IBS DBS User manual

IBS Intelligent Battery System GmbH
Seestrasse 24, CH-3600 Thun, Schweiz
Tel: [phone]
E-Mail: inf @ibs-tech.ch
IBS-DBS_en_v1.2.2.d c 1
IBS-DBS
Dual Battery System
Manual

2
Table of Contents
Language / Sprache / Langue / Lingua .................................................................................................. 3
Pr duct descripti n ............................................................................................................................... 4
Warning ............................................................................................................................................ 4
Applicati ns .......................................................................................................................................... 5
C mbinati ns f IBS devices................................................................................................................. 6
M unting ............................................................................................................................................... 7
Relay p wer wire .............................................................................................................................. 7
N tes n installati n .............................................................................................................................. 7
Cauti n ............................................................................................................................................. 7
Starting the M nit r ............................................................................................................................... 8
Adjustable m des.............................................................................................................................. 8
Setting the m des ............................................................................................................................. 8
S ftware Display ............................................................................................................................... 9
S ftware versi n ........................................................................................................................... 9
S ftware m de .............................................................................................................................. 9
Call up the s ftware display ........................................................................................................... 9
Installati n / Wiring .............................................................................................................................. 10
Classic 12V Installati n ................................................................................................................... 10
Classic 12V with RBM ..................................................................................................................... 11
DBM Supp rted Installati n ............................................................................................................. 12
Additi nal functi ns / applicati ns with IBS-DBS .......................................................................... 12
N te ............................................................................................................................................ 13
Triple battery installati n (with DBR) ................................................................................................ 14
Classic 24V Installati n ................................................................................................................... 15
Classic 24V with RBM ..................................................................................................................... 16
Explanati n: Display............................................................................................................................ 17
Battery V ltage & Charge ................................................................................................................ 17
Linked LED ..................................................................................................................................... 17
Manually linked LED ....................................................................................................................... 17
V ltage indicati n ............................................................................................................................ 17
Explanati n: Butt ns ........................................................................................................................... 18
Display butt n ................................................................................................................................. 18
Link butt n ...................................................................................................................................... 18
Aut butt n ..................................................................................................................................... 18
Err r descripti n ................................................................................................................................. 19
List f err rs .................................................................................................................................... 19
Measures / Suspensi n ................................................................................................................... 19
Specificati ns...................................................................................................................................... 20
Technical specificati ns .................................................................................................................. 20
Access ries ........................................................................................................................................ 21
N tes .................................................................................................................................................. 22
Delivery c ntent .................................................................................................................................. 23

3
Language / Sprache / Langue / Lingua
F r manual in an ther language f ll w the path r scan QR-C de.
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P ur les manuels dans une autre langue suivez le link u scannez le c de QR.
Per il manuale in una tra lingua seguite il link scannerizzate il c dice QR.
English Deutsch Francais Italian
Uscita pr ssimamente
http://www.ibs-tech.ch/d wnl ad/manuals-ibs.html

4
Product description
The classic IBS-DBS Dual Battery System is used f r charge distributi n while driving (alternat r
charging) and disc nnecting the batteries after driving (alternat r ff). F r emergencies, the batteries
can be manually c nnected f r 30 minutes r 2 h urs. F r example, in the case f an empty / faulty
starter battery (Main) the m t r can be started fr m the additi nal battery Aux (RBM necessary). During
the rec very winch perati n, the batteries can be used t p wer the winch by manually c nnecting the
batteries. With the new s ftware 8.1, further functi ns, e.g. when used with the DBM20A r Li-type
batteries.
Warning
The installati n and c mmissi ning f IBS pr ducts sh uld nly be carried ut by specialists with
specialist kn wledge in vehicle electr nics and battery techn l gy.
Vari us batteries pr duce expl sive gases while charging; Fitting instructi ns f r these batteries must
be bserved.

