Philadelphia Scientific iBOS Pro 6 Series User manual

DOC0505
Installation Manual
iBOS® Pro 6 Series
Battery Manager
Updated October 19, 2022

Philadelphia Scientific® iBOS® Pro 6 Series Installation Manual
Page ii
Table of Contents
iBOS® Pro 6 Series Battery Manager Installation Manual
1. Introduction....................................................................................................................................................1
1.1 System Overview .....................................................................................................................................1
1.2 Organization of Manual ............................................................................................................................1
1.3 Contact Information..................................................................................................................................1
2. System Components......................................................................................................................................2
2.1 Components Received.............................................................................................................................3
3. Pre-Installation...............................................................................................................................................6
3.1 Locate Shipment Pallet ............................................................................................................................6
3.2 Update/verify Existing iBOS® Pro 6 Series System .................................................................................6
3.3 Determine Battery Manager Work Center Location ..................................................................................6
4. Primary System Installation............................................................................................................................7
4.1 Verify Cellular Modem Operation .............................................................................................................7
4.2 Unpack UPS and Set Up..........................................................................................................................7
4.3 Battery Manager & Controller Connections ..............................................................................................7
4.3.1 Black Cable.......................................................................................................................................9
4.3.2 Blue Cable ......................................................................................................................................10
4.3.3 Yellow Cable ...................................................................................................................................11
4.3.4 Red Cable .......................................................................................................................................12
4.4 Battery Manager Barcode Printer Setup.................................................................................................14
4.5 Installing Touch Computer Cradles ........................................................................................................15
4.6 Plugging in Battery Manager Work Center .............................................................................................15
4.7 Checking Battery Manager Software Version.........................................................................................15
4.8 Starting Battery Manager Touch Computer ............................................................................................16
4.9 Printing Test Barcodes...........................................................................................................................16
5. Barcode Label Installation............................................................................................................................17
5.1 Barcode Printing from the Touchscreen Monitor ....................................................................................17
5.2 Printing and Applying Charger Barcodes................................................................................................17
5.2.1. Printing Charger Barcodes from Touchscreen Monitor: ..................................................................17
5.2.2. Printing Charger Barcodes from Touch Computer: .........................................................................18
5.2.3. Verify and Apply Charger Labels ....................................................................................................18
5.3 Printing and Applying Battery Barcodes .................................................................................................18
5.4 Printing and Applying Truck Barcodes....................................................................................................19
5.5 Printing Battery Barcodes When Assets Pre-Entered.............................................................................20
5.6 Printing Truck Barcodes When Assets Pre-Entered ...............................................................................20
5.7 Asset Registration When Assets Pre-Entered ........................................................................................21
6. Training........................................................................................................................................................25
6.1 Training on Use of Battery Manager.......................................................................................................25
6.2 Remove/Attach Battery Barcode Holder.................................................................................................25
Appendix A. Troubleshooting ..............................................................................................................................I
A.1 Battery Manager Barcode Printer..............................................................................................................I
A.2 Confirmation of Communication on Cell Modem .......................................................................................I
A.3 Confirmation of Proper Operations after Start or Restart of System..........................................................I
A.4 Reference Diagrams and Illustrations .....................................................................................................III

Philadelphia Scientific® iBOS® Pro 6 Series Installation Manual
Page 1
1. Introduction
1.1 System Overview
This manual provides all information needed for a qualified person to install the iBOS® Pro 6 Series. The
purpose for this type of installation is to:
1) Add a Battery Manager to an operational site with an existing iBOS® Pro 6 Series only;
2) Upgrade a Battery Tracker to a Battery Manager at an operational site with an existing iBOS® Pro 6
Series;
3) Add a Battery Manager after adding a new iBOS® Pro 6 Series to an otherwise operational site that
will incorporate these systems together; or
4) Perform an installation of both the Battery Manager and immediately prior the iBOS® Pro 6 Series at
a brand-new facility (i.e., Distribution Center).
This procedure focuses on installation of the Battery Manager specifically, including adding barcodes to all
chargers on the site, and as many battery barcode holders and truck barcode labels as time permits during
installation. In cases where the iBOS® Pro 6 Series is also being installed, refer first to DOC0023 and
associated task documents.
1.2 Organization of Manual
This manual has been divided into each of the stages of an installation project found in the following
Sections:
2. System Components
3. Pre-Installation
4. Primary System Installation
5. Barcode Label Installation
6. Training
Note that pre-installation information prior to work on-site will be managed separately.
1.3 Contact Information
Philadelphia Scientific LLC
207 Progress Drive
Montgomeryville, PA 18936
USA
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Philadelphia Scientific UK Ltd.
Atlas Mill
Bolton BL14LB
United Kingdom
Phone: [phone]-
467777
Fax: [phone]-
493300
Email: [e-mail]
Philadelphia Scientific-
Asia/Pacific
2/17 Norman Street
NSW, 2225
Australia
Phone: [phone]-
2447
Fax: [phone]-
0383
Email: [email protected]

