Philadelphia Scientific IBOS Lite User manual

DOC0025
Installation Manual
iBOS® Lite
Updated October 2019
Version 1.4

Philadelphia Scientific® iBOS® Lite Installation Manual
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Table of Contents
iBOS® Plus 6 Series
1. Introduction................................................................................................................................................... 3
1.1 System Overview.................................................................................................................................... 3
1.2 Organization of this Manual.................................................................................................................... 3
1.3 Contact Information ................................................................................................................................ 3
2. System Components .................................................................................................................................... 4
3. Pre-Installation.............................................................................................................................................. 5
4. Installation..................................................................................................................................................... 6
4.1 Controller................................................................................................................................................. 6
4.2 Voltage Confirmation Check................................................................................................................... 6
4.3 Sentinel™ Install..................................................................................................................................... 6
4.4 Mounting Sentinel™ ............................................................................................................................... 6
4.5 Connect Sentinel™ Flexi-Tap to Charger DC Cable:............................................................................ 6
5. Operation and Sentinel™ Status.................................................................................................................. 8
5.1 Operation ................................................................................................................................................ 8
5.2 Sentinel™ Status .................................................................................................................................... 8
5.2.1 Green LED –Communication status............................................................................................... 8
5.2.2 Amber LED –Charging status......................................................................................................... 8
5.2.3 Blue LED –Termination status........................................................................................................ 8
5.2.4 Red LED –Bad communication cable ............................................................................................ 8
6. Final Inspection and Testing......................................................................................................................... 8
7. Troubleshooting............................................................................................................................................ 9
Appendix A –Instructional Placards............................................................................................................... 10

Philadelphia Scientific® iBOS® Lite Installation Manual
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1. Introduction
1.1 System Overview
This manual will give you all the information you need to install the iBOS® Lite battery room management
system. Once installed, this system will help create a smooth running battery room. Before getting into all
the details of installation, a quick overview of how the system works may be helpful.
iBOS® Lite saves money in your warehouse or DC by eliminating waste and increasing productivity.
Changing batteries on an electric forklift truck can be a confusing, time consuming process that, when done
incorrectly, leads to shortened battery run times and battery life. iBOS® Lite provides a simple, cost-
effective solution that takes the guesswork out of choosing the proper battery. The proper battery is the
one that is fully charged and the most cooled down. You find it by following the blue light. iBOS® Lite
manages up to 50 chargers for each battery type and uses easy-to see pick lights to provide clear direction
on which charged battery to select.
The system saves money in three ways:
1. Faster battery changes.
2. Less frequent battery changes.
3. Longer lasting batteries, reducing the frequency of battery purchases.
1.2 Organization of this Manual
This manual has been divided into sections for each of the stages of an installation project:
•Section 2 –System components
•Section 3 –Pre-Installation
•Section 4 –Installation
•Section 5 –Operation and Sentinel™Status
•Section 6 –Final Inspection and Testing
•Section 7 –Troubleshooting
•Appendix A –Instructional Placards
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]
Fax: [phone]
Email: [e-mail]
Philadelphia Scientific-
Asia/Pacific
2/17 Norman Street
NSW, 2225
Australia
Phone: [phone]
Fax: [phone]
Email: [e-mail]

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2. System Components
iBOS® Lite Controller
BOS-CB6300
Includes:
1. Operational Placard
2. 25ft (7.6m) cable w/coupler (2 sets)
3. Controller
4. AC Adapter w/International plugs
(100-240 VAC 50/60Hz)
iBOS® Sentinel™
BOS-SU6003
Includes:
1. Cable Ties (6)
2. Sentinel™
3. 7ft. (2.1m) cable
Optional:
Extension Cable with Coupler
BOS-143
1. 25ft (7.6m) cable
2. Coupler

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3. Pre-Installation
Description: The iBOS® Lite is a system of Sentinels™daisy chained to a Controller that manages one pool
of up to 50 chargers. A pool is group of the same battery type. iBOS® Lite Sentinels™are not voltage
specific and are powered by the Controller. The pool voltage is determined by the Controller. There is a
jumper on the Controller that sets the pool voltage.
Required items:
•iBOS® Lite Controller Kit
•1 Sentinel™per charger in that pool.
•100-240 VAC 50/60 Hz power source for Controller
Optional items:
•Extension cable for gaps greater than 7’ (2.1 m). (Two are included with the Controller Kit)
•Wire snips to trim cable ties.
Prep:
•Determine where to mount each Sentinel™. Take into consideration that it should be located in a
place where the user can easily identify the battery to be picked.
•Determine where to mount the Controller and the distance to power source (100-240 VAC 50/60
Hz). The Controller must be located at the beginning of the daisy chain.
•Determine best route of cable from charger to charger considering customer location and work
practices.
Refer to the Quick Start Guide included with the product.

