norbar 60166 Service manual

BATTERY POWER UNIT
MODEL No 60166
OPERATOR’S HANDBOOK (PART No 34221)
ISSUE 4
NORBAR TORQUE TOOLS LTD, Beaumont Road, Banbury, Oxfordshire, OX16 7XJ, United Kingdom
Tel : + 44 (0) 1295 270333, Fax : + 44 (0) 1295 753643

BATTERY POWER UNIT OPERATORS HANDBOOK PAGE 1 OF 6
ISSUE 4.0
OCT 1997
CONTENTS
PAGE
Introduction 2
Mains Plug Fitting 2
Specifications 3
Operating Instructions 4
Recharging Instructions 5
Trouble Shooting 6

BATTERY POWER UNIT OPERATORS HANDBOOK PAGE 2 OF 6
ISSUE 4.0
OCT 1997
INTRODUCTION
BATTERY CHARGING
WARNING, LIMITED
BATTERY LIFE LEFT
BATTERY DISCHARGED,
SWITCH OFF OR RECHARGE
OFF
BATTERY
CHARGE
BATTERY POWER UNIT
The Norbar Battery Power Unit (BPU) is a ruggedly built, dual voltage re-chargable unit containing
nickel cadmium cells that conforms to current EC Directives and Safety standards.
The BPU can power up to two Norbar display instruments, Electronic Transducer System (ETS),
Dedicated Transducer System (DTS) or Torque Wrench Analyser (TWA), or one instrument and one
Norbar DATA PRINTER, allowing portability of the whole measurement system. Housed in an
instrument style case, the BPU can be stacked with display instruments, printers and 5 way switch
units, with the addition of coupling extrusions.
A battery management circuit board is incorporated in the BPU to give an indication via a front panel
Light Emitting Diode (LED) when approximately 30 minuites life is left in the batteries. If the BPU is
used beyond this point it will automatically switch off (indicated by another front panel LED), before
inaccurate readings can be obtained.
The mains inlet socket on the back panel and internal re-charge circuitry enable the BPU to be
recharged via the mains supply.
MAINS PLUG FITTING :- ____________________________________________________________
If a mains plug is not fitted, follow the plug’s own instructions. The following may be useful :
BROWN-LIVE BLUE-NEUTRAL GREEN / YELLOW-EARTH
WARNING! It is important that live, neutral and earth are all connected between the BPU and
the mains supply. If no earth is available (2 wire mains supply) it is recommended
that a separate earth is connected between the case (the bottom right hand fixing
screw in the corner of the back panel is ideal) and a suitable earth.
If the plug has an internal fuse, a 1 amp value is recommended.
CLEANING :-______________________________________________________________________
Do not use abrasives or solvent based cleaners. We recommend a propriety brand of foam based
fabric / vinyl cleaner. Use a soft cloth to avoid scratches.

BATTERY POWER UNIT OPERATORS HANDBOOK PAGE 3 OF 6
ISSUE 4.0
OCT 1997
SPECIFICATIONS
BATTERY ROWER UNIT SPECIFICATIONS :- __________________________________________
OPERATION TIME AFTER FULL CHARGE Minimum of 8 hours with a load of 1 display instrument
and 1 data printer.
RECHARGE TIME 16 Hours from fully discharged.
BATTERY PACK TYPE Rechargable nickel cadmium - Not user replaceable.
POSITIVE BATTERY PACK +14.4 Volts, 4 amp hour.
NEGATIVE BATTERY PACK -14.4 Volts, 1.4 amp hour.
POWER REQUIREMENTS Selectable 110/120 Volts AC +/- 10 % or
220/240 Volts AC +/- 10% at 50-60 Hz.
MAINS POWER FUSE T500 mA anti-surge.
POWER CONSUMPTION (RECHARGE) 24 W - maximum.
BATTERY FUSES (INTERNAL) T2 Amp anti-surge (2 off)
OPERATING TEMP RANGE 0 °C to 50 °C.
MAXIMUM OPERATING HUMIDITY 85% Relative Humidity @30°C.
MAINS POWER CABLE 2.5 metres (8 ft 2 ins) long.
BATTERY CABLES 0.5 metres (1 ft 8 ins) long (2 off).
WEIGHT 5.35 kg (11.57 lb)
DIMENSIONS 108 mm high x 197 mm wide x 282 mm long.
CASE MATERIALS / FINISH Case engineered in aluminium extrusions and
castings. Finished in tough texture paint.
ENVIRONMENT Indoor use within a light industrial environment.
ELECTROMAGNETIC COMPATIBILITY In conformance with EN 50081-1 : 1992
(EMC) DIRECTIVE & EN 50082-1 : 1992.
LOW VOLTAGE DIRECTIVE In conformance with EN 61010-1 : 1993.
To environmental conditions Pollution Degree 2 &
Installation Category (Overvoltage Category) II.
Note : If equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment could be impaired.

