ASL INTERCOM BPC130 Series User manual

Product Manual
ASL Document Ref.: U-0456-0145.doc
Issue: 04 complete, approved - Date: 25/10/11
BPC130 / BDIST / MDIST
Battery Pack, Charger, Battery and Mains Distribution
BATTERY TRAY
(for rack with 800 mm depth)
CHARGER
AND
BATTERY DISTRIBUTION TRAY

BPC130 / BDIST / MDIST – Product Manual
Copyright © 2011 Application Solutions (Safety and Security) Limited
Application Solutions (Safety and Security) Limited
Unit 17 Cliffe Industrial Estate
Lewes - East Sussex
BN8 6JL - UK
Tel: [phone] Fax: [phone]
www.asl-control.co.uk
All rights reserved.
Information contained in this document is believed to be accurate. However, no representation or warranty is given and Application
Solutions (Safety and Security) Limited assumes no liability with respect to the accuracy of such information.
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This equipment is designed and manufactured to conform to the following EC standards:
EMC: EN 61000-6-4:2007, EN 61000-6-2:2005, EN 50121-4:2006,
EN 61000-4-13:2002, ENV 50204:1995, EN 50130-4:1996
Safety: EN 60950-1:2006 (pollution degree 2)
Voice Alarm: When installed in a Voice Alarm system designed in accordance with the
ASL EN 54-16 & ISO 7240-16 System Design Guide (T-0667-0016) and
configured as described in its user documentation, this equipment meets
the requirement of EN 54-16:2008, ISO 7240-16:2007, BS 5839-8:2008,
EN 54-4:1997, EN 54-4:1997/A1:2002 and EN 54-4:1997/A2:2006.
A ‘Declaration of Conformity’ statement to the above standards, and a list of auxiliary
equipment used for compliance verification, is available on request.
Failure to use the equipment in the manner described in the product literature will
invalidate the warranty.
This product must be disposed of in accordance with the WEEE directive.

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Contents
1Overview .....................................................................................................................................................5
2Operation ....................................................................................................................................................7
2.1 Controls.......................................................................................................................................7
2.2 Indicators.....................................................................................................................................7
3Installation..................................................................................................................................................8
3.1 Equipment and Tool Requirements ............................................................................................8
3.2 Cabling Requirements.................................................................................................................8
3.3 Main Components........................................................................................................................9
3.4 Recommended Installation Procedure .......................................................................................9
3.4.1 Battery Backup System Installation – Rack with 800 mm Depth ......................................10
3.4.1.1 Installing the Battery Tray and Batteries................................................................10
3.4.1.2 Installing the Charger Tray and Charger ................................................................12
3.4.1.3 Connecting the Power Distribution (BDIST)............................................................14
3.4.1.4 Connecting the Batteries.........................................................................................15
3.4.1.5 Fitting the Front Panel ............................................................................................15
3.4.1.6 Powering the system up..........................................................................................16
3.4.1.7 Commissioning the Battery Backup System at the Router.....................................16
3.4.2 Battery Backup System Installation – Rack with 600 mm Depth ......................................17
3.4.2.1 Installing the Battery Tray and Batteries................................................................17
3.4.2.2 Installing the Charger Tray and Charger ................................................................18
3.4.2.3 Connecting the Power Distribution (BDIST)............................................................18
3.4.2.4 Connecting the Batteries.........................................................................................19
3.4.2.5 Fitting the Front Panel ............................................................................................20
3.4.2.6 Powering the system up..........................................................................................20
3.4.2.7 Commissioning the Battery Backup System at the Router.....................................20
3.4.3 MDIST Installation .............................................................................................................20
4Connection Diagram .................................................................................................................................21
5Commissioning .........................................................................................................................................22
5.1 Obtaining the Router’s Contact .................................................................................................22
5.2 Configuring the Router Contact for Fault Reporting ................................................................22
5.3 Configuring the Fault Text ........................................................................................................24
5.4 Configuring the Fault Type........................................................................................................24
6Fault Finding.............................................................................................................................................25
7Maintenance .............................................................................................................................................27
7.1 Visual Inspection .......................................................................................................................27
7.2 Resistance Measurement..........................................................................................................27
7.3 Battery Replacement ................................................................................................................28
7.3.1 800 mm Deep Rack ............................................................................................................28
7.3.2 600 mm Deep Rack ............................................................................................................29
8Product Specification................................................................................................................................30
9Mechanical Dimensions............................................................................................................................32
10 Safety and Precautions.............................................................................................................................35
10.1 Handling ....................................................................................................................................35
10.2 Installation ................................................................................................................................35
10.3 Weight Safety.............................................................................................................................35
10.4 Environmental...........................................................................................................................35
10.5 Electrical Safety ........................................................................................................................35
10.6 Fire / Burn Safety ......................................................................................................................36
10.7 Battery Disposal ........................................................................................................................36