5
Applications

6
Combinations of IBS devices

7
Mounting
Install the relay with wires r c nnecti ns facing d wnwards. Symmetry between p wer wires has n
effect. Keep the wires between the batteries and the relay as sh rt as p ssible t minimize the line
resistance.
elay power wire
The Relay p wer wires sh uld have at least a cr ss secti n f 25mm2!
Notes on installation
The installati n steps are sh wn bel w. F ll w these steps sequentially t ensure the device functi ns
pr perly.
Caution
Before installation
 F r the installati n with Lithium type batteries as auxiliary battery: make sure that the battery
has 4 cells! (Cauti n: Use Li-type battery nly as auxiliary battery!)
 Ensure which applicati ns y u are installing. Only f ll w the c rrect installati n steps!
The f ll wing installati ns are p ssible
System
Description
Page
12V / 12V System Classic 12V installati n 10
12V / 12V System Classic 12V with RBM 11
12V / 12V System DBM Supp rting installati n 12
12V / 12V System Triple battery installati n (with DBR) 14
24V / 24V System Classic 24V installati n 15
24V / 24V System Classic 24V with RBM 16
 Read the installati n steps first.
 Please als read the n tes n the installation, relay, power wire and wire extension n this
page.
During installation
 The red wire always bel ngs t the starter (Main) battery and the blue t the auxiliary (Aux)
battery!
 C nnect the red wire directly t the p sitive p le f the starter battery and the blue wire directly
t the p sitive p le f the additi nal battery! (N t n the relay c nnecti ns).
After installation
Carry ut the c ntr l steps (y u can find the d cument n ur
website at www.ibs-tech.ch \ D wnl ads \ Testpr cedures IBS-
DBS_Test_e1.pdf r the QR c de next t it).

8
Starting the Monitor
Adjustable modes
*Select the desired m de 1-6 r S and f ll w the instructi ns in Setting the mode.
**The m nit r may have already been set in advance. T find ut which m de the DBS is in, f ll w the
instructi ns in the software display n page 9.
*** F r Li-type wire installati n f ll w the classic installati n.
Setting the modes
The m des can be set via a dip switch in the device:
*ATTENTION: TO SWITCH TO A 24V SYSTEM A 24V ELAY (AND BM) MUST BE USED!
ACCO DINGLY A 12V ELAY (AND BM) MUST BE USED TO SWITCH TO A 12V
SYSTEM!
** The m nit r can be c nfigured t be silent in any m de. (silent m de f r l w battery alarm)
Where is the dip switch for setting the modes?
T access the DipSwitch, y u must pen the device. First rem ve
the 2 screws n the back f the m nit r t rem ve the m unting
plate. Then l sen the 4 screws that h ld the h using c ver and the
h using base t gether. Lift ff the c ver. The DipSwitch is l cated at
the b tt m left f the circuit b ard:
If the pr tective film is still present, rem ve it. Using tweezers r
s mething similar, y u can n w adjust the p siti ns as desired. The
p siti ns are marked n the DipSwitch ( n the picture: leftm st ->
p siti n 1, rightm st -> p siti n 4). (Default setting: All p siti ns in
"OFF" -> 12V Classic).
Setting options
12V
24V
Li
-
type
DBM
1 X
2 X X
3 X X
4 X X X
5 X
6 X X
S
D
esignation
12V Classic
12V Aux Li-type
12V DBM
12V DBM with Li-type
24V Classic
24V Aux Li-type
Silent
Dip switch positions
1 (1) ff/ ff/ ff/ ff (default)
12V Classic
*!
2
(1) ff/ ff/ ff/
on
12V
Aux
Li
-
type
*!
3
(1)
ff/ ff/
on
/ ff
12V DBM
4
(1) ff/ ff/
on
/
on
DBM with Li-type
5
(1)
on
/ ff/ ff/ ff
24V Classic
*!
6
(1)
on
/ ff/ ff/
on
24V
Aux
Li
-
type
*!
S
(1) ff/
on
/ ff/ ff
Silent**