BATTERY POWER UNIT OPERATORS HANDBOOK PAGE 4 OF 6
ISSUE 4.0
OCT 1997
OPERATING INSTRUCTIONS
220
110
MAX POWER - 24 W
50-60 Hz
VOLTS 110-120v OR 220-240v ac
FUSE-T500mA 250v
MODEL No.
SERIAL No.
BATTERY
OUTPUTS
MADE IN ENGLAND BY NORBAR TORQUE TOOLS
1. Ensure the Battery Power Unit (BPU) front panel ‘FUNCTION SWITCH’ is in the ‘OFF’ position.
2. Fit the BPU connecting cable(s) to the back panels of the BPU and the instrument(s) being used.
3. Switch the front panel ‘FUNCTION SWITCH’ to the ‘BATTERY’ position. The equipment connected
to the BPU can only be switched ‘ON’ and ‘OFF’ via the BPU front panel ‘FUNCTION SWITCH’.
4. The equipment connected should now power up, allow 5 minutes for the instrument to warm up and
stabilize. For operation refer to operators handbook for equipment connected.

BATTERY POWER UNIT OPERATORS HANDBOOK PAGE 5 OF 6
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OCT 1997
RECHARGE INSTRUCTIONS
1. Switch the front panel ‘FUNCTION SWITCH’ to the ‘CHARGE’ position.
2. Ensure mains voltage selector at the rear of the BPU is correctly positioned for your mains
supply.
Voltage selector indicates 110/120 or 220/240 V AC mains input. To alter voltage selection,
firstly remove the mains lead, then place a small screwdriver into the slot and turn until the
correct voltage is shown beneath the arrow head.
3. Connect AC mains lead and switch on mains supply to the BPU.
4. The ‘BATTERY CHARGING’ LED should now illuminate. Charge the BPU for 16 hours to ensure
the batteries are fully charged. The equipment connected will no longer be powered by the BPU
and can only be powered via the mains supply.
Note : To obtain maximum battery life and performance, it is highly recommended that the battery
power unit is used in a cycle of :-
FULLY DISCHARGE - FULLY CHARGE (minimum 16 hours) - FULLY DISCHARGE
5. After charging, switch the front panel ‘FUNCTION SWITCH’ to the ‘OFF’ position and remove the
mains lead.

BATTERY POWER UNIT OPERATORS HANDBOOK PAGE 6 OF 6
ISSUE 4.0
OCT 1997
TROUBLE SHOOTING
1. Charge LED does not illuminate when charging.
a) Check the Voltage Selector is in the correct position for your mains supply.
b) Check the mains power fuse which is located on the right hand side of the voltage selector.
Always replace the fuse with the same value and type as originally fitted.
c) Check fuse in mains plug.
2. Battery Power Unit fails to power equipment.
If Battery Power Unit (BPU) fails to power the equipment connected after recharging, check the
two fuses protecting the batteries that are mounted on the Battery Pack P.C.B. This is achieved
by following the proceedure below :-
WARNING! Switch off the BPU and remove the power lead.
1. Remove the two upper most cross head screws on the BPU front and back panels
(four screws in all).
2. Loosen the two lower cross head screws on the front panel half a turn.
3. Lift off the lid.
WARNING! Unplug the batteries from the battery pack p.c.b. before attempting to remove
the fuses (2 A anti-surge), and reconnect once the fuses have been replaced. If
problems are still incurred, return to Norbar or a Norbar appointed agent, for
evaluation.
3. Repair of Battery Power Unit.
If there is any doubt concerning the functionality of the Battery Power Unit, it should be
returned to Norbar, or a Norbar appointed agent for repair / recalibration.