Installation And Operation Manual For Battery

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Installation and Operation Manual for Battery Backup System Model 6160-E/H-48-NG Manual Part Number 7-9524-4 8625 Industrial Parkway, Angola, NY 14006 Tel: 716-549-4700 Fax: 716-549-4772 [email protected] www.birdrf.com Warranty This warranty applies for one year from shipping date. TX RX Systems Inc. warrants its products to be free from defect in material and workmanship at the time of shipment. Our obligation under warranty is limited to replacement or repair, at our option, of any such products that shall have been defective at the time of manufacture. TX RX Systems Inc. reserves the right to replace with merchandise of equal performance although not identical in every way to that originally sold. TX RX Systems Inc. is not liable for damage caused by lightning or other natural disasters. No product will be accepted for repair or replacement without our prior written approval. The purchaser must prepay all shipping charges on returned products. TX RX Systems Inc. shall in no event be liable for consequential damages, installation costs or expense of any nature resulting from the purchase or use of products, whether or not they are used in accordance with instructions. This warranty is in lieu of all other warranties, either expressed or implied, including any implied warranty or merchantability of fitness. No representative is authorized to assume for TX RX Systems Inc. any other liability or warranty than set forth above in connection with our products or services. TERMS AND CONDITIONS OF SALE PRICES AND TERMS: Prices are FOB seller’s plant in Angola, NY domestic packaging only, and are subject to change without notice. Federal, State and local sales or excise taxes are not included in prices. When Net 30 terms are applicable, payment is due within 30 days of invoice date. All orders are subject to a $100.00 net minimum. QUOTATIONS: Only written quotations are valid. ACCEPTANCE OF ORDERS: Acceptance of orders is valid only when so acknowledged in writing by the seller. SHIPPING: Unless otherwise agreed at the time the order is placed, seller reserves the right to make partial shipments for which payment shall be made in accordance with seller’s stated terms. Shipments are made with transportation charges collect unless otherwise specified by the buyer. Seller’s best judgement will be used in routing, except that buyer’s routing is used where practicable. The seller is not responsible for selection of most economical or timeliest routing. CLAIMS: All claims for damage or loss in transit must be made promptly by the buyer against the carrier. All claims for shortages must be made within 30 days after date of shipment of material from the seller’s plant. SPECIFICATION CHANGES OR MODIFICATIONS: All designs and specifications of seller’s products are subject to change without notice provided the changes or modifications do not affect performance. RETURN MATERIAL: Product or material may be returned for credit only after written authorization from the seller, as to which seller shall have sole discretion. In the event of such authorization, credit given shall not exceed 80 percent of the original purchase. In no case will Seller authorize return of material more than 90 days after shipment from Seller’s plant. Credit for returned material is issued by the Seller only to the original purchaser. ORDER CANCELLATION OR ALTERATION: Cancellation or alteration of acknowledged orders by the buyer will be accepted only on terms that protect the seller against loss. NON WARRANTY REPAIRS AND RETURN WORK: Consult seller’s plant for pricing. Buyer must prepay all transportation charges to seller’s plant. Standard shipping policy set forth above shall apply with respect to return shipment from TX RX Systems Inc. to buyer. DISCLAIMER Product part numbering in photographs and drawings is accurate at time of printing. Part number labels on TX RX products supersede part numbers given within this manual. Information is subject to change without notice. Bird Technologies Bird Technologies Manual 7-9524-4 04/14/16 Page 2 Manual Part Number 7-9524 Copyright © 2016 TX RX Systems, Inc. First Printing: March 2013 Version Number Version Date 1 03/15/13 2 03/28/14 2.1 11/26/14 3 10/05/15 4 04/14/15 Symbols Commonly Used NOTE VIDEO WARNING !!! High Voltage CAUTION or ATTENTION Hot Surface Important Information ESD Electrostatic Discharge Training Video Available Electrial Shock Hazard Heavy Lifting Safety Glasses Required Bird Technologies Manual 7-9524-4 04/14/16 Page 3 Changes to this Manual We have made every effort to ensure this manual is accurate. If you discover any errors, or if you have suggestions for improving this manual, please send your comments to our Angola, New York facility to the attention of the Technical Publications Department. This manual may be periodically updated. When inquiring about updates to this manual refer to the manual part number and revision number on the revision page following the front cover. Bird Technologies Technical Publications Angola Facility 8625 Industrial Parkway, Angola, NY 14006 Contact Information Sales Support at 800-866-8979 Customer Service at 866-695-4569 Technical Publications at 716-549-4700 extension 5019 Bird Technologies Manual 7-9524-4 Bird Technologies 04/14/16 Page 4 Table of Contents General Description ............................................................................................ 