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.

1110
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
Connection
CONNECTION INDICATORS
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
AC PRESENT
BATTERY POLARITY REVERSED
Conguration Mode
1. Connect the charger to the batteries as indicated under
Installation.
2. Check the POL LED on the front panel. If it is glowing red,
the battery is connected in reverse polarity. Correct the
connection to the battery (The red terminal should go to
Positive and black to Negative).
3. Once the POL LED is off, connect the charger to the AC
power source. The AC LED should start glowing green.
This indicates that the charger is receiving power from the
AC source and that its internal power supply is working.
1. Press and hold the Program (PRG) button for three seconds until you hear a beep and the
DEV LED starts blinking. This indicates that the unit is in Conguration mode.
2. Press the Program (PRG) button to cycle through the parameters you can program. The pa-
rameter which you programming can be determined by which bottom row LED is blinking.
If the DEV LED is
blinking, you are
programming
the Battery Type
parameters.
If the FLT LED is
blinking, you are
programming the
Default Battery
Temperature
parameters.
If the BAT LED is blinking, you are
programming the Current Limit
parameters.
3. Press the Select (SEL) button to cycle through the settings for each parameter. The setting
can be determined by the combination of top row LEDs glowing.
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
After turning the charger on, it will immediately begin charging any connected batteries with
its pre-programmed parameters. These parameters can be accessed and changed through
Conguration mode.
TO ACCESS CONFIGURATION MODE:

12
Battery Type
The Battery Type parameters controls the type of charging prole that the unit will use to
charge the battery. Different types of batteries have different optimal charging voltages
and currents due to their physical and chemical construction. This unit is pre-programmed
with four common battery types.
• Flooded Lead-Acid
• Absorbed Glass Mat (AGM)
• Gel Lead-Acid
• Lithium Ion (Li-on)
You can create your own custom charging prole using PowerWizard. For more informa-
tion, see the PowerWizard manual.
BLINKING
FLOODED LEAD ACID (DEFAULT)
GEL LEAD-ACID
ABSORBED GLASS MAT
LITHIUM-ION
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 Limit
The Current Limit parameters controls the unit’s maximum charging current. Depending on the
size and type of your batteries, this unit’s standard maximum current may be more than what
is optimal or recommended. Refer to your battery manufacturer’s documentation to determine
its maximum safe charging current.
If needed, the unit’s maximum charging current can be reduced to 25, 50 or 75 percent of the
standard maximum rating.
BATTERY TYPE INDICATORS

1312
The Default Battery Temperature parameters controls the charger’s estimated value of the
battery temperature. The optimal charging voltage of a battery will decrease as its tempera-
ture increases. The charger uses this value to calculate its charging compensation if there are
no battery temperature sensors installed and it cannot obtain real-time data.
The three settings are 5°C, 21°C and 38°C and Auto. In Auto, the charger measures its own
internal temperature during startup and estimates the batteries to be the same. If the charger
detects the battery temperature sensor(s) is/are installed, their readings will take precedence.
Default Battery Temperature
DEFAULT BATTERY TEMPERATURE INDICATORS
75% OF MAX CURRENT DEFAULT CURRENT (100%)
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
25% OF MAX CURRENT 50% OF MAX CURRENT
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 LIMIT INDICATORS
75
75
DEFAULT WARM (21°C/70°F)
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
AC
POL
TEMP
25
DEV
CH
SVC
FLT
LO V
BAT
50
EQ
PS
75% OF MAX CURRENT
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
DEFAULT (AUTO)
AC
POL
TEMP
25
DEV
CH
SVC
FLT
LO V
BAT
50
EQ
PS
DEFAULT AUTODEFAULT HOT (38°C/105°F)
DEFAULT COLD (5°C/41°F)
BLINKING
BLINKING

1514
To restore the charger to its factory settings, press and hold both the Program (PRG) and
Select (SEL) buttons for 10 seconds until you hear multiple beeps.
Full Reset
Two additional adjustments can be made from the front panel. Using the switches between
the Program and Select buttons, you can select the type of charging cycle used and control
the End of Charging behavior of the unit.
Front Panel Adjustments
The End-of-Charge (EOC) select switch controls the charger’s behavior after it nishes charg-
ing the battery/ batteries.
Setting the switch to Rest:
• Causes the unit to remain in rest mode after nishing the recharge cycle. The charger
will remain like this until it detects that the battery voltage has dropped <90% of the
rated voltage. It will then initiate a new recharge cycle.
• The charger will also initiate a new recharge cycle if power to the unit is disconnected or
cycled.
• This EOC Select Switch MUST be in the Rest position for the unit to meet the California
Energy Commission regulations.
Setting the switch to Float:
• Causes the unit to maintain the battery at the oat voltage indenitely. This will ensure
that the battery is always fully recharged and ready for use.
• A new recharge cycle will only be initiated if the charger is proving its full rated current
to keep the battery at oat, or if the power is disconnected or cycled.
To save your settings and exit Conguration mode at any point, press and hold the Program
(PRG) button until you hear a one second beep.
To exit without saving, simply press then Power Button to turn the unit off.
NOTE: If 60 seconds passes and no button is pressed, the charger will automatically exit
Conguration mode without saving any settings.
Saving and Exiting
End-of-Charge Select