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10.8 Unpacking and Handling ...........................................................................................................36
10.9 Packing for Return for Repair...................................................................................................36
11 Reference Documents ..............................................................................................................................37

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1 Overview
The BPC130 is a 19” rack mounting self-contained 24 V DC battery backup system for use with ASL Voice
Alarm systems. It is designed to comply with EN 54-16, ISO 7240-16 and BS 5839-8.
The BPC130 is for use on 230 V AC mains supply and provides 130Ah of battery capacity with a 6.5 A
recharge rate. The battery system features temperature compensation of the charge voltage to maximise
battery life. The unit is fully monitored to the requirements of EN 54-4 and BS 5839-8 and provide fault-
reporting outputs for direct connection to the Voice Alarm Router1.
Eight BDIST 25 A and two BDIST 3 A outputs are provided. The BDIST (Battery Distribution) comprises all of
the required connectors and miniature circuit breakers. The 25 A outputs are normally used for connecting
ASL Amplifier Mainframes2. The 3 A outputs are used with low current 24 V DC powered equipment such as
the ASL VA Routers. Various battery power distribution cable assemblies are available from ASL for
connecting the relevant equipment.
The BPC130 battery system for racks with 800 mm depth is comprised of one charger tray, one battery tray
and four 6 V batteries3; see Figure 1 (page 6). It requires 8U rack space.
The BPC130 battery system for racks with 600 mm depth is comprised of one charger tray, two battery
trays and four 6 V batteries3. It requires 13U rack space.
The charger tray is designed to fit into racks with 600 mm or 800 mm depth. The battery tray is available for
a variety of 19” rack types. As additional rack types are regularly added, check with ASL for current
availability on any given rack type.
The MDIST (Mains Distribution) provides all of the required components for mains distribution from a
32 A rack input to the required number of outputs. All outputs are 10 A IEC320-IEC320 leads which are
primarily designed for connection to an ASL Amplifier Mainframe but are also suitable for other equipment.

A variety of factors need to be carefully considered when designing battery backup systems
for Voice Alarm applications. To assist in this process, a battery requirements calculator is
available from the ASL’s website at www.asl-control.co.uk.
!
!
At the time of the publication of this manual, only the BPC130 battery system for Schroff
800 mm Eurorack is EN54-16 and EN 54-4:1997+A1:2002+A2:2006 certified. Please refer to
ASL for further details.
1The VA Router can be any ASL rack mounted Voice Alarm and Public Address system: VAR4, VAR12, VAR20, VAR8, or VAR8-ACU
2ASL Amplifier Mainframes: V400, X400, iPA400-DC and iPAM400
3Refer to the Product Specification (page 31) for part numbers.

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Figure 1 BPC130 charger tray and battery tray layout
BATTERY (2 x 6 V) *
BATTERY (2 x 6 V) *
3U
CHARGER BDIST
5U 3U
CHARGER BDIST
RACK DEPTH = 800 mm
660 mm
5U5U
385 mm
RACK DEPTH = 600 mm
BATTERY *
(1 x 6 V)
BATTERY *
(1 x 6 V)
BATTERY *
(1 x 6 V)
BATTERY *
(1 x 6 V)
BATTERY TRAY BATTERY TRAY
CHARGER
TRAY
(PN: BPC130)
CHARGER
TRAY
(PN: BPC130)
(PN: BTRAY130-SER600)
BATTERY TRAY
(PN: BTRAY130-SER600)
(PN: BTRAY130-SER800)
* BATTERY PACK = 4 x 6V
(PN: BPC130-BAT)

