Analytic Systems IBC320W 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

IBC320W

Intelligent AC

Battery Charger

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

2 3

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.

Introduction

The IBC320W Intelligent Battery Charger delivers up to 300 watts of precision charging

power to charge a 12, 24, 32 or 48 volt, one or two bank battery system (the batteries must

share a common ground). The charger features IP66-rated dust and water protection and is

built and tested to meet CSA 22.2/ No.107.1/ UL1012 safety standards.

The charger uses advanced Power Factor Correction circuitry on the AC input and will work

from any standard AC voltage anywhere in the world, using the electricity in the most effec-

tive and efficient way. LLC Resonant Converter technology allows Zero Voltage/Zero Current

switching on the Primary or high voltage side of the main power transformer, and Active

Rectification on the Secondary or low voltage side ensures maximum efficiency and the

minimum Electromagnetic Interference (EMI) so the IBC320 will not interfere with sensitive RF

communication equipment.

The charger is preprogrammed for three standard types of Lead Acid batteries; Flooded (tradi-

tional Lead Acid), AGM (Absorbed Glass Mat Lead Acid) and Gel or VRLA (Valve Regulated

Lead Acid). It also has a 4th setting for a typical Lithium Ion battery. Any of the four charging

profiles can be adjusted to suit a specific make and model of battery using the free-to-down-

load PowerWizard software from www.analyticsystems.com.

The charger is supplied with one waterproof battery temperature sensor. A second sensor can

also be added to monitor two-bank battery systems. Based on the battery temperature, the

unit will adjust its output voltage for optimal charging. In the event a sensor is not used or

becomes faulty, the charger can be pre-set to one of three default battery temperatures, or

the charger can be programmed to automatically estimate the battery temperature by reading

its own temperature at the time it is turned on.

Eight dual color LEDs clearly indicate charging levels and stages as well as indicating faults

with either the charger or the batteries. The ‘PowerWizard’ software adds advanced charg-ing

algorithm programming and monitoring as well as a graphing function through the built in

microUSB port.

Safety features include charger and battery over temperature shutdown, current limiting, short

circuit protection, input under voltage shutdown and output over voltage protection all with

automatic recovery.

The charger requires no maintenance other than the occasional wipe down to remove any

accumulation of dust or dirt.

IBC320W Intelligent Battery Charger USER

GUIDE

4 5

Main Parts

1. LED Indicator Panel

2. Program Push Button

3. Stage Select Switch

4. End-of-Charge Function Switch

5. AC Power Indicator LED

6. Power Push Button

7. Waterproof MicroUSB port

8. Equalize Push Button

Front

Rear

1. AC Power Input connection

2. Input Fuse

3. DC Battery Output connection

4. Waterproof Battery Temperature

Sensor Connection

Package Contents

The box should contain:

• One IBC320W Intelligent Battery Charger,

• One Waterproof Battery Temperature Sensor Cable

• One Micro-USB to Laptop cable

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

• One Warranty Registration Card. Returning this card is not mandatory for warranty

coverage, but will assist us to stay in touch with you for updates and other news.

Warranty registration can also be completed at www.analyticsystems.com

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

If anything is damaged or missing, please contact us immediately at 1-800-668-3884 for by

emailing [email protected]

Location and Mounting

1. Mount the charger so that the indicator LEDs and controls on the front panel are

reasonably easy to see and access.

2. Make sure there is at least 2 inches of clearance all around the charger so that air can

circulate through the charger to keep it cool.

3. Mount the charger in a location that allows easy connection to the batteries. We

recommend using AWG10 wire to connect the charger to the batteries. 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.

4. If you are connecting the charger to two banks of batteries, they MUST share a common

ground. However, it is still a good practice to run a separate ground connection to each

battery from the charger.

5. Decide where to attach the battery temperature sensors. If it is practical, embed each

sensor into the battery platform so that the battery sits on top of it or if in a battery

box, slide it between the battery and the box, or simply use a little silicone to attach

the sensor to the top of the battery. Plug each sensor into the charger. It does not

matter which port is used, as the charger always sets its charging voltage from the

warmer battery. The charger will disconnect from the batteries if either battery reaches

43°C (110°F) and will automatically reconnect when the hottest battery cools to 32°C

(90°F). If the temperature sensors are not used, the charger will use the default battery

temperature programmed during Setup.

6. The charger is constructed to be water and dust resistant to IP66 standards and can be

mounted in moderately wet locations.