Philadelphia Scientific® iBOS® Pro 6 Series Installation Manual
Page 2
2. System Components
This Battery Manager system is composed of two components which communicate with each other and the
iBOS® Pro 6 Series Controller (at left) via hardwire or Wi-Fi (using Wireless Access Point) as indicated
below:
Existing or new components from the iBOS® Pro 6 Series are described separately in DOC0023, which
focuses on that current or previous installation. The largest box contains the already assembled Battery
Manager Work Center (BMWC), and the separate boxes include barcode holders and other accessories.
Use the packing slip to verify the items received, as there may be other items included (e.g., battery
watering systems). The following items are what arrive typically boxed and wrapped onto one pallet when
shipped to the site:
Wired
Battery Manager
Touch Computer
New or Existing
Controller
Battery Manager
Work Center

Philadelphia Scientific® iBOS® Pro 6 Series Installation Manual
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2.1 Components Received
Battery Manager Work
Center (BMWC)
(shipped with all the following
items):
•Keyboard (in drawer,
nothing to install)
•UPS and Surge
Protector (boxed and
shipped underneath
cabinet on pallet)
•Wireless Access Point
(boxed in lower cabinet)
•Barcode Labels (3
boxes each of wide [2-
5/16" x 7-1/2"] and
narrow [3/4" x 2-1/2"]
barcode labels included
in lower cabinet)
•Red, Yellow, Blue and
Black Cables (attached
at other end to various
Battery Manager
interfaces)
•Barcode Printer
(bubblewrapped and
inserted in lower cabinet)

Philadelphia Scientific® iBOS® Pro 6 Series Installation Manual
Page 4
Touch Computer Cradles
Touch Computer cradles will vary based on what the end user ordered. The primary options appear below;
each cradle provided will come with its manufacturer instructions, and should be installed where the client
has indicated. (These will be packed in the additional boxes.)
Extractor Mounted
ⓐ
Charging Cradle
(typically one or two, depending
on extractors on site)
Desktop Charging Cradle
(typically this OR the Clip-on
Charger below is the additional
item included)ⓑ
Clip-on Charger Cradle ⓒ
Battery Manager Touch
Computer(s)
Handheld with protective case
and hand strap. (This will either
be shipped directly to the
installer to bring to the site; or if
not manufacturer-installed, will
be packed in the cabinet.)
Number of units depends upon
how many ordered.
8a
8b
8c

Philadelphia Scientific® iBOS® Pro 6 Series Installation Manual
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Barcode Holders
A separate box will be shipped
with the barcode holders (# of
barcode holders determined
client order, typically a
minimum of the asset list
quantity of batteries on site)
and zip ties to be used for
labeling the batteries on site
(sample barcode holder and zip
tie shown).Barcode holders
are typically blue; exceptions
will be noted.
Placards
One card is included (packaged
under the keyboard); this
outlines how to re-order
supplies for the Battery
Manager.