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4. Installation
4.1 Controller
•Open Controller slot end cap and set jumper to correct pool voltage. The default is auto mode.
(On current models, the auto mode defaults to 24V. If the pool is other than 24V, set the jumper to
the correct pool voltage.)
•With power off, slide the yellow jumper off and place it back onto the Controller board in the desired
pool voltage location (position 1=12V, 2=24V, 3=36V, 4=48V, 5=72V, 6=80V) ensuring both pins
are inserted and the jumper is fully seated. We’ll confirm the setting by counting the number of blue
flashes on power up.
•Insert cable from the first Sentinel™through the Controller end cap and insert into its
communication socket.
•Insert power supply cable also through the end cap and plug into the receptacle on the Controller
board.
•Before mounting, hold the Controller where you can see through the side window, then plug in the
power.
4.2 Voltage Confirmation Check
Upon initial power up, the Controller will test all 3 LED’s by illuminating them, then momentary pause and
begin to flash the blue LED by itself 0-6 times. The number of flashes indicates the voltage setting for the
Controller. For example, if you see 2 blue flashes the Controller is set for a 24V pool.
4.3 Sentinel™Install
•Open a Sentinel™on the slotted side by removing the slotted black end cap.
•Connect the cable provided
oPush the cable from the Controller through the concave end cap by squeezing the short
ends to help open the gap.
oClick the cable end into either of the communication sockets, tab down, and ensure it
clicks in securely.
oTake the cable from the next Sentinel™and do the same as above into the remaining
socket.
oSlide the wires through slotted black end cap and replace the cap on the Sentinel™
enclosure –you are now ready to mount the Sentinel™.
4.4 Mounting Sentinel™
•Included with each Sentinel™are cable ties that can be used to mount the Sentinel™and secure
the excess cable.
•Ensure the Sentinel™front (LED Component Side) is facing out and visible to the user.
•During the installation, it is a good idea to also secure the cable with the Sentinel™to provide a
strain relief on the data cable.
4.5 Connect Sentinel™Flexi-Tap to Charger DC Cable:
•The black Flexi-Taps have two sharp spikes protected by flexible tubing. Remove the tubing when
ready to install the Flexi-Taps.
•Connect one Flexi-Tap to a positive cable and one Flexi-Tap to a negative cable. Keeping the pin
centered on the cable, push the cable fully to the bottom of the recess of the Flexi-Tap allowing the
pins to completely penetrate the insulation and the DC charger cable.

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oFlexi-Taps are not polarity sensitive.
oBe very careful to not bend the pins during installation.
•Secure each Flexi-Tap connection with a cable tie.
•Finally, secure all wires using good wire management techniques.
•Trim all excess from the cable ties.
Repeat installation for all chargers continuing to connect each Sentinel™to the next in a daisy chain
format.
An Operational Placard is included and should be posted in a high visibility area in the battery room or on
the central charger to help users understand the LED flash patterns.

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5. Operation and Sentinel™ Status
5.1 Operation
Once the system is completely installed, one Sentinel™will turn bright blue and have a slow momentary
flash. This indicates the “Battery to be picked”. It will have the longest cool down time since completing
charge. If no batteries have completed charge, then no blue light will be present.
5.2 Sentinel™Status
5.2.1 Green LED –Communication status
•Off –No power
•Solid –Sentinel™is communicating properly with Controller.
•Flashing Slow –Sentinel™has not received its assigned battery voltage.
•Flashing Fast –Sentinel™is not registered with the Controller, yet.
5.2.2 Amber LED –Charging status
•Off –No battery connected.
•Solid –Battery is connected.
•Flashing Slow –Battery is connected but charger has not started yet. Starts flashing in 5 minutes.
•Flashing Fast –Sentinel™has not seen a battery in 7 days.
5.2.3 Blue LED –Termination status
•Off –Battery is not at the top of the queue.
•Bright with Momentary Flashing –This is the correct battery to pick.
5.2.4 Red LED –Bad communication cable
•Solid –Power wires reversed in the data cable.
6. Final Inspection and Testing
Task
Status
All Sentinels™have a solid green LED.
All Sentinels™that are connected to a battery have a solid amber
LED.
Flexi-Taps are secured by cable ties.
Wires are secured.
Cable ties are trimmed.

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7. Troubleshooting
Green LED does not turn on.
•Confirm that the Controller is plugged into its
power source.
•Confirm that the breaker is on for the
receptacle.
•Confirm that the first Sentinel™ is connected
to the Controller via the provided cable.
•If only a portion of the pool does not have the
Green LED illuminated, find the first
Sentinel™ that has the Green LED turned off.
oCheck the cable between the
Sentinel™ with the Green LED on and
the one with the Green LED off.
Amber LED does not turn on.
•Walk down the pool and stop the charger
before disconnecting the battery.
•Reconnect the battery and observe the amber
LED on the Sentinel™. It should light when
the battery is connected.
•If the amber LED does not turn on, recheck
the Flexi-Tap connections to ensure good
connections have been established with the
pins penetrating into the DC charger cables.
No Blue LED on in the system.
•There are no fully charged batteries.
•There may have been a momentary power
outage. If so, a Blue LED should appear in
one hour.
Red LED is on.
•The communication cable is bad.

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Appendix A – Instructional Placards
Instructional Placard for Operators:
English/Spanish
Battery connected
Batería conectada
Check Charger
Chequear el Cargador
Slow Flash- Charger didn’t start after 5 min
Flash Lento- Cargador no funcionó despues de 5 min
Fast Flash- Charger has not seen battery in 7 days
Flash Rápido –Cargador sin batería por 7 días
Pick this Battery
Tomar esta Batería
Operating Instructions
Instrucciones de Operación

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French/Portuguese (Side 2)
Bateria conectada
Batterie connectée
Verifique o Carregador
Vérifier le Chargeur
Flash Lento- Carregador não funcionou depois de 5 min
Flash Lent - Chargeur n’a pas démarré après 5 min
Flash Rápido - Carregador não conectou a nenhuma bateria
depois de 7 dias
Flash Rapide - Chargeur non connecté à une batterie depuis
7 jours
Selecione esta Bateria
Prenez cette Batterie
Operating Instructions
Instructions d’Utilisation

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© 2019 Philadelphia Scientific LLC. All Rights Reserved. Philadelphia Scientific, the PS logo and iBOS are
registered trademarks of Philadelphia Scientific LLC. iBOSworld and Real-Time Monitor are trademarks of
Philadelphia Scientific. E&O.E.