9
Software Display
As s n as y u insert the m nit r and it is c nnected t the starter battery, it will display the s ftware
versi n and the currently set m de f r a few sec nds as f ll wing:
Software version
The actual s ftware versi n is indicated by the display bars Main and Aux. Number f lumin us Led's f
the Main-Bar, equals the first number and the number f Led's f the Aux-Bar give the sec nd number
f the actual device s ftware versi n. Example: 8 LEDs n the main side and 1( ne) LED n the aux
side -> Versi n 8.1
Software mode
Call up the software display
If y u missed the display f the s ftware versi n r if y u w uld like t activate the display f the
s ftware versi n at a later time, y u have tw pti ns:
1. Pushing the link and aut butt n simultane usly causes a system reset and reb ting f the
m nit r, with the m nit r re-displaying the s ftware versi n.
2. The m nit r is als reset by unplugging the m nit r at the grey c nnect r and re-c nnecting it,
which causes re-displaying the s ftware versi n.
1 12V Classic
„linked“
on
2 12V Li-type
„linked“
flashes
3 DBM
“manually linked”
on
4 DBM Li-type
„manually linked“
flashes
5 24V Classic
„linked“
on
6 24V Li-type
„linked“
f
lashes
S Silent

10
Installation / Wiring
Classic 12V Installation
Please read the installation steps before performing for a better understanding.
If p ssible, install the wire in a pr tective tube and fasten with wire ties.
D n t attach t h t engine parts: isk of fire!
1. R ute the wires fr m the wire set fr m the driver's cab int the engine c mpartment.
2. Crimp the wire lugs.
3. Install the m nit r wire as sh wn:
 Screw the black lead t the minus starter battery.
 Screw the red lead n the p sitive starter battery.
 Screw the blue lead t a plus b ard (Aux) battery.
4. C nnect green wire t terminal 86 f the relay.
5. Install the relay (see the m unting instructi ns under mounting page 7).
6. Install the Relay p wer wire (n t supplied, see elay power wire page 7) as sh wn:
 Install a sh rt red wire fr m the wire kit as a c nnecti n wire between terminals 85 and
87.
 Install the p wer wire fr m the Plus starter battery (Main) n terminal 87 f the relay.
 Install the p wer wire fr m the Plus f the b ard battery (Aux) t Terminal 30 f the
Relay.
7. Insert the m nit r (see Starting the Monitor n page 8).

11
Classic 12V with BM
Please read the installation steps before performing for a better understanding.
If p ssible, install the wire in a pr tective tube and fasten with wire ties.
D n t attach t h t engine parts: isk of fire!
1. R ute the wires fr m the wire set fr m the driver's cab int the engine c mpartment.
2. Crimp the wire lugs.
3. Install the m nit r wire as sh wn:
 Screw the black lead t the minus starter battery.
 Screw the red lead n the p sitive starter battery.
 Screw the blue lead t a plus b ard (Aux) battery.
4. C nnect green wire t terminal 86 f the relay.
5. Install the relay (see the m unting instructi ns under mounting page 7).
6. Install the Relay p wer wire (n t supplied, see elay power wire page 7) as sh wn:
 Install the p wer wire fr m the Plus starter battery (Main) n terminal 87 f the relay.
 Install the p wer wire fr m the Plus f the b ard battery (Aux) t Terminal 30 f the
Relay.
7. M unt the RBM near the relay:
 Yell w wire n terminal 85.
 Green line n terminal 86.
 Red wire n terminal 87.
 Blue wire n terminal 30.
8. Insert the m nit r (see Starting the Monitor n page 8).

12
DBM Supported Installation
Additional functions / applications with IBS-DBS
It is necessary t have a micr c ntr lled versi n f the IBS-DBS t access all the extra functi ns.
There has t be the light blue µC-sign n the c ver f the IBS-DBS.
Advantages f a DBM supp rting installati n (additi nal installati n t DBM20A):
1 Link Start:
Vehicle can be started fr m Aux battery by pushing Link-Butt n fr m IBS-DBS.
2 Automatic Winch Support:
The DBM20A rec gnises Winch usage and switches t Relay Supp rt M de f r ptimal
l ad sharing n b th batteries.
3 Manual Winch Support/Link:
Activati n f 30 minutes manual Link by pushing Link-Butt n ( n DBS) once.
By pushing Link Butt n twice within 3 sec nds the 2 h urs manual Link can be
activated.
Manual reset by pushing Aut butt n n DBS.
4 Solar Charge:
With installed s lar panel n Aux battery the Main battery will be charged as well when
Aux v ltage is higher than 13.5V.
5 Fast Charge:
When the car is started the alternat r first charges b th Main and Aux battery (Fast
Charge) and then the DBM20A switches t DC/DC Charge t get a 100% full Charge
as c nfigured.
6 BM function:
Relay B ster M dule Functi n f r Link Start when a l w Main battery is detected.

