ICT ICT24012-30BC2 User manual

IntelliCharge Battery
Charger Series
INSTRUCTION MANUAL
855-342-000
Innovative Circuit
Technology Ltd.
Models:
ICT24012-30BC2, ICT24012-30BC2M
ICT24012-15BC2, ICT24012-15BC2M
ICT24024-15BC2, ICT24024-15BC2M
ICT24024-7BC2, ICT24024-7BC2M
ICT24048-7BC2, ICT24048-7BC2M
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WARNING
Risk of serious personal injury or damage to equipment and property! Always
observe the following:
•Install and operate unit in a Restricted Access location, such as an enclosed
equipment rack
•Operate the supply from a grounded 3-pin 120Vac or 230Vac outlet (50 or
60Hz) with a branch circuit breaker rated 20A or less
•Use only a Lead-Acid battery with rating and capacity appropriate for the
model charger in use
•Use an appropriate dc over-current protection device in line with the battery
connection
•Use a disconnect switch or circuit breaker in series with the battery
connection, to ensure installation and service is done with the battery de-
energised
•Use wire and connectors rated for the maximum load current and size of
battery fuse or circuit breaker
•Ensure battery polarity is correct before connecting
•Do not attempt to charge a frozen battery
•Handle batteries with care, do not short circuit battery terminals
CAUTION
Risk of personal injury or damage to equipment! Always observe the following:
•Install in a protected environment, keep sources of moisture away from unit
•Ensure the total power consumption of the load does not exceed the rated
capacity of the charger output
•Do not block air inlet or outlet openings in the unit
•Do not place the charger directly above or below a battery, due to possible
presence of corrosive and/or flammable gasses
Rev 1.04
2018
Copyright © 2018 Innovative Circuit Technology Ltd. All rights reserved. No part of this
publication may be reproduced, stored in a retrieval system or transmitted in any form or by
any means, electronic, mechanical, photocopying, recording or otherwise, without the prior
written consent of Innovative Circuit Technology Ltd.
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Innovative Circuit Technology Ltd. 3
INTRODUCTION
The ICT BC2 IntelliCharge series of intelligent battery chargers provide reliable dc
power to a system while precisely maintaining an external back-up battery using
an intelligent temperature compensated fast-charge algorithm. The wide-ranging
power factor corrected input supports operation worldwide, while a built in Low
Voltage Disconnect (LVD) relay will protect the battery from over discharge after
prolonged periods of backup operation when AC power has failed. Features
include:
•Dedicated independently controlled backup battery port with LVD relay
•Intelligent 3-stage fast charge algorithm for battery
•Optional remote battery temperature sensor for precise charge voltage
compensation (from -30C to +40C)
•Selectable battery charge settings for AGM, Flooded, or Gel batteries, or
fixed Float voltage operation
•Selectable charge rates to accommodate lower capacity batteries
•Wide range Power Factor corrected AC input supports operation world
wide
•Floating Form-C alarm contact output supports remote monitoring of
unit operation
Model1
Output
Voltage2
Max Output
Current
Continuous
Output Current
ICT24012-30BC2
13.65V
30.0A
30.0A
ICT24012-15BC2
13.65V
15.0A3
12.0A
ICT24024-15BC2
27.3V
15.0A
15.0A
ICT24024-7BC2
27.3V
7.5A3
6.0A
ICT24048-7BC2
54.6V
7.5A
7.5A
Optional Accessories:
19 inch rack mounting kit (mount up to 2 chargers): ICT-RMK5
Remote Battery Temperature Sensor (10ft): ICT-TMP
INSTALLATION
Perform a quick physical check of the unit as it is being taken out of the box to
ensure it has not been damaged during shipping. Check for the included parts
and accessories shipped with your unit:
•3 pin Form-C alarm connector plug (installed on unit)
1
A suffix letter “M” at the end of the model number is added to denote versions with
optional front graphic meter display
2
Fixed AGM Float Voltage
3
Max output current less than 10% duty cycle
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•Power cord (North America 120V 15A)
•Output connector cover (installed on connector)
•Instruction Manual
WARNING
Risk of serious personal injury or damage to equipment and property! Always
observe the following!