7 Unpacking ............................................................................................................ 9 Installation.......................................................................................................... 10 Location ............................................................................................................. 10 Mounting............................................................................................................ 10 AC Connections................................................................................................. 10 Alarm Connections ............................................................................................ 11 Alarm Testing .................................................................................................... 12 DC Output Connections..................................................................................... 12 Battery Installation ............................................................................................. 13 Batteries .......................................................................................................... 14 Battery Handling Precautions .......................................................................... 14 Battery Installation Procedure ......................................................................... 14 Operation............................................................................................................ 17 LED Indicators ................................................................................................... 18 Maintenance....................................................................................................... 18 Figures and Tables Figure 1: Front view of the unit ............................................................................ 8 Figure 2: Functional block diagram of system ...................................................... 9 Figure 3: DIN Rail layout .................................................................................... 10 Figure 4: Photograph of DIN Rails...................................................................... 11 Figure 5: Relay Status Indicator ......................................................................... 12 Figure 6: Battery wiring diagram......................................................................... 15 Figure 7: Battery installation 1 of 5 ..................................................................... 15 Figure 8: Battery installation 2 of 5 ..................................................................... 16 Figure 9: Battery installation 3 of 5 ..................................................................... 16 Figure 10: Battery installation 4 of 5 ................................................................... 16 Figure 11: Operational flow diagram ................................................................. 18 Figure 12: Charger assembly LED indicators .................................................... 19 Table 1: Specifications .......................................................................................... 7 Table 2: Alarm relay truth table ........................................................................... 12 Bird Technologies Manual 7-9524-4 04/14/16 Page 5 GENERAL DESCRIPTION The model 6160-E/H-48-NG Battery Backup System is designed to provide uninterruptible backup voltage for Bird Technologies signal boosters. The backup supply is provided by four high capacity 12 VDC lead acid batteries connected in series, which supplies the 48 VDC needed for backup operation. DC power to the signal booster is supplied either from the power supply assembly in the battery backup unit (if AC power is available) or from the series connected batteries (if AC power is not available). The change over from power supply to battery power is automatic and instantaneous. No mechanical or electronic controls are required. The unit has an integrated battery charger and monitor system that maintains peak battery charge level when AC mains is present. The battery backup unit provides operational status indicators and auxiliary alarm connections for remote monitoring. When used in conjunction with a Resculine™ signal booster, the battery backup provides a fully NFPA compliant system solution. Specifications for the battery backup system are listed in Table 1. A front view of the battery backup unit is shown in Figure 1. Two batteries are mounted below the shelf against the back of the cabinet and two batteries are mounted on the shelf against the back of the cabinet. The battery charger assembly (black) is mounted to the door. An auxiliary control board is attached to an upper DIN Rail on the