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2 Operation
2.1 Controls
Figure 2 BDIST Mini Circuit Breakers
(REAR OF RACK)
BDIST
BDIST: The battery outputs are connected/disconnected to/from the systems by Miniature Circuit Breakers
(MCB) provided with the BDIST at the rear of the charger tray.
2.2 Indicators
Figure 3 Charger indicators
CHARGER
(REAR OF RACK)
LED Status Indication
ON Mains is present
Power
(green) OFF Mains not present
OFF No fault
Single flash
repeated at
regular interval
Mains or charger fail
Two flashes
repeated at
regular interval
Incorrect output
voltage
Three flashes
repeated at
regular interval
High battery
resistance fault
Four flashes
repeated at
regular interval
Battery missing or
reverse battery
Fault
(yellow)
Continuously ON Microprocessor fail

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3 Installation
3.1 Equipment and Tool Requirements
• BPC130 charger tray, battery tray(s), battery pack and front panels
• BDIST cable assembly of suitable size for all rack battery power feeds
• MDIST of suitable size for all rack mains feeds
• Flat-bladed screwdriver (small and medium)
• Pozidriv screwdrivers (1, 2 and 3)
• Wire cutters and strippers
• Ferrules and crimping tool
• AF spanner with insulated handle for 6 mm nuts
• AF spanner for 4 mm nuts
• A 19-inch standard rack fitted with supporting rails and wired with power supply, signal, and control
wiring, as required by your specific system design
3.2 Cabling Requirements
Signals Cable Description Termination Suggested Type
Mains supply 1 x 3-core mains
cable Suitable ferrules Suitably rated standard mains cable
Mains distribution IEC-IEC 10 A
mains lead
• Amplifier Mainframe end:
IEC320-C13 (female)
• MDIST end: IEC320-C14 (male)
ASL MDIST4, MDIST6 or
MDIST8 cable assembly
Battery distribution
(for high current
equipment, e.g.
Amplifier Mainframes)
1 x 1-core red
1 x 1-core black
• Amplifier Mainframe end: 7W2
mixed signal D connector
(female)
• BPC130 end: suitable ferrules
ASL BDIST4-CA,
BDIST6-CA or
BDIST8-CA cable
assembly
Battery distribution (for
low current equipment,
e.g. Routers)
1 x 2-core cable
• VAR4/12/20 end: 2-way
pluggable Wago cage clamp
terminal (male)
• VAR8/VAR8-ACU end: suitable
ferrules
• BPC130 end: suitable ferrules
Suitably rated 2-core
cable
Fault relay 1 x 2-core cable
• VAR4/12/20 end: standard
25-way D connector (male)
• VAR8/VAR8-ACU end: suitable
ferrules
• BPC130 end: suitable ferrules
Suitably rated 2-core
cable

Refer to BS7671:2008 (Requirements for Electrical Installations) or other appropriate local standards
for guidelines on maximum potential cable lengths given the actual installation parameters.

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3.3 Main Components
Figure 4 BPC130 components (rack with 800 mm depth as example)
CHARGER AND BDIST TRAY
BATTERY TRAY
(for rack with 800 mm depth)
BATTERIES
CHARGER
BDIST
3.4 Recommended Installation Procedure
!
!
1) Please read and observe the instructions and guidelines in Section “Safety and
Precautions” (page 35) prior to installation. Failure to follow these instructions and
guidelines may cause personal injury and/or damage to the equipment.
2) Use suitable ferrules for all terminal block connections.
3) This equipment is intended for use in a restricted access location.
4) To prevent injury, the battery backup system must be securely attached to the rack in
accordance with these installation instructions.

