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

2
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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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

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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
1
2
7
Rear
1. AC Power Input connection
2. Input Fuse
3. DC Battery Output connection
4. Waterproof Battery Temperature
Sensor Connection
6
5
3
4
8
1
2
3
4

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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

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Connection
INSTALLATION INDICATORS
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
AC PRESENTBATTERY POLARITY REVERSED
AC
POL
TEMP
25
DEV
CH
75
SVC
FLT
LO V
BAT
50
EQ
PS
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.

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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
AC
POL
FLOODED
BAT
TYPE
GELAGM
AC
POL
FLOODED
BAT
TYPE
GELAGM
GEL
BLINKING
ABSORBED GLASS MAT
AC
POL
FLOODED
BAT
TYPE
GELAGM
OTHER - DEFAULT L-ION
AC
POL BAT
TYPE
CUSTOM

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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
AC
POL
25%
POWER
LIMIT
75%50% AC
POL
25%
POWER
LIMIT
75%50%
AC
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

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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