Analytic Systems IBC320 User manual

INSTALLATION &

OPERATION MANUAL

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

IBC320

Intelligent Battery Charger

Revised - March 9, 2018

AC SOURCE BATTERY CHARGER

IMPORTANT SAFETY INSTRUCTIONS

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

Medical Equipment Notice

Analytic Systems does not recommend the use of their products in life support

applications where failure or malfunction of the 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 another electrical part and 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 the area around battery is well ventilated.

vii. Clean the battery terminals regularly. 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.

Specications

Input

Volts (VAC) 85 - 265, 1 Phase, 45 - 65 Hz

Current (max) * 4 Amps w. Inrush Protection

Input Fuse AGC 5 Amp

Power Factor > 0.99 at Full Load

Efciency > 90% at Full Load

*Maximum Input Current Specied at 85 VAC

Output

Nominal Voltage (VDC) 12 24 28 32 36 48

Voltage Range (VDC)** 12.0-15.5 24.0-31.0 28.0-36.2 32.0-41.3 36.0-46.5 48.0-62.0

Output Current (A) 20 10 8 7.5 7 5

Recommended Battery Amp-Hours 100 50 45 40 33 25

Std. Temperature Compensation -15mV/C -30mV/C -35mV/C -40mV/C -45mV/C -60mV/C

Number of Battery Banks 1 or 2

Charging Stages 2 or 3 stage (user-selectable)

End of Charge Float or Rest (user-selectable)

** Actual Output Voltage determined by User Settings or by Charger Firmware

Mechanical

Dimensions 9.5 in./24.1 cm Long x 8.0 in./20.3 cm Wide x 3.25 in./8.3 cm High

Clearance 2.0 in./5.0 cm all around

Weight 6.2 lb / 2.8 kg

Material and Finish Marine Grade Black Anodized Aluminum with 18-8 Stainless Fasteners

Mounting Wall or Shelf Mount

Connections DC Output - Phoenix VDFK Terminal Block (Red and Black)

AC Input - One 6-foot (2-meter) cable ending in a NEMA 5-15 plug

Environmental and Safety

Operating Temperature Range -25°C+ to +40°C (-40°C to +55°C Optional)

Storage Temperature Range -55°C to +85°C

Humidity 0 - 95% Relative Humidity (non-condensing)

Vibration Built to meet MIL810g

Emissions Complies with FCC Class B, Part 15

Isolation > 1500 VDC Input-Output, Input-Case, Output-Case

Audible Noise None (Ø db)

Duty Cycle Continuous

Warranty Five Years Parts and Labor

Safety Built to meet ABS, CE, UL458 and CSA 22.2.107.1

* Specications subjects to change without notice.

Introduction

The IBC320 Intelligent series Battery Charger delivers up to 300 watts of precision charging

power to charge up to two 12, 24, 32, or 48 volt battery systems (the batteries must share a

common ground).

This unit uses advanced Power Factor Correction circuitry on the AC input to use the electricity

in the most effective and efcient way and will work from any standard AC voltage worldwide.

Inside, LLC Resonant Converter technology allows Zero Voltage/Zero Current switching on

the primary or high voltage side of the main power transformer, while active rectication on

the secondary or low voltage side ensures maximum efciency and minimum electromagnetic

interference (EMI) for operation near sensitive radio frequency communication equipment.

The charger is pre-programmed with the charging proles for three standard types of Lead

Acid batteries; Flooded (traditional Lead Acid), AGM (Absorbed Glass Mat Lead Acid) and Gel

or VRLA (Valve Regulated Lead Acid). A fourth prole pre-set for a typical Lithium Ion battery

is also available. These proles can be further customized by choosing 2 or 3 stage charging

using the stage select switch on the front panel.

Any of the charging proles can adjusted to suit any specic make and model of battery using

the free-to-download PowerWizard software from www.analyticsystems.com. PowerWizard

adds advanced algorithm reprogramming, charger monitoring and graphing function all acces-

sible through the front panel USB port.

On the front panel, the charger comes standard eight dual color LEDs to clearly indicate charg-

ing levels and operating condition. Two sets of easy-to-use color coded battery connection

terminals. Two battery temperature sensor ports are available for connection with the supplied

battery temperature sensor (a second sensor can be added for monitoring two bank systems).

The charger uses the temperature data to compensate the output voltage for optimal charging

as well as for monitoring purposes to prevent the battery from overheating during charg-

ing and equalize cycles. Other safety features include charger over temperature shutdown,

current limiting, short circuit protection, input under voltage shutdown and output over voltage

protection all with automatic recovery.

We are condent that this charger will provide you with many years of safe and reliable

service.

Main Parts

Package Contents

The box should contain:

• One IBC320 Intelligent Battery Charger

• One Battery Temperature Sensor (a second sensor is available from Analytic Systems or

your dealer at additional cost, if required)

• One USB to Laptop cable

• This user guide (a .pdf copy can be downloaded from www.analyticsystems.com)

• One Warranty Registration Card

• The ‘PowerWizard’ software can be downloaded from www.analyticsystems.com

If anything is damaged or missing, please contact us by emailing [email protected]

1. Battery Temperature Sensor

Connection

2. MicroUSB Communications Port

3. Indicator LED Panel

4. Lighted Power Button

5. Program Push Button

6. Stage Select Switch

7. End-of-Charge Function Switch

8. Select/Equalize Push Button

9. DC Output Connection: Phoenix VDFK

Terminal Block (Red and Black)

Front Panel

1. AC Input Connection: One 6 foot (2 meter)

power cord ending in a NEMA 5-15 Plug

Rear Panel

Operation

1. Connect the unit to the battery and AC power source.

2. Press the Power Button on the unit’s front panel.

3. The charger will go through its startup sequence. All 6 microprocessor-controlled LEDs

ash red and then green. When the Power Button starts glowing, the sequence is

complete.