13
F r a better understanding f the pr gramming f the system, please first read page 6 f the DBM20A
manual. Otherwise, the system may have t be reinstalled.
Please read the instructi ns f r m unting and wire extensi n n page 8 f the DBM20A manual.
Please read the installation steps before performing for a better understanding.
Ch ice f the c nnecti n f the light blue wire IGN:
 F r an alternat r with charge cut- ff, c nnect IGN t igniti n (terminal 15). When the alternat r
is switched ff, DC / DC charging is carried ut until the main v ltage reaches 11.9V. The DC /
DC charge starts aut matically when Umain is m re than 13.3V.
 F r all ther alternat rs: d n t c nnect IGN, charge is switched ff at main v ltage 12.7V. The
DC / DC charge starts aut matically when Umain is m re than 13.3V.
1. If necessary, c nnect light blue lead IGN t igniti n (terminal 15). Leave pen with ut need.
2. C nnect the IBS-DBS as sh wn ab ve (red t Plus Main, blue t Plus Aux, black t minus).
3. C nnect the relay t the green line (terminal 86) and the negative line (terminal 85).
4. R ute the p wer wires (minimum 25mm2) fr m Main Plus to elay and Aux Plus to elay.
5. C nnect the black (GND) wires.
6. Then c nnect the red (+ Main) wire (NOTICE: System starts up  see page 6 Pr gramming the
system in the DBM20A manual). (D n t c ntinue installati n until standby m de is activated).
7. N w c nnect the green line f the IBS-DBS t the yell w Link / Pr g line f the DBM20A.
8. Finally c nnect the blue (+ Aux) line.
If the relay was n t detected during the pr gramming step, because the Aux line was c nnected
afterwards, see the steps under elay not recognized - what to do?
Note
To ensure a safe installation, fuses must be installed in the red path (+ Main: 30A) and in the
blue path (+ Aux: 30A)!

14
Triple battery installation (with DB )
Please read the installation steps before performing for a better understanding.
If p ssible, install the wire in a pr tective tube and fasten with wire ties.
D n t attach t h t engine parts: isk of fire!
1. R ute the wires fr m the wire set fr m the driver's cab int the engine c mpartment.
2. Crimp the wire lugs.
3. Install the m nit r wire as sh wn:
 Screw the black lead t the minus starter (Main) battery.
 Screw the red lead n the p sitive starter (Main) battery.
 Screw the blue lead t a plus b ard(Aux) battery.
4. C nnect green wire t terminal 86 f the relay.
5. Install the relay (see the m unting instructi ns under mounting page 7).
6. Install the Relay p wer wire (n t supplied, see elay power wire page 7) as sh wn:
 Install a sh rt red wire fr m the wire kit as a c nnecti n wire between terminals 85 and
87.
 Install the p wer wire fr m the Plus starter battery (Main) n terminal 87 f the relay.
 Install the p wer wire fr m the Plus f the b ard battery (Aux) t Terminal 30 f the
Relay.
7. M nit r Insert the m nit r (see Starting the M nit r n page 8).
8. C nnect the IBS-DBR t the p wer wire:
 Fr m battery b rd (Aux) plus t terminal 87.
 Fr m plug r trailer / b x battery terminal t terminal 30.
 Fr m terminal 85 t minus.
9. C nnect IBS-DBR butt n t terminal 86 and minus.

15
Classic 24V Installation
Please read the installation steps before performing for a better understanding.
If p ssible, install the wire in a pr tective tube and fasten with wire ties.
D n t attach t h t engine parts: isk of fire!
1. R ute the wires fr m the wire set fr m the driver's cab int the engine c mpartment.
2. Crimp the wire lugs.
3. Install the m nit r wire as sh wn:
 Screw the black lead t the minus starter (Main) battery.
 Screw the red lead n the p sitive starter (Main) battery.
 Screw the blue lead t a plus b ard(Aux) battery.
 C nnect green wire t terminal 86 f the relay.
4. Install the relay (see the m unting instructi ns under mounting page 7).
5. Install the Relay p wer wire (n t supplied, see Relay p wer wire page 7) as sh wn:
 Install a sh rt red wire fr m the wire kit as a c nnecti n wire between terminals 85 and 87.
 Install the p wer wire fr m the Plus starter battery (Main) n terminal 87 f the relay.
 Install the p wer wire fr m the Plus f the b ard battery (Aux) t Terminal 30 f the Relay.
6. Insert the m nit r (see Starting the M nit r n page 8).