top inside of the door. The upper DIN Rail is also used to mount control signal relays, fuses, and various terminal screw blocks. The power supply assembly is mounted to a lower DIN Rail to the left of the charger assembly. Parameter Specification AC Input 120 VAC (9.5 Amp) 60 Hz. DC Output 48 VDC at 4.5 Amps (max load)* Alarm Outputs Charger Fail Low Battery Voltage Loss of AC Alarm Contact Ratings Form-C 2A @ 24 VDC (or) 0.25A @ 120 VAC Status Indications DC Fuse LED’s Relay Status Indicator Windows Charger Status LED’s Operating Temperature Range 0 to 50°C Batteries Model 6160-H-48-NG/NR Model 6160-E-48-NG/NR Four (12) Volt (6 cell) Maintenance free sealed lead-acid 75 Amp Hour 120 Amp Hour Forced Air Cooling Thermostatically controlled Cabinet Size 38” W x 25.56” H x 14.02” D Cabinet Color NG = Grey, NR = Red Weight Model 6160-H-48-NG/NR (75 AH batteries) Model 6160-E-48-NG/NR (120 AH batteries) 108 lbs. (cabinet only) 308 lbs. (cabinet and 4 batteries) 436 lbs. (cabinet and 4 batteries) * Note: The configuration of the signal booster will determine the amount of current drawn from the battery backup unit. The maximum load on the battery backup unit would be offered by an SBIII configured with two 30-filter modules, three power amps, and a control card. Table 1: Specifications. Bird Technologies Manual 7-9524-4 04/14/16 Page 7 Upper DIN Rail mounted relays, fuses, terminal block Auxiliary Board Lower DIN Rail Charger Assembly Power Supply Assembly Battery 2 Battery 3 Charger to Batteries Plug Battery 4 Fan/Vent Battery 1 Figure 1: Front view of the Battery Backup System. A block diagram of the battery backup system is shown in Figure 2. As an example the battery backup unit is shown in the diagram connected to an NFPA compliant signal booster. However, please keep in mind that the battery backup unit is capable of supplying backup power to a wide variety of products or systems. AC power is applied to the charger assembly which produces a charging voltage to recharge the batteries. A power supply assembly is used to supply 48 Volt operating voltage to the signal booster cabinet. When there is a loss of AC power the stored charge in the batteries will provide a DC operating voltage for the booster. Before the DC output voltage leaves the battery backup unit it passes Bird Technologies Manual 7-9524-4 through a pair of 6.3 Amp fuses (F1 and F2) located on the upper DIN Rail. Fuses F3 and F4 are located on the lower DIN Rail. Fuse F3 protects the 24 Volt center tap on the batteries and Fuse F4 protects the positive output of the power supply. The Auxiliary Board is used to control two signal relays. Each signal relay controls a pair of Form-C contacts (one pair is normally open and the other pair is normally closed) which are used to indicate a “Low Battery” condition and a “Charge Failure” condition. A third signal relay is connected to the output of the power supply and is used to indicate a loss of AC power. This relay also has a pair of Form-C contacts (normally open and normally closed). 04/14/16 Page 8 48V Battery Backup Unit + VDC Charge Fail Relay K1 +48VDC from Battery Backup F1 F3 + 12V - + 12V - + 12V Power and Alarms + + Liquid Tight Conduit Power Supply DC F4 Out Charge Fail Loss of AC Relay K3 Fire Alarm Panel interface Facility Fire Alarm Panel Antenna Malfunction In SB Failure AC COM - Loss of AC Power - COM + 12V Low Batt - Antenna Line Alarm Monitoring Unit COM F2 Control Card COM Charger to Batteries Plug Low Batt Relay K2 COM Auxilliary Board Charger Assembly SBIII Signal Booster Unit Antenna Line Sender Unit Fault Signals to Fire Alarm Panel To Distributed Antenna System Donor Antenna Zone 1 Zone 2 Liquid Tight Conduit Zone 3 Zone 4 Weather Proofed Remote Antenna Line Sensor Zone 5 Figure 2: Block diagram of the 48 Volt Battery Backup system. The K3 relay is mounted next to the power supply. This relay is used to switch the load between the power supply and the batteries. This is an AC energized relay and will be in the energized state whenever AC power is supplied to the battery backup unit. In the energized state the relay contacts route the power supply to the load. When a loss of AC power occurs the relay will de-energize and the relay contacts will then route the batteries to the load. the battery backup unit if there is visible damage. It is the customer’s responsibility to file damage claims with the carrier within a short period of time after delivery (1 to 5 days). Care should be used when removing the unit from the packing box to avoid unnecessar y damage. The unit is not intended to be transported with the batteries in place. Damage to the batteries, electronic equipment and case may result if this is attempted. The batteries should not be installed until the unit is positioned in it’s final location. UNPACKING It is very important to report any visible damage to the carrier immediately. Do not install or operate Bird Technologies Manual 7-9524-4 04/14/16 Page 9 INSTALLATION The following sections discuss general considerations for installing the booster. All work should be performed by qualified personal in accordance with local