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3.4.1 Battery Backup System Installation – Rack with 800 mm Depth
!
!
1) Ensure that all safety precautions detailed in Section “Safety and Precautions” (page 35)
are taken.
2) Note the correct polarity when connecting the interlink cable(s):
Red band terminal=Positive and Black band terminal=Negative.
3) For all cable connections use the terminal screws supplied with the batteries and ensure
that they are sufficiently tight.
3.4.1.1 Installing the Battery Tray and Batteries
1. Fit the battery tray to the rack in appropriate position securing it with twelve M6 screws;
see Figure 5.
Figure 5 Installing the battery tray
(Battery tray model varies
to suit the rack type)
3 x M6 POZIDRIV SCREW
3 x M6 WASHER
3 x M6 CAGE NUT
FRONT OF RACK
!
!Ensure that:
1) Three M6 cage nuts and screws are used in
each corner of the tray and that they are
tightly fitted.
2) One (minimum) earthing washer must be
used to ensure that the battery tray is
bonded to the rack.

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2. Slide the batteries into the tray and then connect the interlink cables (short) noting the layout
diagram in Figure 6.
Figure 6 Fitting the batteries into the tray and connecting the interlink cables
FRONT OF RACK
-
-
+
+
6V
6V
6V
6V
+
-
-
+
Fit protective cap to battery
terminals!
(Depending on the model supplied,
the battery terminal protective caps
must be fitted to the lead before its
connection to the battery terminal.)
!
!
Note the correct polarity when
connecting the interlink cable(s):
Red band terminal=positive
Black band terminal=negative
!
!
Always use insulated tools!
!
!
Batteries are heavy (23 kg each).
Please move and handle with care to
avoid personal injuries and/or
damages to the batteries.
!
!
3. Fit a protective cap (supplied) to each of the battery terminals connected to a interlink cable.

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3.4.1.2 Installing the Charger Tray and Charger
4. Ensure that the AC mains supply to the charger is isolated.
5. Install the charger tray onto the support rails securing it with the M4 screws, nuts and washers
supplied; see Figure 7.
Figure 7 Installing the charger tray
FRONT OF RACK
LEFT-HAND SIDE
SUPPORTING RAIL
RIGHT-HAND SIDE
SUPPORTING RAIL
CHARGER TRAY
M4 PLAIN NUT
PLAIN WASHER SHAKE-PROOF WASHER
M4 PAN HEAD POZIDRIV SCREW
MUDGUARD WASHER
CHARGER TRAY
!
! Distance from battery tray = 5U
!
! Ensure that the charger tray is
attached to the rack by six M4
screws and nuts and that they are
tightly fitted.
!
! Protection cap must be fitted.
6. Connect the charger mains cable to the terminal block marked N-L-E; see Figure 8.
Figure 8 Charger connections (front of rack)
CHARGER
(FRONT OF RACK)
MAINS CONNECTOR
Harmonised Colours:
N = Blue
L = Brown
Earth = Green/Yellow
LNE
Mains supply: 230 V ±10% RMS 50Hz AC

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7. Connect the fault relay contact of the charger to the required Router contact; see Figure 9
 Check the system design documentation for connection details.
Figure 9 Fault relay contacts (rear of rack)
CHARGER
REAR OF RACK
1
Terminal Signal Description
1 FLTNO Fault relay N/O contact Volt-free relay contact (for connection to any
available Router contact)
2 FLTNC Fault relay N/C contact Not used
3 FLTCOM Fault relay COM contact Volt-free relay contact (for connection to 0 V from
the Router)
4 OSNO DC power available relay N/O contact
5 OSCOM DC power available relay COM contact Volt-free relay contact (not used)
6 0V Auxiliary DC power supply output: 0V wiring (black)
7 +V Auxiliary DC power supply output: +VE wiring (red) Wired at manufacture to +BATT&-BATT lead pair
8 -BT Battery connection –BATT wiring (black)
9 +BT Battery connection +BATT wiring (red) Wired at manufacture to +VE&0V lead pair