Installation

Connection

INSTALLATION INDICATORS

POL

TEMP

DEV

SVC

FLT

LO V

BAT

AC PRESENTBATTERY POLARITY REVERSED

POL

TEMP

DEV

SVC

FLT

LO V

BAT

1. Connect the charger to the batteries before connecting to the AC mains.

2. As you complete the connection to each battery, check the ‘POL’ indicator light on

the charger front panel. If it glows RED, the battery is connected in reverse. Stop and

reverse the connections to the battery (Red should go to Positive and Black should go to

Negative). After all battery banks are connected, double check that the POL indicator light

is still OFF.

3. Connect the charger to the AC mains. The AC LED should illuminate. This indicates that

the charger is receiving power from the AC mains and that the internal power supply is

running. Turn the charger OFF again.

Press the Power button on the front panel to turn the

charger ON. The Power button will illuminate once

the charger has turned on. Once the startup routine is

complete, enter Setup mode by pressing and holding

the PRG button for 3 seconds until you hear a one

second beep and the Charge LED starts blinking

Setup

Battery Type

Each press of the Select (SEL) button will advance the battery selection. The three LED’s on

the top will indicate Flooded, AGM and Gel, or Lithium Ion when lit.

Flooded – *The lead–acid battery was invented in 1859 by French physicist Gaston Planté

and is the oldest type of rechargeable battery. Despite having a very low energy-to-weight

ratio and a low energy-to-volume ratio, its ability to supply high surge currents means that the

cells have a relatively large power-to-weight ratio. These features, along with their low cost,

make them attractive for use in motor vehicles to provide the high current required by motors.

This is the Default setting.

AGM – **AGM (Absorbed Glass Mat) batteries differ from ooded lead acid batteries in that

the electrolyte is held in the glass mats, as opposed to freely ooding the plates. Very thin

glass bers are woven into a mat to increase surface area enough to hold sufcient electrolyte

on the cells for their lifetime. The bers that compose the ne glass mat do not absorb nor are

they affected by the acidic electrolyte.

Gel – **A modern gel battery (also known as a “gel cell”) is a VRLA (Valve Regulated

Lead Acid) battery with a gelied electrolyte; the sulfuric acid is mixed with fumed silica,

which makes the resulting mass gel-like and immobile. Unlike a ooded wet-cell lead-acid

battery, these batteries do not need to be kept upright. Gel batteries reduce the electrolyte

evaporation, spillage (and subsequent corrosion problems) common to the wet-cell battery,

and boast greater resistance to extreme temperatures, shock and vibration. Chemically they

are almost the same as wet (non-sealed) batteries except that the antimony in the lead plates

is replaced by calcium, and gas recombination can take place.

Lithium Ion – ***A lithium-ion battery (sometimes Li-ion battery or LIB) is a member of a

family of rechargeable battery types in which lithium ions move from the negative electrode to

the positive electrode during discharge and back when charging. Nominal cell voltage is 3.6V

and a 12V battery consists of 4 cells in series to create 14.4V. The charging routine is Constant

Current (Bulk Charge) to Constant Voltage (Float) at 14.4 Volts.

BATTERY TYPE INDICATORS

FLOODED LEAD ACID

POL

FLOODED

BAT

TYPE

GELAGM

POL

FLOODED

BAT

TYPE

GELAGM

GEL

BLINKING

ABSORBED GLASS MAT

POL

FLOODED

BAT

TYPE

GELAGM

OTHER - DEFAULT L-ION

POL BAT

TYPE

CUSTOM

8 9

Depending on the size and type of the battery or batteries connected to the charger,

the standard charging current output of the charger may be more than is optimal or

recommended. Refer to the documentation from your battery manufacturer to determine the

maximum safe charging current. If needed, the maximum charging current can be reduced

to 25, 50 or 75 percent of the rated output of the charger. The three LED’s on the top will

indicate 25%, 50% and 75% respectively. All three LED’s will be simultaneously lit to

indicate 100% charging current (Default).

Power Limit

CHARGE POWER INDICATORS

MAX CURRENT 25% OF RATED

MAX CURRENT 75% OF RATED

BLINKING

MAX CURRENT 50% OF RATED

MAX CURRENT 100% OF RATED

POL

25%

POWER

LIMIT

75%50% AC

POL

25%

POWER

LIMIT

75%50%

POL

25%

POWER

LIMIT

75%50% AC

POL

25%

POWER

LIMIT

75%50%

The recommended charging voltage for any type of battery will vary with temperature.

