Analytic Systems IBC320 Manuale utente

INSTALLATION &

OPERATION MANUAL

IBC320

Intelligent Battery Charger

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 and AS9100 Registered Company Battery Chargers•Inverters•Power Supplies•Voltage Converters

Revised - March 23, 2015

IMPORTANT & SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS — this user guide 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

attempting 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.

v. If acid enters eye, immediately ood eye with running cold water for at least 10

minutes and get medical attention immediately.

vi. NEVER smoke or allow a spark or ame in the vicinity of a battery.

vii. 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.

viii. 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.

ix. NEVER charge a frozen battery.

x. 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.

xi. Be sure area around battery is well ventilated.

xii. Clean the battery terminals. Be careful to keep corrosion from coming in contact

with eyes.

xiii. 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.

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.

Medical Equipment Notice

Analytic Systems does not recommend the use of the IBC Series Battery Chargers 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.

Specications

Input

Volts 85 - 265VAC, 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 12 VDC 24 VDC 32 VDC 48 VDC

Voltage Range ** 12.0 - 15.5 VDC 24.0 - 31.0 VDC 32.0 - 41.3 VDC 48.0 - 62.0 VDC

Output Current 20 Amps 10 Amps 7.5 Amps 5 Amps

Recommended Battery Amp-Hours 100 50 40 25

Standard Temperature Compensation -15mV/C -30mV/C -40mV/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”/24.1cm Long x 8.0”/20.3cm Wide x 3.25”/8.3cm High

Clearance 2.0”/5.0cm 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 Integrated Color Coded Terminal Blocks

Environmental and Safety

Operating Temperature Range -25 to +40 C (-40 to +55 C Optional)

Storage Temperature Range -55 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

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.

Designed and manufactured by: ANALYTIC SYSTEMS WARE (1993) LTD.

8128 River Way

Delta, BC V4G 1K5 Canada

p. 604.946.9981 f. 604.946.9983

tf. 800.668.3884 US/Canada

www.analyticsystems.com [email protected]

Introduction

The IBC320 Intelligent Battery Charger delivers a full 300 watts of charging power to charge a

12, 24, 32 or 48 volt, one or two bank battery system (batteries must share a common ground).

The charger comes standard with easy to use color coded battery connection terminals.

The charger uses advanced Power Factor Correction circuitry on the AC input so it will work

from any standard AC voltage anywhere in the world and use the electricity in the most

effective and efcient 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 Rectication on the Secondary or low voltage side ensures maximum efciency and

the lowest Electromagnetic Interference (EMI) so the EBC320 will not interfere with sensitive

voice or data RF communication equipment.

The charger is preprogrammed 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). It also has a 4th that is preset for a typical Lithium Ion battery. Any of

the 4 charging proles can be adjusted to suit a specic make and model of battery using the

PowerWizard software that is free to download from www.analyticsystems.com.

The charger is supplied with one battery temperature sensor and a second sensor can be

added for two bank battery systems. Based on the temperature of the batteries the charger

will adjust its charging 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

it 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 charging

algorithm programming and charger monitoring as well as a graphing function through the

built in USB 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.

IBC320 Intelligent Battery Charger

USER GUIDE

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 Mini-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. Make sure the charger is protected from water. In a marine environment, install the

optional drip shield above the charger if there is any possibility of water dripping onto it.

Installation

Connection

INSTALLATION INDICATORS

POL

TEMP 25

DEV

SVC

FLT

LO V

BAT

AC PRESENTBATTERY POLARITY REVERSED

POL

TEMP 25

DEV

SVC

FLT

LO V

BAT

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.

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

POL

FLOODED

BAT

TYPE

GELAGM

POL

FLOODED

BAT

TYPE

GELAGM

GEL

BLINKING

ABSORBED GLASS MAT

POL

FLOODED

BAT

TYPE

GELAGM

OTHER - DEFAULT L-ION

POL BAT

TYPE

CUSTOM

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

POL

25%

POWER

LIMIT

75%50% AC

POL

25%

POWER

LIMIT

75%50%

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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