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3.4.1.3 Connecting the Power Distribution (BDIST)
8. Ensure that all 24 V Mini Circuit Breakers are switched OFF (switch toggle towards the rear of the
rack).
9. ASL BDISTx-CA cable assemblies are cut to length and terminated with a suitable ferrule on one end
and a Power-D connector on the other end for connection to an ASL Amplifier Mainframe.
Note that the Amplifier Mainframes must the fitted into the rack according to the ASL rack layout
specification; please refer to ASL for details.
10. If assembling the 25 A distribution cable, then terminate one end of
the red and black cable to the Power-D connector for connection to
an ASL Amplifier Mainframe (see diagram on the right).
11. Cut the other end of the 10 mm2red and black cable to length, and
terminate it with a suitable ferrule.
1 2
3 4 5
BATTERY +
(RED)
A1 A2
BATTERY -
(BLACK)
MAINFRAME CONNECTOR:
POWER-D CONNECTOR (MALE)
12. Fit the Power-D connector to the related ASL Amplifier Mainframe using the jackscrews provided.
13. Connect the other end of the red cable to a free 25 A MCB output at the BDIST; see Figure 10.
14. Connect the other end of the black cable to a free terminal at the BDIST; see Figure 10.
Figure 10 BDIST connection
(REAR OF RACK)
25
A OUTPUTS3 A OUTPUTS
+24 V DC: 10 mm2 RED CABLE(S)
0 V DC: 10 mm2 BLACK CABLE(S)
+24
V DC
0
V DC
TO AMPLIFIER MAINFRAME (S)TO LOW CURRENT EQUIPMENT, e.g. ROUTER
15. If the 3 A output is used, then cable any required low current equipment to the 3 A output(s)
terminating the BDIST end of the cable with a suitable ferrule; see Figure 10.
!
!
1) Note correct polarity at the BDIST:
MCB output = +24 V DC
Adjacent terminal = 0 V DC
2) Ensure that the 3 A current limit will not be exceeded in use.
16. Ensure that all cables are tied back neatly and clear from any sharp edges or other risk of chafing.

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3.4.1.4 Connecting the Batteries
17. Pass the red terminal lead from the charger through the cable hole down to the battery tray, and
then connect it to the right-hand battery positive terminal at the rear of the rack; see Figure 11.
18. Pass the black terminal lead from the charger through the cable hole down to the battery tray, and
then connect it to the left-hand battery negative terminal at the front of the rack; see Figure 11.
Figure 11 BPC130 terminal lead connection
FRONT OF RACK
+24V (RED)
-
-
+
+
6V
6V
6V
6V
+
-
-
0V (BLACK)
+
Always use insulated tools!
!
!
Fit protective cap to battery terminals!
(Depending on the model supplied, the
battery terminal protective caps must
be fitted to the lead before its
connection to the battery terminal.)
!
!
Note that a small spark is usually
generated when the negative terminal
lead (black) is connected as the
charger circuitry is energized.

19. Fit a protective cap (supplied) to each of the battery terminals.
20. Secure the batteries in position using the strap(s) fitted to the battery tray see Figure 12.
Figure 12 Securing the batteries (front of rack)
Buckle must be positioned on the right or left
hand-side of the batteries.
!
!
STRAP
FRONT OF RACK
3.4.1.5 Fitting the Front Panel
21. After batteries have been installed and commissioned, fit all front panels using M6 cage nuts, screws
and nylon washers.
22. Fit the supplied caution label to the appropriate front panel.

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3.4.1.6 Powering the system up
23. Connect the AC mains supply to the charger.
24. Wait for the batteries to fully charge (24 hours) and then switch the Mini Circuit Breakers on as
required.
3.4.1.7 Commissioning the Battery Backup System at the Router
25. Commission the BPC130 as described in Section “5 Commissioning” (page 22).

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3.4.2 Battery Backup System Installation – Rack with 600 mm Depth
!
!
1) Ensure that all safety precautions detailed in Section “Safety and Precautions” (page 35)
are taken.
2) Note the correct polarity when connecting the interlink cable(s):
Red band terminal=Positive and Black band terminal=Negative.
3) For all cable connections use the terminal screws supplied with the batteries and ensure
that they are sufficiently tight.
3.4.2.1 Installing the Battery Tray and Batteries
1. Ensure that the AC mains supply to the charger is isolated.
2. Fit the battery trays to the rack in appropriate positions securing it with twelve M6 screws;
see Figure 13.
Figure 13 Installing the battery tray
(Battery tray model varies
to suit the rack type)
3 x M6 POZIDRIV SCREW
3 x M6 WASHER
3 x M6 CAGE NUT
FRONT OF RACK
5U SPACE
!
!Ensure that:
1) The battery trays are installed with 5U
space between the trays.
2) Three M6 cage nuts and screws are used in
each corner of the tray and that they are
tightly fitted.
3) One (minimum) earthing washer must be
used to ensure that the battery tray is
bonded to the rack.
3. Slide two batteries into each of the battery trays noting the layout diagram in Figure 14.
4. Connect the rear interlink cables (long) and the front interlink cable (short) to both pairs of batteries
as shown in Figure 14.