The warmer the battery, the lower the charging voltage required. This adjustment will set

the battery temperature to use for charge compensation if there are no installed battery

temperature sensors.

The three top LED’s indicate Cold, Warm, Hot and Auto. Cold, Warm and Hot and correspond

to battery temperatures of 5, 21 and 38 degrees Celsius respectively. In Auto, the charger

measures its own internal temperature during startup, and estimates the batteries to be the

same temperature and applies the appropriate compensation (Default).

If the charger detects one or two battery temperature sensors, their measurements will take

precedence.

Default Battery Temperature

To save the conguration and exit Setup at any point in the process, press and hold the PRG

button for 3 seconds until you hear a one second beep.

Saving

To exit without saving, either press the On/Off button or do nothing. The charger will exit

the conguration mode without changing the stored conguration after 60 seconds elapses

without any button being pressed.

Exit without Saving

To restore the charger to its factory settings, press and hold both the PRG and EQL buttons for

10 seconds until you hear multiple beeps

Full Reset

Two additional adjustments can be made from the front panel. These are to select the charging

prole as well as the behavior of the charger at the conclusion of a recharge cycle.

Front Panel Adjustments

DEFAULT BATTERY TEMPERATURE INDICATORS

DEFAULT BATTERY TEMP 5C

POL BAT

TEMP

AC COLD HOTWARM

BLINKING

AUTO BATTERY TEMP

DEFAULT BATTERY TEMP 21C

DEFAULT BATTERY TEMP 38C

POL BAT

TEMP

AC COLD HOTWARM

POL BAT

TEMP

AC COLD HOTWARM

POL BAT

TEMP

AC COLD HOTWARM

Table of contents

Other Analytic Systems Batteries Charger manuals

Analytic Systems

Analytic Systems BCD615-48-48 User manual

Analytic Systems

Analytic Systems BCA150 User manual

Analytic Systems

Analytic Systems BCA1505MW-24 User manual

Analytic Systems

Analytic Systems BCD310 Series User manual

Analytic Systems

Analytic Systems BCD805W-24-24 User manual

Analytic Systems

Analytic Systems BCD1015 SERIES User manual

Analytic Systems

Analytic Systems BCD610 User manual

Analytic Systems

Analytic Systems BCA1505 SERIES User manual

Analytic Systems

Analytic Systems BCA1505MS Series User manual

Analytic Systems

Analytic Systems BCA610 Series User manual

Analytic Systems

Analytic Systems BCH10W User manual

Analytic Systems

Analytic Systems BCA1505M Series User manual

Analytic Systems

Analytic Systems BCD600-32-12 User manual

Analytic Systems

Analytic Systems BCD605 User manual

Analytic Systems

Analytic Systems BCA1510MS-24 User manual

Analytic Systems

Analytic Systems BCA310MS User manual

Analytic Systems

Analytic Systems BCA1000 User manual

Analytic Systems

Analytic Systems BCDi320 User manual

Analytic Systems

Analytic Systems BCD315-12-24 User manual

Analytic Systems

Analytic Systems BCD305 Series User manual

Analytic Systems

Analytic Systems BCD1000-110-12 User manual

Analytic Systems

Analytic Systems BCD615R User manual

Analytic Systems

Analytic Systems BCA1000R User manual

Analytic Systems

Analytic Systems BCA1505U-24DW User manual

Popular Batteries Charger manuals by other brands

AA Portable Power Corp

AA Portable Power Corp Universal Smart Charger user manual

Enelion

Enelion Vertica manual

RCA

RCA CHU6 instruction manual

ANSMANN

ANSMANN ALCT 6/24-10 manual

Hitachi

Hitachi UC 18YRSL Safety instructions and instruction manual

Olympus

Olympus B-20 LPC instructions

Exibel

Exibel ZH1708143 operating instructions

Lenmar

Lenmar Mach 1 user manual

CTEK

CTEK MXS 5.0 manual

ABB

ABB HT842379 Operation manual

Nitecore

Nitecore Superb Charger SC4 user manual

Renogy

Renogy RBC2125DS-21W quick guide

Braun

Braun BWC02M User instructions

CTEK

CTEK MXS 3.6 manual

Black & Decker

Black & Decker BDV090 Original instructions

Trinity

Trinity DPD quick start guide

Hulkman

Hulkman Sigma 1 user guide

IKEA

IKEA koppla manual