16
Classic 24V with BM
Please read the installation steps before performing for a better understanding.
If p ssible, install the wire in a pr tective tube and fasten with wire ties.
D n t attach t h t engine parts: isk of fire!
1. R ute the wires fr m the wire set fr m the driver's cab int the engine c mpartment.
2. Crimp the wire lugs.
3. Install the m nit r wire as sh wn:
 Screw the black lead t the minus starter (Main) battery.
 Screw the red lead n the p sitive starter (Main) battery.
 Screw the blue lead t a plus b ard(Aux) battery.
 C nnect green wire t terminal 86 f the relay.
4. Install the relay (see the m unting instructi ns under mounting page 7).
5. Install the Relay p wer wire (n t supplied, see elay power wire page 7) as sh wn:
 Install a sh rt red wire fr m the wire kit as a c nnecti n wire between terminals 85 and 87.
 Install the p wer wire fr m the Plus starter battery (Main) n terminal 87 f the relay.
 Install the p wer wire fr m the Plus f the b ard battery (Aux) t Terminal 30 f the Relay.
6. M unt the RBM near the relay:
 Yell w wire n terminal 85.
 Green line n terminal 86.
 Red wire n terminal 87.
 Blue wire n terminal 30.
7. Insert the m nit r (see Starting the Monitor n page 8).

17
Explanation: Display
Battery Voltage & Charge
The v ltages f the c nnected batteries can be read n the
respective LED bar. As s n as charge is present n a battery,
this is indicated by the charge LED.
Linked LED
The linked LED indicates whether the batteries are linked via
the relay r n t. (steady n -> linked)
Manually linked LED
The manually linked LED indicates whether the link has been
set manually (LED lights up red) r aut matically (LED is ff).
(In case f 2h link LED blinks every 30 sec nds acc mpanied
with an audible signal)
Voltage indication
Classic 12V
12V
Li
-
type
*
Classic
24V
24V
Li
-
type
*
Display bar
Main and Aux Aux Main and Aux Aux
Led 1
L w Battery L w Battery L w Battery L w Battery
Led 2
11.2V 11.6V 22.4V 23.2V
Led 3
11.4V 11.8V 22.8V 23.6V
Led 4
11.6V 12.0V 23.2V 24.0V
Led 5
11.8V 12.2V 23.6V 24.4V
Led 6
12.0V 12.4V 24.0V 24.8V
Led 7
12.2V 12.6V 24.4V 25.2V
Led 8
12.4V 12.8V 24.8V 25.6V
Led 9
12.6V 13.0V 25.2V 26.0V
Led 10
12.8V 13.2V 25.6V 26.4V
Charge Led 1
13.0V 13.0V 26.0V 26.0V
Charge Led 2
13.5V 13.5V 27.0V 27.0V
Charge Led 3
14.0V 14.0V 28.0V 28.0V
Charge Led 4
14.5V 14.5V 29.0V 29.0V
The pen-circuit battery v ltage f lead batteries is appr x. 12.5V, the LiFePO battery is ab ut 13.2V.
*When set with Li-type as an Aux battery, the "Aux-LED Display bar " fr m the m nit r is
adapted t the higher pen-circuit v ltage f the LiFePO batteries. The "Main- LED Display
bar " remains as in the classic system!
(F r Li-type, 0.4V, r 0.8V f r 24V systems, are deducted fr m the effective battery v ltage
f r the display)

