Replying to my own thread in hopes that someone has had similar problems and has come up with an answer.
We have sent a BDI to Curtis who tested it and said that there was nothing wrong with it.
We are still having ongoing problems with these. On some BDI's, you can charge the battery forever and the BDI will not change. Take the exact same BDI and plug it into another battery and again it will not change.
This is ONLY to be used to report flooding, spam, advertising and problematic (harassing, abusive or crude) posts.