codes. NOTE Mounting Mounting areas must be clean, dry and free from combustible materials and open flames. The ambient temperature of the mounting location should be between 0°C and 50°C. The unit is designed for floor or bench mounting. Install on a surface of non-combustible material, such as stone, brick, concrete or metal. For additional stability an angled bracket can be mounted to the floor/bench then attached to the side of the cabinet to prevent the unit from moving after it is installed. In areas of known seismic activity, additional devices such as tether lines may be necessary. The Battery Backup Unit is intended for indoor use only. Location The layout of the communications system will be the prime factor in determining the mounting location of the battery backup unit. However, safety and serviceability are also key considerations. The unit should be located where it cannot be tampered with by the general public, yet is easily accessible to service personnel. Also consider the weight of the unit and the possibility of injury if the unit should become detached from its mounting location for any reason. NOTE AC Connections The battery backup must be connected to a 120 VAC source (+/- 10%), single-phase at 60 Hz, and capable of providing 9.5 Amps. There are holes in the left-side of the cabinet for the connection of conduit. The AC feedline should be brought into the cabinet through the conduit and terminated at the AC Input ter minal strip on the lower DIN rail attached to the inside of the door. Connections should be made to the top terminal screws on the terminal block. See Figure 3. The AC input wire size should be 12 - 10 AWG. The terminal is rated Due to the weight of the unit after the batteries are installed in the cabinet, the unit is designed for floor or bench mounting only. TB2 TB1 TB3 8 - K3 7 - K3 COM 6 - K2 5 - K2 3 - K1 4 - K2 COM 2 - K1 1 - K1 COM 9 - K3 No Connection No Connection No Connection 2 DC OUT - DC Fuse 4 Note: User connections should be to the top side of terminals as required. GND GND 2 AC 2 AC 1 AC 1 AC K3 Relay DC Fuse 2 DC Fuse 3 1 DC OUT + DC Fuse 1 K2 Relay K1 Relay NOTE 48 Volt Power Source Aux Board Figure 3: Upper and lower DIN Rail layout. Bird Technologies Manual 7-9524-4 04/14/16 Page 10 for 22 AWG to 10 AWG wire with a recommended torque value of 12 in/lbs. To reduce the risk of fire, the AC supply should have branch circuit breaker protection of 15 Amps maximum rating in accordance with the National Electric Code, ANSI/NFPA 70 or equivalent. CAUTION: Use 75 °C wiring for supply connections. Ground the charger properly using ground terminal provided. Use copper-clad aluminum, aluminum, or copper conductors only. Alarm Connections There are three alarm connections available in the battery backup unit including; Charge Fail, Low Battery, and Loss of AC. Each alarm is announced using a pair of Form-C contacts. One pair is norFuse Open Indicator LED’s mally open and the other pair is normally closed. A Charge Fail alarm occurs whenever the charger assembly fails to produce a charging voltage. The Low Battery alarm occurs whenever the battery voltage falls below the 1.83 VPC (volts per cell) threshold. There are a total of 24 cells within the pair of series connected batteries. At a threshold of 1.83 VPC the low battery alarm will occur at 44.0 Volts. This threshold level is factory set and is not field adjustable. The Loss of AC alarm occurs when the power supply output is interrupted. Refer to Table 2 which lists a truth table of the alarm relays operation. Relay K1 is used for the Charge Fail alarm, relay K2 is used for the Low Battery alarm, and relay K3 is used for the Loss of AC alarm. Under normal operating conditions the alarm relays are energized. NorOutput Power and Alarm Terminal Connections Charger Status LED’s Relay Status Indicator AC Input Power Terminal Connections Fuse Open Indicator LED’s Relay Status Indicator Power Supply On Indicator LED Figure 4: The DIN Rails mounted to the inside of the cabinet door. Bird Technologies Manual 7-9524-4 04/14/16 Page 11 mal operating condition is defined as the battery backup unit powered-up, operating as usual, with no alarms being announced. An alarm condition being detected will result in the associated relay becoming de-energized. When energized the status indicator on the relay will be filled, refer to Figure 4. So under normal operating conditions the relay status indicators should all be filled. A closeup of the relay status indicator is shown in Figure 5. Status Indicator Windows Figure 5: Close-up of the Relay Status Indicator. When connecting to the alarm terminals use 10 22 gauge wire. Route the alarm wiring out the holes in the left side of the cabinet making sure that they are run through conduit separate from the AC supply wires and the DC Output wires. NOTE NOTE State K1-1 to K1-2 (normally closed) Continuity K1-1 to K1-3 (normally open) NO Continuity K2-4 to K2-5 (normally closed) Continuity K2-4 to K2-6 (normally open) NO Continuity K3-7 to K3-8 (normally closed) Continuity K3-7 to K3-9 (normally open) NO Continuity Note: The state conditions in