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

Copyright (2005-2018) Analytic Systems Ware (1993) Ltd.
Revised - March 9, 2018

3
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

4
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.

5
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.

6
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.

76
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]
2
1
3
6
7
5
4
8
9
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

98
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
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CHARGING CURRENT 60-84%
CHARGING CURRENT 40-59% CHARGING CURRENT 11-39%
CHARGING CURRENT 1-10% CHARGE COMPLETE
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CHARGING CURRENT >85%
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
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

98
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).
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
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

10
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.