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Figure 14 Fitting the batteries into the tray and connecting the interlink cables
6V
6V
6V
6V
UPPER TRAY
FRONT OF RACK
LOWER TRAY
FRONT OF RACK
-
+
+
-
-
+
+
-
Fit protective cap to battery terminals!
(Depending on the model supplied, the
battery terminal protective caps must
be fitted to the lead before its
connection to the battery terminal.)
!
!
Note the correct polarity when
connecting the interlink cable(s):
Red band terminal=positive
Black band terminal=negative
!
!
Always use insulated tools!
!
!
Batteries are heavy (23 kg each).
Please move and handle with care to
avoid personal injuries and/or
damages to the batteries.
!
!
5. Fit a protective cap (supplied) to each of the battery terminals connected to a interlink cable.
3.4.2.2 Installing the Charger Tray and Charger
Refer to Section “3.4.1.2 Installing the Charger Tray and Charger” (page 12).
3.4.2.3 Connecting the Power Distribution (BDIST)
Refer to Section “3.4.1.3 Connecting the Power Distribution (BDIST)” (page 14).

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3.4.2.4 Connecting the Batteries
6. Pass the red terminal lead from the charger through the cable hole down to the upper battery tray,
and then connect it to the right-hand positive battery terminal at the front of the rack; see Figure 15.
7. Pass the black terminal lead from the charger through the cable hole down to the upper battery tray,
and then connect it to the left-hand negative battery terminal at the front of the rack; see Figure 15.
8. Fit a protective cap (supplied) to each of the battery terminals.
Figure 15 BPC130 positive terminal lead connection
6V
6V
6V
6V
UPPER TRAY
FRONT OF RACK
LOWER TRAY
FRONT OF RACK
-
+
+
-
-
+
+24V (RED)
+
-
0V (BLACK)
Note that a small spark is
usually generated when the
negative terminal lead (black)
is connected as the charger
circuitry is energized.

Fit protective cap to battery
terminals!
(Depending on the model
supplied, the battery terminal
protective caps must be fitted
to the lead before its
connection to the battery
terminal.)
!
!
Always use insulated tools!
!
!
9. Secure the batteries in position using the straps fitted to each battery tray; see Figure 16.
Figure 16 Securing the batteries (front of rack)
FRONT OF RACK
STRAP

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3.4.2.5 Fitting the Front Panel
10. After batteries have been installed and commissioned, fit all front panels using M6 cage nuts, screws
and nylon washers.
11. Fit the supplied caution label to the appropriate front panel.
3.4.2.6 Powering the system up
12. Connect the AC mains supply to the charger.
13. Wait for the batteries to fully charge (24 hours) and then switch the Mini Circuit Breakers on as
required.
3.4.2.7 Commissioning the Battery Backup System at the Router
14. Commission the BPC130 as described in Section “5 Commissioning” (page 22).
3.4.3 MDIST Installation

MDIST comprises a distribution block and a number of IEC320-IEC320 leads with lengths to
suit ASL rack layout specification; please refer to ASL for details.
1. Ensure that the AC mains supply to the MDIST is isolated.
2. Fit the incoming mains cable through the gland and connect it into the terminal block inside the end
of the distribution block.
!
!
1) Ensure that the incoming mains cable is suitably rated for the load.
2) Ensure that the gland and terminals are tightly fitted.
3. The MDIST distribution block should be mounted behind the charger tray using the fixings provided.
4. Ensure that the earth strap provided on the distribution block is connected to the rack.
5. Connect all required IEC320-IEC320 leads between the distribution block and equipment.
6. Ensure that all cables are tied back neatly and clear from any sharp edges or other risk of chafing.
7. Connect the AC mains supply to the MDIST.