this list are shown while the battery backup is in its normal operating condition, which is powered up, operating as usual, with no alarm indications. An alarm event will cause the state of the affected pairs to flip (closed will open and open will close). Reminder: K1 = Charge Fail, K2 = Low Battery, and K3 = Loss of AC Table 2: Alarm relay truth table. Bird Technologies Manual 7-9524-4 Do not exceed the relay contacts maximum current rating of 2 Amps @ 24 VDC or 0.25 Amps @ 120 VAC. Alarm Testing During system installation it may be necessary to temporarily generate an alarm condition for each of the alarm functions in the battery backup unit. To test the charger fail alarm simply disconnect the AC operating voltage from the battery backup. The charge fail relay K1 will switch from the normally energized state to the de-energized state. NOTE Contact Pair (with no alarm occurring) When AC supply voltage is removed from the batter y backup unit the charge fail relay and loss of AC relay will change state. It takes awhile for the charge fail relay to de-energize after AC power to the battery backup is removed. This is due to the discharge time constant of capacitors in the charging assembly. To test the loss of AC alarm simply disconnect the AC operating voltage from the battery backup. The loss of AC relay K3 will switch from the normally energized state to the de-energized state. To test the low battery alarm disconnect the red battery voltage sensing wire at the auxiliary board. This wire brings the battery voltage to the auxiliary board to be measured. When the voltage on this sensing wire drops to 44 VDC a low battery alarm is generated. By disconnecting the wire the auxiliary board will assume that the battery voltage is 0 volts and relay K2 will be de-energized. The red wire is attached to a terminal screw at the bottom of the auxiliary board. DC Output Connections A pair of terminal screws are available on the upper DIN Rail for DC output from the battery charger to the backed-up equipment such as the Bird Technologies signal booster. The screw terminals are 04/14/16 Page 12 available at terminal block 2 (TB2) and are labeled “1 DC Output +” and “2 DC output -”. The DC Output voltage level is 48 VDC at 4.5 Amps max load. See figure 4. There are holes in the left-side of the cabinet for the connection of conduit. The DC Output voltage should be brought out of the cabinet and routed to the equipment requiring backup voltage through the conduit. When connecting to the DC Output screw terminals use a minimum of 14 gauge wire. Route the DC Output wires through a conduit that is separate from the AC supply wires and alarm wires. Both the positive and negative leg of the DC output are protected by a 6.3 Amp fuse connected in series with the output leg (F1 for positive and F2 for negative). The fuses are mounted to the DIN Rail and each has an associated indicator LED as shown in figure 4. When the fuse LED indicator is illuminated the fuse is open and current flow to the user’s equipment is interrupted. Battery Installation The battery backup unit and the batteries are shipped separately. The batteries must be installed in the unit as part of the installation process. Batt 3 Batt 2 24 Volt Tap Batt 4 Batt 1 (+) Charger to Batteries Plug To Charger To Charger (Red) To DC Fuse 1 (Black) To DC Fuse 2 To DC Fuse 3 (Yellow) (-) Figure 6: Battery wiring diagram. Bird Technologies Manual 7-9524-4 04/14/16 Page 13 CAUTION: The batteries should not be installed until the unit is physically positioned into it’s final location. The unit should not be moved while the batteries are installed. BATTERIES Working with and in the vicinity of lead acid batteries is dangerous and caution must be taken to prevent possible injury. The batteries used in the battery charger system are sealed. However they are equipped with an internal safety release valve which is designed to open, vent, then reseal if internal gas pressure reaches sufficient levels. The battery used in the battery backup unit is an efficient maintenance free electro-chemical system designed to provide years of trouble free service. The battery is fabricated with sealed construction techniques that guarantee leak-proof operation. There is no need to check the specific gravity of the electrolyte or add water. In fact, there is no provision for this type of maintenance. The batteries performance and service can be maximized by observing the following guidelines. 1) Heat kills batteries. Do not install or operate the battery backup unit in close proximity to heat sources of any kind. Ideal service life will be realized when the batteries are operated in an ambient temperature of 20° to 25°C (68° to 77° F). 2) The battery backup unit should not be installed in air-tight rooms or compartments, adequate ventilation must be provided. 