1514
A two-stage charging cycle occurs in two stages.
During the bulk stage, the battery is charged at a constant current until reaching the oat
voltage. Then during the oat stage, the battery is held at the oat voltage while the current
reduces as necessary to maintain this. The charging is considered complete when the charging
current drops to 10% of its rated output.
Two-stage charging is gentler on the battery than three-stage. The battery is subjected to lower
voltages than in three-stage charging and in addition, a reasonable load can be put on the bat-
tery without altering its ability to keep the battery at full charge.
The Stage (STG) select switch controls whether the unit uses a two-stage or three-stage charg-
ing cycle. Generally, two-stage charging is preferred for loaded batteries and three-stage for idle
or unloaded batteries. The two settings are detailed below.
TWO-STAGE CHARGING
A three-stage charging cycle occurs in three stages.
During the bulk stage, the battery is charged at a constant current until reaching the absorp-
tion voltage. Then during the absorption stage, the battery is held at that voltage while the
current reduces as necessary to maintain it. Finally during the Float stage, the battery voltage
is lowered to the oat voltage. The charging is considered complete when the charging current
drops to 10% of its rated output.
Three-stage charging is faster than two-stage charging. However, the charger cannot differ-
entiate between a current going to a load on the battery, and a current being absorbed by the
battery, so it can overcharge a battery that is powering a load.
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Maintenance
(Constant Volts)
Time
Two Stage Charger
Volts
Amps
100%
75%
50%
25%
0%
Bulk
(Constant Current)
Absorption
(Constant Volts)
Maintenance
(Constant Volts)
Time
Three Stage Charger
Volts
Amps
THREE-STAGE CHARGING
Stage Select

1716
Equalize Cycle
If a battery’s cells are left discharged for too long, sulfate crystals can form on the plates inter-
fering with their conductance. This reduces the battery’s capacity and recharging ability.
An equalize cycle is a deliberate overcharge of the battery at high voltage (110% of oat
voltage) and low current (10% of standard output) to force undercharged cells to match
charge of the good cells in the battery.
An equalize cycle should only be performed once every six months as it is hard on the good
cells of the battery and can cause water loss in non-sealed batteries.
DANGER: An equalize cycle can only be performed in a well ventilated area.
Hydrogen gas is a normal by-product of the cycle and is explosive at concentrations greater
than 4%.
CAUTION: A battery temperature sensor must be used.
A battery temperature sensor must be connected and installed at the battery. Careful
temperature monitoring is required during the equalize cycle. Failure to do so can result in
severe damage to the battery!
TO PERFORM AN EQUALIZE CYCLE
1. Connect the battery temperature sensor to the unit and install the sensor at the battery
as indicated in Installation.
2. The charger must be in battery charger mode and not power supply mode.
3. Push the Equalize button on the front panel. The button is recessed to prevent accidental
operation; a ballpoint pen can be used to access it.
4. The EQUALIZE LED will glow green indicating the beginning of the equalize cycle. If the
battery charger is currently charging a battery, the EQUALIZE LED will blink green. Once
the charging cycle is complete, the EQUALIZE LED will glow green
5. Three hours later, the Equalize cycle will end and the EQUALIZE LED will turn off. The
cycle will also end if the charger detects that the battery temperature has reached 40°C
or higher.
6. Afterwards, the charger will maintain that battery at either standby or rest depending on
the position of the End-of-Charge switch.
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
EQUALIZING EQUALIZE PENDING
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
EQUALIZATION INDICATORS