4. The charger will automatically begin charging the connected battery or batteries accord-

ing to the settings selected during setup. See Conguration Mode for more information.

The IBC320 battery charger is designed for simple and intuitive operation. It is intended to

operate fully unattended and will attempt to recover from any fault, including Charger Over-

Temperature, Battery Over-Temperature, Low Input Voltage, AC Power Failure and more.

BATTERY CHARGER MODE

POL

TEMP

DEV

SVC

FLT

LO V

BAT

CHARGING CURRENT 60-84%

CHARGING CURRENT 40-59% CHARGING CURRENT 11-39%

CHARGING CURRENT 1-10% CHARGE COMPLETE

POL

TEMP

DEV

SVC

FLT

LO V

BAT

POL

TEMP

DEV

SVC

FLT

LO V

BAT

POL

TEMP

DEV

SVC

FLT

LO V

BAT

POL

TEMP

DEV

SVC

FLT

LO V

BAT

CHARGING CURRENT >85%

POL

TEMP

DEV

SVC

FLT

LO V

BAT

In Charger mode, the LEDs indicate the amount of current being supplied to the battery.

This current drops as the battery’s voltage rises.

BLINKING

1. Connect the unit to the load and AC power source.

2. Press the Power Button on the unit’s front panel.

3. The charger will go through its startup sequence. All 6 microprocessor-controlled LEDs

ash red and then green. When the Power Button starts glowing, the sequence is

complete.

4. Press and hold the Power Button until you hear two beeps,to change the unit to Power

Supply mode. The unit will remain in Power Supply mode until switched back to Charger

mode, even if it is turned off.

5. To change the unit back to Battery Charger mode, press and hold the Power Button until

you hear one beep.

POWER SUPPLY MODE

In Power Supply mode, the LEDs indicate the amount of current being drawn by the

load(s).

POL

TEMP

DEV

SVC

FLT

LO V

BAT

POL

TEMP

DEV

SVC

FLT

LO V

BAT

POL

TEMP

DEV

SVC

FLT

LO V

BAT

POL

TEMP

DEV

SVC

FLT

LO V

BAT

POL

TEMP

DEV

SVC

FLT

LO V

BAT

POL

TEMP

DEV

SVC

FLT

LO V

BAT

CURRENT < 10% CURRENT >11 - 39%

CURRENT > 40-59% CURRENT > 60-84%

CURRENT > 85% CURRENT = 100%

In addition to being a battery charger, the IBC320 is also capable of functioning as a power

supply. While in Power Supply Mode, the unit’s functionality is changed in the following

ways:

• The DC outputs will be live regardless of whether or not a battery is detected.

• The End-of-Charge switch and Stage Select switch have no function.

• The Equalize push button has no function.

• The output voltage of the Power Supply is set to the Float Voltage. This value can be

changed using PowerWizard. For more information, see the PowerWizard manual.

BLINKING

Installation

MOUNTING

When mounting your unit, take the following into consideration:

• The indicator LEDs and front panel controls should be easy to see and access.

• There are at least 2 inches of clearance all around the charger for air circulation and heat

dissipation.

• The battery should be close to the charger to easy connection and to prevent trampling of

the wiring.

• If there is possibility of water drippage, such as if the charger is in a marine environment,

install the optional drip shield above the unit.

DC OUTPUT CONNECTION

This unit is equipped with 2 sets of VDFK Phoenix Terminal block connectors as DC Battery

Output Connections. The recommended gauge of wire for this connection is 10AWG. That is

the maximum gauge of wire that the battery connection terminals will accept and provides the

best protection against vibration or breakdown of the wires over time.

The red terminal block connector connects to the positive terminal of the battery. The black

terminal block connector connects to the negative terminal of the battery.

CAUTION: If you are charging two banks of batteries, they MUST share a common ground!

AC INPUT CONNECTION

This unit is equipped with a 6-foot (2-meter) power cord ending in a NEMA 5-15 plug as an AC

Power Input Connection. This plug is suitable for connection with any standard North Ameri-

can wall outlet. Active Power Factor correction allows this unit to work from all conventional

AC voltages.

BATTERY TEMPERATURE SENSOR CONNECTION

This unit is equipped with 2 RJ45 ‘telephone jack’ ports to serve as Battery Temperature Sen-

sor connections. You may connect your sensor to either port. If you are using two sensors to

measure two battery banks, the charger will use the temperature of the warmer battery for its

calculations.

To install the sensor at the battery, you may:

• Slide the sensor so it is ush between the battery and battery platform. Alternatively, the

battery can also be placed on top of the sensor to hold it in place.

• Apply a little silicone RTV sealant to the sensor and stick it to the top of the battery.

If the temperature sensors are not used, the charger will use the default battery temperature

programmed during setup. See Default Battery Temperature for more information.

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