3) Avoid installing the battery backup unit in an atmosphere where organic solvents or adhesives may be present. Do not clean the batteries with oils, thinners or similar substances. The case of the batteries is ABS plastic resin which may suffer damage from these chemicals. If cleaning is required use a damp rag and avoid contact with the terminals. Terminals can be cleaned carefully with a wire brush. BATTERY HANDLING PRECAUTIONS Batteries are live at ALL times and can cause severe shock or eye damage if handled improperly. Installation should be performed by experienced personnel. The following precautionary measures should be observed whenever working with the batteries. Bird Technologies Manual 7-9524-4 • Always wear insulated gloves and wear eye protection when handling the batteries. • Do not solder to the battery terminals. • Handle batteries cautiously, do not drop them. The electrolyte contains sulfuric acid which can cause serious damage to your eyes and skin. Should this occur, flush profusely with water and seek medical attention immediately. • Highly flammable hydrogen gas may be vented by the battery if internal gas pressure reaches sufficient levels. To avoid risk of fire or explosion, keep sparks or other sources of ignition away from the immediate vicinity of the battery. • Do not smoke or allow an open flame near the battery. • Do not allow metallic materials to simultaneously contact the negative and positive terminals of the battery. • Mixing batteries of different capacities, age and/or manufacture is not recommended. • Do not crush, incinerate or dismantle the battery. • Batteries MUST be recycled or disposed of properly. BATTERY INSTALLATION PROCEDURE The battery backup unit is available with two different batteries, 75 or 120 AH. These two battery types differ physically but install into the cabinet using the same procedural steps. This manual shows the installation of the 75 AH type batteries as an example but the procedure would be the same if 120 AH batteries were used instead. All of the parts (cables, plug, nuts/bolts) required to install the batteries are packaged in a plastic bag which is shipped attached inside of the cabinet. To install the batteries into the unit refer to the wiring diagram shown in Figure 6 and perform the following in a step-by-step fashion; 1) Set two batteries in an upright vertical posture, side by side on the upper shelf. Set two batteries in an upright vertical posture on the lower shelf. Keep the batteries towards the front of the unit slightly. This will give you as much room as possible in order to make the wiring connec- 04/14/16 Page 14 Figure 7: Place the batteries into the cabinet. Connect the negative terminal of battery 2 to the positive terminal of battery 3. Also connect the yellow 24 Volt tap wire (from DC Fuse 3) to the positive terminal of battery 3. Figure 8: Connect the positive terminal of battery 2 to the negative terminal of battery 1. Bird Technologies Manual 7-9524-4 04/14/16 Page 15 Figure 9: Connect the negative terminal of battery 3 to the positive terminal of battery 4. Figure 10: Connect the red wire from the “charger to batteries plug” and the red wire from DC Fuse 1 to the positive (red) terminal of battery 1. Connect the black wire from the “charger to batteries plug” and the black wire from DC Fuse 2 to the negative (black) terminal of battery 4. Pay critical attention to the wire color coding for this step, red to red and black to black. (Refer to figure 6 and make sure all the wires are connected as shown in the diagram) Bird Technologies Manual 7-9524-4 04/14/16 Page 16 tions. Each of the four batteries can be pushed back into place at the end of the installation procedure, see Figure 7. 2) Connect a short cable between the negative terminal of battery two and the positive terminal of battery three. This piece of cable is supplied with the unit and is packed into a plastic bag in the bottom of the cabinet. Also attach the 24 Volt tap (yellow wire) from DC Fuse 3 on the lower Din Rail to the positive terminal of battery three. Use a nut, bolt, and two washers for each terminal. Place a washer on each side of the battery terminal then pass a bolt through the washers/terminal and secure with a nut. Tighten the bolt to the torque specification of 3.9 to 5.4 Nxm. See figure 7. 3) Connect a long cable between the positive terminal of battery two and the negative terminal of battery one. This piece of cable is supplied with the unit and is packed into a plastic bag in the bottom of the cabinet. Use a nut, bolt, and two washers for each terminal. Place a washer on each side of the battery terminal then pass a bolt through the washers/terminal and secure with a nut. Tighten the bolt to the torque specification of 3.9 to 5.4 Nxm. See Figure 8. 4) Connect a long cable between the negative terminal of battery three and the positive terminal of battery four. This piece of cable is supplied with the unit and is packed into a plastic bag in the bottom of the cabinet. Use a nut, bolt, and two washers for each terminal. Place a washer on each side of the battery terminal then pass a bolt through the washers/terminal and secure with a nut. Tighten the bolt to the torque specification of 3.9 to 5.4 Nxm. See Figure 9. 