1716
Maintenance
Dry Contact Relay
Digital Meter - Option V
This charger requires no maintenance other than the occasional wipe down to remove dust
that could reduce its ability to dissipate heat. Carefully blow air through the cooling vent to
remove any dust buildup inside the unit.
The charger can be tted with a 1 amp dry contact relay to indicate charger status to a moni-
toring system. It has both a normally-open and normally-closed contact which changes state
depending on the presence or absence of charging voltage on the output and is independent
of the microprocessor.
If the charger is producing voltage on the output, the normally closed contact will be closed
and there will be an electrical connection between NC and COM. If the voltage on the output
of the charger goes to zero, the contact will change state. The Normally Open contact oper-
ates exactly in the reverse of the Normally Closed contact.
The IBC320 can be equipped (by factory order) with a bright chassis-integrated digital meter
to display the battery voltage and charging current being supplied to up to both connected
batteries. This digital meter option adds 2.5-3 inches to the length of the chassis.
There are three possible displays that can be cycled through using the push button
on the digital meter.
• Battery 1: Battery Voltage and Charging Current
• Battery 2: Battery Voltage and Charging Current
• Display OFF

1918
Troubleshooting
The IBC320 is designed to provide years of reliable service and to auto-recover in the event of
an operational failure. In the event of malfunction, the unit is tted with eight LED indicators
and an audible alarm to help diagnose the cause of the issue. Below is a list of potential
issues, and how to repair them.
NO AC POWER DETECTED
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
No AC Power Detected
First, make sure any external circuit breaker is ON. Unplug
the unit from the AC power. Using a multimeter, make
sure AC power is present in the receptacle. Check that the
input fuse hasn’t blown. If the fuse is open, replace it with
the recommended fuse listed on the label and reconnect
to AC power. If the AC LED still does not glow, then there
is likely an internal failure and the charger will have to be
returned for service.
Low Input Voltage Indication
The charger has detected that the input voltage has
dropped below the minimum level needed for normal
operation. The charger will shut off and wait for the
voltage to recover.
BATTERY OVERTEMP
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CHARGER LO VOLTAGE
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
CHARGER OVERTEMP
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
Charger Over Temperature Indication
The charger has detected that its internal temperature
is above safe operating limits. The charger will shut
off until the temperature has returned to normal limits.
If this happens frequently, the charger may need to be
remounted for better air circulation.
Battery Over Temperature Indication
The charger has detected that the battery is too hot to
safely charge (>43°C/110°F) and shut off. The charger
will automatically reconnect when the battery cools to a
safe temperature (<32°C/90°F). If this happens frequently,
particularly in relatively normal ambient temperatures,
the battery is likely damaged or defective and should be
replaced.
FAULT INDICATORS BLINKING

1918
BATTERY LO VOLTAGE
NO BATTERY
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
No Battery Detected
The charger has detected that no battery is connected.
Connect a battery to the unit to clear this fault.
If a battery IS connected and you see this fault, this
usually means the battery is completely discharged.
Try switching the unit to Power Supply mode for a few
minutes and then back to Charger mode to see if it will
return the battery to life. If it doesn’t, the battery is defec-
tive and will have to be replaced.
Battery Low Voltage Indication
If the battery is seriously discharged, and the charger
voltage drops below 85% of nominal (ie. 10V for a 12V
charger), the charger will show this display until the
battery voltage exceeds 85% of nominal.
BATTERY FAILED
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
Battery Fail Indication
The charger has detected the connected battery is defec-
tive and will not accept a charge, the charger will stop
attempting to charge the battery. Replace the battery and
cycle power to the unit using the Power Button to reset
this condition.
CHARGER FAILED
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
Charger Failure Indication
The microprocessor has detected a condition that prevents
the charger from operating. Try disconnecting the AC
power and re-connecting it. If this does not clear the fault,
the cause is likely an internal component failure and the
charger will have to be returned for service
FAULT INDICATORS BLINKING

2120
Abbreviations and Denitions
We use a number of abbreviations on the labels to save space. Here are the full words
corresponding to each abbreviation along with common battery charger terms and their
denitions:
ABBREVIATIONS
POL – Polarity. Refers to the correct connection of the Positive and Negative terminals of the
battery to the charger.
DEV – Device. Refers to the charger. Used together with the Fault LED to indicate a problem
with the Device.
BAT – Battery. Refers to the battery. Used together with the Fault LED to indicate a problem
with the Battery.
FLT – Fault. Used to indicate a problem with the battery (BAT) or the device (DEV) AC –
Alternating Current
TEMP – Temperature. Used to indicate that either the Battery or the Device is too hot.
LO V – Low Voltage. Used to indicate that either the Input Voltage or the Battery Voltage is too
low.
FAIL – Used to indicate that either the battery or the device needs repair or replacement.
PRG – Program - Button used to initiate the Programming Mode
STG – Stage – Switch used to select between 2-Stage or 3-Stage charging prole
EOC – End Of Charge – Switch used to select Rest or Float at the end of a charge cycle
SEL – Select – Button used to make choices during front panel programming CH – Charging
EQ – Equalize
PS – Power Supply