18
Explanation: Buttons
Display button
 By briefly pushing the display butt n, the display is activated (which aut matically turns ff after
30 sec nds).
 Push and h ld the display butt n f r appr x. 2 sec nds, the display can be dimmed (back t full
brightness by repeatedly h lding the display butt n f r appr x. 2 sec nds).
 In case f an underv ltage audible signal (err r 1, see Error description p. 19), the device can
be muted by pushing the display butt n (If device audible signal changes instead f being
muted immediately charge the respective battery due t super l w v ltage!)
Link button
 By briefly pushing the link butt n, the manual 30 minute Link, can be executed.
 By pushing twice briefly within 3 sec nds, the manual 2 hours Link can be triggered (m nit r
c nfirms activati n with a "beep").
 By pushing and h lding the link butt n f r appr x. 10 sec nds, the aut matic Link can be
suppressed r prevented: No Link mode (F r the return t the aut matic functi n, see the
Auto button)
Auto button
 By briefly pushing the Aut butt n, an active manual link can be ab rted. The m nit r returns t
the Auto mode.
 By pushing and h lding the Aut butt n f r appr x. 10 sec nds, the No Link mode (f r
releasing this m de, see Link button) can be switched ff. Thus, the m nit r perates again in
the aut matic m de.

19
Error description
List of errors
The DBS M nit r sh ws err rs as f ll ws
Error
Illustration
Description
0 N flashing lights, n ac ustic signal N err r
1
Low
Battery
Led flashing, ac ustic
signal
Deep discharge
Charge and chec
k the batteries,
possibly defective battery
2 Linked Led flashing, audible signal Link err r
P ssible faulty battery r defective relay.
3 Top Charge Led flashing, audible
signal
Over-v ltage
The batteries are charged with excessive v ltage. If
this happens t l ng, the batteries can be ver-
charged. Check the l ad v ltage and check.
*Ac ustic signal can be suppressed (see Setting the modes n page 8).
**Ac ustic signal f under-v ltage err r 1 can be muted (see Explanation: Buttons p. 18). If device
audible signal changes instead f being muted immediately charge the respective battery due t super
l w v ltage!
Measures / Suspension
There are tw ways t perf rm a system reset:
 Pushing the Link- and Auto-button simultane usly will cause a system reset and restart the
m nit r.
 The m nit r is als reset by pulling the m nit r ut and plugging it back in again (the plug is
ab ut 15cm behind the m nit r).
In case f a n t fully w rking system please check the c nfigurati n in starting the monitor n page 8.

20
Specifications
Technical specifications
Input v ltage 6V-32V
Link v ltage Main t Aux
12V
12V
Li
-
type
24V
24V
Li
-
type
13.1V 13.3V 26.2V 26.6V
Link v ltage Aux t Main
12V
12V
Li
-
type
24V
24V
Li
-
type
13.1V 13.5V 26.2V 27.0V
De-link v ltage
12V
12V
Li
-
type
24V
24V
Li
-
type
13.0V 13.2V 26.0V 26.4V
Over-v ltage
12V
12V
Li
-
type
24V
24V
Li
-
type
15.0V 15.5V 30.0V 31.0V
Under-v ltage
12V
12V
Li
-
type
24V
24V
Li
-
type
12.0V 12.4V 24.0V 24.8V
Relay manual linking times 30 min / 2 h
Standby p wer c nsumpti n m nit r < 5 mA
P wer c nsumpti n display active (30s) < 20 mA
PCB quality IPC3 R HS (Military standard)
Efficiency Typical 95%
Temperature range -40 °C - +80°C
Dimensi ns m nit r 100 x 65 x 24 mm
Pr tecti n type h using m nit r IP40
Weight m nit r 0.1 kg
Wire cr ss-secti n blue / green 0.5mm
2
Wire cr ss-secti n black / red 1.0mm
2
Sealing relay Silik n
Dimensi ns relay 46 x 46 x 45 (78) mm
Pr tecti n type h using relay IP52
Weight relay 0.1 kg
Current c nsumpti n relay active 0.6 A 0.18 A
N minal current relay 200 A 100 A
Peak current relay 500 A 250 A
Relay w rking v ltage 9...15 V 20...30 V
Material p wer c ntacts relay silver AgSnO2
H using material relay NYLON Pa 6,6
Life relay (cycles) 100'000 @ 200 A 100`000 @ 100A
Tighten t rque relay M6 b lts 8 Nm max
Dimensi ns packaging 80 x 92 x 215 mm
Weight packaged 0.75 kg
Guarantee 5 Jahre
EMV Nach CISPER 25 (Aut m tive)
H m l gati n E24 ECE 10R
Pr ducti n standard ISO9001:2008
Click n installati n system IBS RMS System