Philadelphia Scientific® iBOS® Pro 6 Series Installation Manual
Page 6
3. Pre-Installation
3.1 Locate Shipment Pallet
An Operations Manager (OM) may have guidance for location and can have pallet brought to Battery Room
if not already there. Verify that all the Battery Manager hardware have been shipped (see list in 2. System
Components and check actual packing list).
3.2 Update/verify Existing iBOS® Pro 6 Series System
When Installing a Battery Manager with an existing iBOS® Pro 6 Series system only:
•Prior to actively starting the Battery Manager, install a new iBOS® Pro 6 Series Controller CF card (see
DOC0252). iBOS® Pro 6 Series may take up to 60 minutes to get the status of all chargers, during
which time the installation team can perform other pre-installation steps.
•Check to ensure there are two new (4G LTE) antennas connected to the cell modem in iBOS® Pro 6
Series Controller, and that they are at least a foot apart from each other and as high above the
Controller as possible. If not, install antennas.
•Check there are no issues with assignment and communication of Sentinels on-site; fix non-reporting or
unassigned Sentinels and perform any Sentinel software upgrades needed.*
•Visually verify that the iBOS® Pro 6 Series Controller is on and running (pools and chargers show up on
iDisplay).
NOTES: If a new iBOS® Pro 6 Series and Battery Manager are being installed at the same time, this step
isn’t needed as installers will be using the DOC0023 concurrently with this manual.
Sometimes a customer with existing system may have already noted a part of the Controller (e.g., iDisplay)
that needs replacement; replacement parts may be included in the installation shipment to complete these
needs during the Battery Manager installation.
*For new systems entirely, ensure Sentinels are installed and running prior to installing Battery Manager.
3.3 Determine Battery Manager Work Center Location
Location considerations, depending on floor layout of Distribution Center, include:
•Keep Battery Room Attendant’s accessibility and safety in mind for location.
•Ensure Battery Manager Work Center (BMWC) near A/C Power (power cord is XX ft.)
•Ensure BMWC placed within 15 ft. of the iBOS® Pro 6 Series Controller.
•Overall BMWC dimensions: 24-1/2"W x 22-1/2"D x 62-3/4"H

Philadelphia Scientific® iBOS® Pro 6 Series Installation Manual
Page 7
4. Primary System Installation
4.1 Verify Cellular Modem Operation
For all sites, iBOS® Pro 6 Series and Battery Manager installations the cellular
modem may be mounted in or outside and above the iBOS® Pro 6 Series Controller.
The modem in Controller should read as follows:
Power — On
Status — Flashing
CD — On
LS — On or Flashing
Signal Strength — 2 or 3 LEDs (bars) On
Avoid mounting antennas near something that could cause
interference (e.g., conveyor with big motor). If determined that there
is not enough signal strength reaching cellular modem, set up signal
amplifier following DOC0520.
4.2 Unpack UPS and Set Up
UPS should be set up according to instructions in box and for ease of
access is most convenient placed on second shelf from bottom of the
Battery Manager Work Center (BMWC) (should be on same shelf as the
barcode printer).
The power cords for the Barcode Printer, and the Touchscreen Monitor and
main computer for system (both located in the backside of the BMWC), get
plugged into the Battery Backup side of the UPS.
4.3 Battery Manager & Controller Connections
Once power has been established as available to the Battery Manager and the cellular modem is operating
properly, connect the Battery Manager cables to the Controller.
Four colored cables with RJ-45 connectors are connected to back panel of BMWC, leading down to the bottom
of BMWC cabinet:
•One ~15 ft. Blue (Cellular Modem)
•One ~15 ft. Black (Controller ENET)
•One ~15 ft. Yellow (Controller REMOTE DISPLAY)
•One 50 ft. Red (Wireless Access Point)

Philadelphia Scientific® iBOS® Pro 6 Series Installation Manual
Page 8
Note on Pulling Cables through Battery Manager Work Center to iBOS® Pro 6 Series Controller:
Minor variations in cabinets for the Battery Manager Work Center (BMWC) do not affect performance; for
bringing the colored cables out from the BMWC to the Controller, the following holes may be observed in the
cabinets upon delivery:
ⓐWhen facing the front of the BMWC, on right side in the middle there is a hole with a removeable
plastic covering. This is typically used to pull the cables through. Sometimes due to convenience and
proximity of the Controller, it is better to have a hole on the left side of the cabinet, so an equivalent one may
be drilled in the similar location.
ⓑWhen facing the back of the BMWC, at the very bottom shelf of the cabinet is also a hole where it is
possible the cables may be pulled through. This method is typically not convenient for cable length or
Controller positioning and is not recommended.
ⓐ
ⓑ