5) Connect the red wire from the large black barrel shaped connector (charger to batteries plug) included in the parts bag, to the positive terminal of battery one. Also connect the red (+) wire from DC Fuse 1 on the upper Din Rail to the positive terminal of battery one. Use a nut, bolt, and two washers for each terminal. Place a washer on each side of the battery terminal then pass a bolt through the washers/terminal and secure with a nut. Tighten the bolt to the torque specification of 3.9 to 5.4 Nxm. See Figure 10. Bird Technologies Manual 7-9524-4 6) Connect the black wire from the large black barrel shaped connector (charger to batteries plug) included in the parts bag, to the negative terminal of battery four. Also connect the black (-) wire from DC Fuse 2 on the Din Rail to the negative terminal of battery four. Use a nut, bolt, and two washers for each terminal. Place a washer on each side of the battery terminal then pass a bolt through the washers/terminal and secure with a nut. Tighten the bolt to the torque specification of 3.9 to 5.4 Nxm. See figure 10. 7) Push all of the batteries back against the rear of the enclosure or shelf. 8) Connect together the two sides of the large black barrel shaped connector (charger to batteries plug). This connector is keyed. The two threaded halves must mate completely. This completes the battery installation procedure. OPERATION The operation of the battery backup system is illustrated by the operational flow diagram shown in Figure 11. WARNING: Verify that the battery voltage is correct before applying AC power to the battery backup system. Do not apply AC power if a voltmeter does not indicate a battery voltage between 40.8 to 60.0 Volts as measured across the four in-series batteries. Measure from the positive terminal of battery one to the negative terminal of battery four. When AC power is applied the charger will perform a brief power-up test then start charging. Charging begins with a slow voltage walk-up until approximately 2.35 VPC (volts per cell) is achieved. There are 6 cells per battery and 4 batteries connected in series so the walk-up should continue until about 56.4 Volts is reached (24 x 2.35 = 56.4). The charger delivers maximum current during this mode of operation. If the charging voltage is below approximately 2.35 VPC the charger will remain in the walk-up mode (delivering maximum current) until the 2.35 VPC threshold is reached. Once 2.35 VPC is reached the charger will switch to a constant voltage mode maintaining approximately 2.35 to 2.40 VPC. At 04/14/16 Page 17 this point the charging current will begin to slowly drop as the batteries reach peak charge. When the charging current drops below approximately 1 Amp the charger will turn off. There is a 30 minute delay mode between charge termination and the start of float mode. During the float mode the charger will maintain battery voltage at approximately 2.2 VPC. There are 6 cells per battery and four batteries connected in series so the float voltage should be about 52.8 Volts (24 x 2.20 = 52.8). The float mode may include short charge pulses of low current. as needed to keep the batteries topped-off. LED Indicators There is a green and a yellow status LED located on the top of the charger assembly, see Figure 12. During the start of charging (constant current flowing) the yellow LED will be illuminated solid. During the constant voltage mode the green LED will be illuminated solid. Both LED’s will be out during the 30 minute delay. The float mode is indicated by both LED’s flashing rapidly. There are also status indicators for the alarm relays and LED indicators for the DC fuses. These are located on the DIN Rail and explained in a earlier section of the manual tilted Alarm Connections. MAINTENANCE The battery backup system can be expected to operate for years with little maintenance or repair. Routine inspection of the battery backup unit is recommended and the following items should be checked. 1) Verify all wiring connections are tight and properly connected. 2) The yellow and green status LED’s on the charger assembly should both be flashing, indicating the charger is in the float mode. 3) The fuse LED’s should be OFF indicating the fuses are OK. 4) The relay status indicators should be filled indicating the alarm relays are energized and no alarm conditions exist. 5) The power supply LED On indicator should be green indicating the power supply is functioning properly. Figure 11: Operational flow diagram. Bird Technologies Manual 7-9524-4 04/14/16 Page 18 6) The power supply output should be 48.0 VDC and should be measured at the DC output fuses. 7) Check the batteries for any evidence of cracking or leakage of the electrolyte. NOTE If for any reason the battery backup unit needs to be returned to the factory for service it is important that the batteries be removed before shipping. DO NOT ship the batteries to the factory. 8) Check the battery terminals and battery cable connections for signs of corrosion. 9) Using compressed air clean dust from the cooling slots and fan. Green and Yellow Status LED’s Figure 12: Charger assembly LED Indicators. Bird Technologies Manual 7-9524-4 04/14/16 Page 19 8625 Industrial Parkway, Angola, NY 14006 Tel: 716-549-4700 Fax: 716-549-4772 [email protected] www.birdrfcom