•Ensure the nominal battery voltage is correct for the model of charger, and
that the battery positive is connected to the BAT positive (+) terminal and
the battery negative is connected to the BAT negative (-) terminal.
•Use an appropriate dc over-current protection device such as a fuse or
circuit breaker in line with the battery connection
•Do not tie any of the LOAD and BATT terminals together, as this will bypass
internal circuitry
•Make Ground connection to only a single LOAD or BATT terminal if required.
Do not ground both LOAD and BATT as this will bypass internal circuitry
•The internal LVD relay switches the BATT + terminal. Do not connect the
battery + to any other terminal
•AC input wiring to the charger must be protected using an outlet with a
branch rated circuit breaker of 20A or lower value
Rear View (Connectors and BAT Switch 1-4)
Mounting:
The unit should be placed on a shelf near the backup battery and the load in a
location that restricts access to the wiring and battery terminals, such as in an
enclosed equipment cabinet. The unit may also be rack mounted using the
optional 19” 1U rack mounting kit (capacity for 2 chargers) ICT-RMK5.
Configure the Charger:
Always switch off the charger before changing the settings or making connections
to the unit.
•Choose a lead-acid battery bank with a nominal voltage rating
(12/24/48V) that matches the BC2 Series charger output.
•Configure the unit for the battery Type (BATT switches 1, 2) and
maximum charge current Size (BATT switches 3, 4) for the backup
battery used, by setting the BATT switches 1-4 on the back panel per the
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Innovative Circuit Technology Ltd. 5
tables below. Note that for good battery life the battery should have a
combined Ahr capacity of at least 3 times the maximum charge current
being used. (e.g. Use a 45Ahr or larger rated battery (3 x 15A) with a 15A
max charge setting)
Charge Mode Battery Type
BAT SW1
BAT SW2
Fixed AGM Float
1
1
AGM 3-Stage Fast Charge
1
0
GEL 3-Stage Fast Charge
0
1
FLOODED 3-Stage Fast Charge (default)
0
0
Battery Charge Mode - Switch Settings (1 = UP, 0 = Down)
AGM (or Absorbed Glass Mat) are the most common type of sealed battery
GEL is a more durable type of sealed battery, with a gelled electrolyte
FLOODED are the traditional vented lead-acid batteries with liquid electrolyte
Fixed AGM Float setting holds the BATT port at the AGM Float Voltage level (see
specifications page for value), with a max charge current limit set by the BATT
Switch settings 3, 4. Use this setting if the connected load requires a non-varying
output voltage, or if the backup battery is not used, or if it does not need to be
fast charged.
3-Stage Fast Charge settings will initially boost the voltage limit up to the battery
Absorption Voltage (see specifications page for values) for a faster rate of charge,
limiting the charge current to the maximum set by BATT Switches 3, 4. Once the
battery reaches the Absorption Voltage level, the charger will hold this voltage
until the current drops to a low value, or a maximum time limit is reached
indicating the battery is fully charged. The charger will then step the voltage
down to the Float Voltage level for long term maintenance. This cycle will be
repeated when AC power returns after outages, or may be triggered periodically
if the battery is left on charge for long periods.
Typical 3-Stage Charge Cycle
Bulk Charge
Time
Float Voltage
Absorption Voltage
V
I
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Max Charge
(% of Output)
Max Charge
(30A Models)
Max Charge
(15A Models)
Max Charge
(7.5A Models)
BAT
SW3
BAT
SW4
100%
30A
15A
7.5A
1
1
75%
22.5A
11.3A
5.6A
0
1
50%
15A
7.5A
3.8A
1
0
25% (Default)
7.5A
3.8A
1.9A
0
0
Maximum Charge Current –Switch Settings (1 = UP, 0 = Down)
Connect the Charger:
Connect the external alarm monitoring wiring to the Form-C alarm contact
output if desired, using 22-26AWG wire clamped in the removable Alarm/Temp
plug. (See Alarm Output Contacts table, below)
ALARM Pin
Name
Description
1
NC
Alarm State Normally
Closed contact
2
NO
Alarm State Normally
Open contact
3
C
Alarm output common
Alarm Output Contacts
Connect the optional remote battery temperature sensor (ICT-TMP) to the
TEMP input on the back panel removable connector. Using the TMP sensor will
enable the unit to compensate the charge Float voltage according to the battery
case temperature, to help fully charge cold batteries and ensure warm batteries
are not over charged. Connect each of the two wires on the remote temperature
probe to the two TEMP inputs on the back panel connector. (Polarity does not
matter) Affix the probe body to a side midpoint on one of the battery cases using
the adhesive backed plastic clip included with the sensor.
