anytime it is plugged into an AC outlet, even if it is switched off.
4. To reduce risk of electric shock, unplug the battery charger from the AC outlet before 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
AC SOURCE BATTERY CHARGER
IMPORTANT SAFETY INSTRUCTIONS

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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.
i. NEVER smoke or allow a spark or ame in the vicinity of a battery.
ii. 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.
iii. 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.
iv. NEVER charge a frozen battery.
v. 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.
vi. Be sure area around battery is well ventilated.
vii.Clean the battery terminals. Be careful to keep corrosion from coming in contact with eyes
viii.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.

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Copyright (2005-2022) Analytic Systems Ware (1993) Ltd.
Revised - Nov 10,2022
TABLE OF CONTENTS
• Front Cover, Product Photo and Title
• Product Warnings and Advisories
• Table of Contents
• Introduction
• Main Parts/Box Contents
• Operation
• Operational Indicators
• Charging Proles
• Installation
• Battery Temperature Sensor
• Equalize Cycle
• Troubleshooting
• Specications
• Warranty

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Introduction
The BCA1550MW AC-source battery charger provides up to 1500 watts of precision charging
power to charge up to two connected 24V bank battery systems.
Internally, the recently updated design incorporates a Power Factor Corrected (PFC) input
stage allowing the charger to run continuously from 85 – 264 VAC at 50 or 60 Hz with a Power
Factor of 0.99 or better from 10% to 100% load. Heavy input and output ltering reduces EMI
to extremely low levels to prevent radio interference.
These units are constructed with a heavy-duty extruded aluminum chassis and heavy gauge
aluminum front and rear panels with thermostatically controlled cooling fans and all stainless
steel fasteners for rugged duty. These units feature IP66 rated construction.(IP67-rated
construction with certication and testing also available). Additionally military ruggedization
upgrades include MIL-spec connectors, expanded operating temperature and shock and
vibration protection.
Reliability features of this product line include LED status indicators, input circuit breaker,
thermal shutdown, current limiting, reverse polarity battery connection protection, output short
circuit shutdown with automatic recovery and output over-voltage protection.
Box Contents
The box you have received should contain the following:
• One BCA1550MW AC Battery Charger
• One Battery Temperature Sensor
• This Manual
• One Warranty Card
If anything is missing or damaged please contact your dealer or Analytic Systems for a replacement

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Main Parts
1. Battery Temp. Sensor Connection:
PT07A8-4S MIL-Spec Connector
2. DC Output Connection: MS3102E22-
22S circular MIL-Spec Connector
3. Output Voltage Adjust
4. Indicator LEDs
5. Stage Select Switch
6. Power Switch
7. AC Input Connection:
D38999/20WC4PN MIL-Spec Connector
8. Equalize Cycle Start Button
FRONT PANEL
1
7
26
8
3
4
5

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Operation
This unit is 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. Check that the Battery Reversed B1 and B2 LEDs are OFF. If either are glowing, check the
battery connection to insure it is in the correct polarity.
2. Select the type of charging prole using the Stage Select switch on the front panel.
See Charging Proles for more information.
3. 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.
4. The CHARGING LED will glow green and the unit will charge the battery at the voltage
and current listed on the label.
5. 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 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 Adjus tis 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.

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EQUALIZE
THIS FUNCTION REQUIRES THE BATTERY TEMP. SENSOR INSTALLED
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
THIS FUNCTION REQUIRES THE BATTERY TEMP. SENSOR INSTALLED
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
BATTERY REVERSED B1/B2
This LED will glow red when a battery is connected to Output 1/2 in reverse polarity,
respectively. Do not turn the unit ON until this is corrected, failing to do so will damage the
battery charger and is NOT covered under the Warranty.
POWER ON
This LED glows green when the unit is connected to an AC power source and turned ON.
CHARGING
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
voltage for as long as it is connected.
OVERTEMP
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 OUT
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 IN
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.
Operational Indicators
This unit features several 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.

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Charging Proles
This unit has both two-stage and three-stage charging capability. You can choose which type
of charging is used during operation by using the Stage Select switch located on the front
panel. Below are explanations of the two charging proles:
1. The battery is charged at constant
current until the battery’s voltage
reaches the oat voltage.
2. The charging current diminishes as
necessary to maintain the battery at
that voltage.
TWO-STAGE CHARGING
Two-stage charging eliminates any risk of
overcharging the battery if it is connected to
a load while being charged.
THREE-STAGE CHARGING
1. The battery is charged at constant
current until the battery voltage
reaches the absorption voltage.
2. Then the charging current diminishes
as necessary to maintain the battery
at that voltage.
3. Once the charging current drops
below 10% of the rated output,
the charging cycle is complete. The
charger then switches to the oat
voltage to maintain the battery at
full charge.
Three-stage charging is more complete than two-stage, but the charging current must drop
below 10% of the rated output current of the charger for the Absorption Mode to terminate.
For that reason, three-stage charging is not recommended for charging loaded batteries
because the unit cannot differentiate between current going to a load connected to the
battery and current being absorbed by the battery, which may cause overcharging.