ASL INTERCOM BPC65 User manual

Installation Guide
ASL Document Ref.: U-0456-0142.doc
Issue: 03 complete, approved - Date: 25/10/11
Part Number: M0456_67
BPC65 / BDIST / MDIST
Battery Pack, Charger, Battery and Mains Distribution
BATTERY TRAY
(for rack with 800 mm depth)
CHARGER
AND
BATTERY DISTRIBUTION TRAY

BPC65 / BDIST / MDIST – Installation Guide
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.
Failure to use the equipment in the manner described in the product literature will invalidate the
warranty.
A ‘Declaration of Conformity’ statement to the above standards, and a list of auxiliary equipment used
for compliance verification, is available on request.
This product must be disposed of in accordance with the WEEE directive.
Contents
1General Information ................................................................................................................................................... 3
2Installation ................................................................................................................................................................. 5
3Mechanical Dimensions............................................................................................................................................ 14
4Safety and Precautions............................................................................................................................................. 17
Additional User Documentation:
1. BPC65 Product Manual (U-0456-0143)
2. ASL EN 54-16 & ISO 7240-16 System Design Guide (T-0667-0016)
3. Above documentation and additional reference information are available from the ASL’s website at
www.asl-control.co.uk

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1 General Information
Technical Specification Summary
BPC65
AC Supply Voltage.........................................................................................................................230 V ±10% RMS 50Hz AC
In-rush Current (worst case) ......................................................................................................................................... 40 A
Maximum AC VA Rating (110 V).................................................................................................................................. 253 VA
AC Supply Fuse Rating............................................................................................................................... T3.15A IEC60127
Output Voltage .............................................................................................................................................. 27.3 V (@ 20°C)
Charger Output Fuse Rating ...................................................................................................... 7.5 A (mini blade type fuse)
Lowest voltage to which the battery can be discharged .................................................................................................21 V
Rated Continuous Maximum Output Current (Imax. a) ................................................................................................... 1.75 A
Rated Maximum Output Current (Imax. b) ........................................................................................................................... 5 A
Minimum Loading of the Equipment (Imin) ................................................................................................................... 50 mA
Maximum value of internal battery resistance
for which rack functionality can be maintained (Ri max)..................................................................................................0.1 Ω
Charger Output Current.................................................................................................... 3 A / Type C Mini Circuit Breaker
Battery Output Current ................................................................................................... 25 A / Type C Mini Circuit Breaker
Batteries ....................................................................................................................................2 x Yuasa NPL65-12 (VLRA)
Charging Time..............................................................................................................24 hours to charge to 100% capacity
Temperature Compensation......................................................................................................................... –36 mV/cell/°C
Fault Status Output (Pins 1 and 3)........................................................................... volt-free relay contacts (N/O and COM)
Overall Dimensions (H x W x D) / Weight:
Charger and BDIST Tray.......................................................................................... 80 mm x 450 mm x 385 mm / 5.5 kg
Battery Tray with Batteries (for 800 mm deep rack) ........................................... 176 mm x 476 mm x 660 mm / 55.4 kg
Battery Tray with Batteries (for 600 mm deep rack) ........................................... 176 mm x 476 mm x 460 mm / 51.6 kg
Battery (Yuasa NPL65-12) ...................................................................................... 174 mm x 350 mm x 166 mm / 23 kg
MDIST
Operating Voltage ........................................................................................................................230 V ±10% RMS 50 Hz AC
Input Current ..........................................................................................................................................................32 A max
Output Current (per output)....................................................................................................................................10 A max
General
Temperature ............................................ −20°C to +50°C (storage, fully charged condition) / −10°C to +50°C (operation)
(battery performance is dependent on average operational temperature;
refer to manufacturer’s literature)
Humidity Range.......................................................................................................................... 0% to 93% non-condensing
!
!
At the time of the publication of this Installation Guide, only the BPC65 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.

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Indicators and Controls
Figure 1 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.
Figure 2 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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2 Installation
2.1 Equipment and Tool Requirements
• BPC65 charger tray, battery tray, 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
2.2 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)
• BPC65 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
• BPC65 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
• BPC65 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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2.3 Main Components
Figure 3 BPC65 components (rack with 800 mm depth as example)
CHARGER AND BDIST TRAY
BATTERY TRAY
(for rack with 800 mm depth)
BATTERIES
CHARGER
BDIST
2.4 Recommended Installation Procedure
!
!
1) Please read and observe the instructions and guidelines in Section “4 Safety and Precautions”
(page 17) 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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2.4.1 Battery Backup System Installation
!
!
1) Ensure that all safety precautions detailed in Section “Safety and Precautions” (page 17) 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.
2.4.1.1 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 4.
Figure 4 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 cable noting the layout diagram in
Figure 5.
Figure 5 Fitting the batteries into the tray
12V
FRONT OF
RACK
+
+
-
(Battery tray for rack with
800 mm depth as example)
12V
-
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.)
!
!
Batteries are heavy (23 kg each).
Please move and handle with care to
avoid personal injuries and/or
damages to the batteries.
!
!
Note the correct polarity when
connecting the interlink cable:
Red band terminal=positive
Black band terminal=negative
!
!
3. Fit a protective cap (supplied) to each of the battery terminals connected to the interlink cable.

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2.4.1.2 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 6.
Figure 6 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 7.
Figure 7 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 8.
 Check the system design documentation for connection details.
Figure 8 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