The unit will maintain the charge voltage at the nominal 25°C level if no
temperature sensor is detected.
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Innovative Circuit Technology Ltd. 7
Wire the load device to be powered by the charger directly to the LOAD +/-
output terminals on the charger back panel. Remove the snap on connector
cover and use appropriately sized wire with crimped on spade lugs sized to mate
with the output terminal block.
Connect the backup battery (or series string of batteries) negative wire to the
BATT –terminal. Connect the battery positive terminal to a suitably sized over
current protection device (fuse or Circuit breaker, 30A max) then to the charger
BATT + terminal. Use appropriately sized wire rated for the maximum operating
current, with crimped on spade lugs sized to mate with the output terminal block
screws.
Make a Ground connection (if required) to only a single +/- battery or load
terminal (Load side preferred). Do not connect both the load and battery to
ground as this will bypass critical internal circuitry, disabling the charge control
functions. The internal LVD relay is in series with the BATT + terminal.
Check that all connections to the charger are correct and tight; re-install the
snap on connector cover
Connect the AC power cord, with the front panel switch in the off position.
OPERATION
With the unit mounted, wired, and powered as described in the INSTALLATION
section, close the external battery breaker, or install the external battery fuse.
Turn the front panel power switch to the ON position and check that the green
CHARGE indicator on the front panel is flashing, indicating the battery is charging,
or is lit continuously indicating the battery is charged or the Fixed Float mode is
selected.
Front View (optional meter display shown)
The unit is now ready to power the load, and charge the backup battery. If AC
power should fail (or be switched off) the internal LVD relay will keep the battery
connected to the LOAD output, to ensure there is no interruption in output
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8 Innovative Circuit Technology Ltd.
power. Once the battery discharges to the LVD disconnection point the internal
LVD relay will open the BATT+ lead to prevent over-discharging the battery.
When AC power returns the unit will close the LVD contactor, and initiate a
battery charge cycle.
The unit may be used as a fixed output power supply without back-up, if no back-
up battery is connected to the BAT terminals. Set the charge mode to Fixed Float
on the BATT switch 1 and 2 settings.
Optional Front Graphic Display
An optional metering display is available on some charger models to show output
voltage, output load current and battery current, plus an indication of the charge
mode (Bulk, Absorb, or Float, or Battery not connected), Temperature Probe
connection, and any faults or warnings. The typical home screen is as shown.
Press the button below the display to turn on the display, and toggle the display
between output current and battery current measurements. Each step of the bar
graph represents a 10% increment in current. Note that the display will turn off
approximately 15 minutes after last use.
Status Indicators and Alarms
The 2 LEDs on the front panel and the Form-C alarm contacts on the back
indicate the status of the charger:
Alarm or
Notification
Trigger Condition
LOAD
Output
BATT
LVD
Red
FAULT
LED
Green
CHARGE
LED
Input AC OK,
battery charging
Normal operation,
battery charging
Enabled
CLOSED
-
BLINK
Input AC OK,
battery charged
Normal operation,
battery fully charged
(or unit is set to Fixed
Float V mode)
Enabled
CLOSED
-
ON
AC Under-
voltage Warning
Triggers when Input
Voltage drops below
approx. 90Vac
Enabled
CLOSED
ON
-
AC Fail
AC fails or front switch
is off (Battery above
LVD level)
Battery
power
only
CLOSED
ON
OFF
Battery Low
Triggers when battery
OFF
OPEN
ON
OFF
Current Bar Graph
Temperature probe
connected indicator
Charge Mode
(Bulk/Absorb/
Float/Battery
not connected)
Output (or Battery)
current
Output Voltage
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Innovative Circuit Technology Ltd. 9
Alarm or
Notification
Trigger Condition
LOAD
Output
BATT
LVD
Red
FAULT
LED
Green
CHARGE
LED
(when AC Off)
voltage falls below the
LVD threshold
System Fault
Indicates internal
circuit fault - Clears
when all fault
conditions are cleared.
Battery
power
only
CLOSED
ON
OFF
Battery Over
Voltage Fault
(AC present)
Triggers when the
battery voltage
exceeds the internal
OVP threshold for 3s
Enabled
OPEN
ON
OFF
DC Overvoltage
Shutdown
Triggers when the
Load output voltage
rises above
16.5/33/66VDC for 3s.
Clears when Input
power cycled off/on
Battery
power
only
CLOSED
ON
OFF
Over-
temperature
Shutdown
Triggers when internal
temperature is too
high. Clears when
back to normal range.
Battery
Power
only
CLOSED
ON
OFF
The form-C alarm contact will be triggered for any condition that lights the red
FAULT LED, or shuts down the output of the unit.
EMC Note: This equipment has been tested and found to comply with the limits
for a Class B digital device, pursuant to part 15 of the FCC Rules and ICES 003.
These limits are designed to provide reasonable protection against harmful
interference in a residential installation. This equipment generates uses and can
radiate radio frequency energy and, if not installed and used in accordance with
the instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular
installation. If this equipment does cause harmful interference to radio or
television reception, which can be determined by turning the equipment off and
on, the user is encouraged to try to correct the interference by one or more of
the following measures:
•Reorient or relocate the receiving antenna.
•Increase the separation between the equipment and receiver.
•Connect the equipment into an outlet on a circuit different from that to
which the receiver is connected.
•Consult the dealer or an experienced RF technician for help.
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PRODUCT SPECIFICATIONS
AC Input (IEC C 14 connector): 100 to 254Vac 50/60Hz
Peak Efficiency (typical): 90%
Model:
12V 30A
12V 15A
24V 15A
24V 7.5A
48V 7.5A
Output Voltage range
(Operating point set by auto 3
stage charge cycle)
12 –15.5V
12 –15.5V
24 –31.0V
24 –31.0V
48 –62V
Max Current Limit at nominal
rated output (12V, 24V or
48V) (+3%, -0% tol)
30A
15A
15A
7.5A
7.5A
Max Current Limit at max V4
23A
11.5A
11.5A
5.75A
5.75A
Continuous Current Rating at
nominal rated output
30A
12A
15A
6A
7.5A
Output Power (max, at
nominal V, 12, 24, or 48V)
360W
180W
360W
180W
360W
Input Current (max at 90Vac)
4.8A
2.4A
4.8A
2.4A
4.8A
Idle DC Power Draw5
<200mW
<200mW
<200mW
<200mW
<200mW
3-Stage Charge Parameters
(at 25°C)
Absorb V: AGM
14.55
14.55
29.1
29.1
58.2
Flooded
14.4
14.4
28.8
28.8
57.6
Gel
14.2
14.2
28.4
28.4
56.8
Float V: AGM
13.65
13.65
27.3
27.3
54.6
Flooded
13.2
13.2
26.4
26.4
52.8
Gel
13.8
13.8
27.6
27.6
55.2
Temperature Compensation
of V absorb and V float (with
optional remote temp sensor
ICT-TMP)
-30mV/°C
-30mV/°C
-60mV/°C
-60mV/°C
-120mV/°C
LVD Threshold V
11.0V
11.0V
22.0V
22.0V
44.0V
LVD Reconnect Threshold V
12.5V
12.5V
25.0V
25.0V
50.0V
4
Output current limit linearly de-rates with output voltage. Max limit at nominal rated 12.0, 24 or
48.0V, reducing at maximum output voltage of 15.5, 31, or 62V to levels shown
5
AC mains power off; backup battery connected; LVD open
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