Philadelphia Scientific iBOS Pro 6 Series User manual

DOC0023
Installation Manual
iBOS®Pro 6 Series
08
Fall
Updated January, 2015
Version 1.5

Philadelphia Scientific® iBOS®Pro 6 Series Installation Manual
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Table of Contents
iBOS®Pro 6 Series
1. Introduction..............................................................................................................................................4
1.1 System overview................................................................................................................................4
1.2 Organization of this Manual................................................................................................................4
1.3 Contact Information............................................................................................................................5
1.4 Installation Outline .............................................................................................................................5
2. System Components................................................................................................................................6
2.1 Individual Components.......................................................................................................................6
2.2 Control Box........................................................................................................................................7
2.3 BOS-CB6700 Ports............................................................................................................................8
2.4 BOS-CB6710 Ports............................................................................................................................8
2.5 Control Box Rear of Front Door..........................................................................................................9
2.6 Sentinel™ BOS-SU6000 Anatomy...................................................................................................10
2.7 System Components........................................................................................................................11
Sentinel™..........................................................................................................................................11
Scrolling Display ................................................................................................................................11
Wireless Display ................................................................................................................................11
Sentinel™Data Cable and Coupler 25’ (7.6 m)..................................................................................11
Sentinel™Data Cable and Coupler 100’ (30.5 m) (CAT3) .................................................................11
Peripheral Data Cable (CAT5e) and Coupler 50’ (15.2 m)..................................................................12
Wireless Display Antenna Extension Cable........................................................................................12
External Shouter................................................................................................................................12
Custom Sentinel™Data Cable Kit .....................................................................................................13
2.8 Wireless Display System Diagram ...................................................................................................14
2.9 Scrolling Display System Diagram ...................................................................................................14
3. Planning / Specifying Job.......................................................................................................................16
3.1 Decide on Pools...............................................................................................................................16
3.2 Count Chargers in Each Pool...........................................................................................................16
3.3 Wireless Display Location................................................................................................................17
3.4 Scrolling Display Location................................................................................................................18
3.5 Control Box Location........................................................................................................................18
3.6 Sentinel™ Data Cable Requirements...............................................................................................19
3.7 Installation Service...........................................................................................................................21
4. Pre-Installation.......................................................................................................................................22
4.1 Check data connection availability ...................................................................................................22
4.2 Check power availability...................................................................................................................22
4.3 Charger Configuration......................................................................................................................23
4.4 Pre-installation Phone Conference...................................................................................................23
4.5 Useful Tools and Materials...............................................................................................................23
5. Installing System Components...............................................................................................................25
5.1 Installing Control Box.......................................................................................................................25
5.1.1 Install Mounting Bracket............................................................................................................25
5.1.2 Mounting the Control Box..........................................................................................................25
5.1.3 Securing the Control Box to Wall...............................................................................................25
5.2 Installing the Battery Backup into the Control Box............................................................................25
5.2.1 UPS in Control Box (Optional)...................................................................................................25
5.2.2 Route UPS Cable to Power.......................................................................................................26
5.3 Installing the Sentinel™ ...................................................................................................................26
5.3.1 Run Sentinel™ Data Cable to 1st Sentinel™ of Each Bus..........................................................26
5.3.2 Connect Sentinel™ Data Cable to Sentinel™ Socket................................................................27
5.3.3 Mount Sentinel™.......................................................................................................................28
5.3.4 Connect Sentinel™ to charger ..................................................................................................29
5.4 Install Scrolling Display(s)................................................................................................................30

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5.4.1 Install Scrolling Display .............................................................................................................30
5.4.2 Program Display Settings..........................................................................................................32
5.5 Install Wireless Display....................................................................................................................33
5.5.1 Wireless Display Antenna Install: ..............................................................................................34
5.6 Label Battery Chargers and Bays.....................................................................................................35
5.6.1 Number your chargers and bays ...............................................................................................35
5.7 Data Uploads...................................................................................................................................36
5.8 Install External Shouter....................................................................................................................36
6. System Configuration and Settings........................................................................................................38
6.1 Configuring Pools and Chargers ......................................................................................................38
6.2 Configuring Internet Connections.....................................................................................................43
6.2.1 Selection Options......................................................................................................................43
6.3 Password Setting.............................................................................................................................45
6.4 Language Setting.............................................................................................................................46
6.5 Date and Time Setting .....................................................................................................................47
6.6 Volume Adjustment..........................................................................................................................49
6.7 Linked Pools....................................................................................................................................50
6.7.1 Name the Pools.........................................................................................................................50
6.7.2 Select Link Pools.......................................................................................................................50
6.7.3 Set Pool Pairs ...........................................................................................................................50
6.8 Home Screen Display ......................................................................................................................51
6.9 Message Length ..............................................................................................................................52
6.10 Pick Light.......................................................................................................................................53
6.11 Running System Dark ....................................................................................................................54
7. Final Inspection and Testing..................................................................................................................55
7.1 Sentinels™ ......................................................................................................................................55
7.2 Scrolling Display(s) ..........................................................................................................................56
7.3 Shouter............................................................................................................................................57
7.4 Check Data Upload to Web..............................................................................................................57
7.5 Wireless Communications Test........................................................................................................59
8. Troubleshooting.....................................................................................................................................61
8.1 Version Determination......................................................................................................................62
8.2 Control Box......................................................................................................................................63
8.3 Sentinel™ ........................................................................................................................................64
8.4 Shouter............................................................................................................................................65
8.5 Scrolling Displays.............................................................................................................................67
8.6 Wireless Touch Screen....................................................................................................................69
8.7 System Trouble Shooting Reference................................................................................................70
8.7.1 System Information. ..................................................................................................................70
8.7.2 Wireless Display RF Antenna Relocation..................................................................................70
8.7.3 Changing out a Sentinel™.........................................................................................................71
8.7.4 Reconfiguring a Sentinel™ that has been configured for the wrong charger .............................73
8.7.5 Troubleshooting with Blue Light ................................................................................................73
Appendix A –Sentinel™ Information .........................................................................................................74
Appendix B –Scrolling Display Information................................................................................................75
Section 1 –Sign Types..........................................................................................................................75
Section 2 –Type B Signs.......................................................................................................................76
Section 3 –Type A Signs.......................................................................................................................77
Appendix C –Internet Connection Requirements ......................................................................................80
Appendix D –Display Protection................................................................................................................81
Appendix E –Custom Sentinel™ Data Cable ............................................................................................82
Appendix F –Glossary...............................................................................................................................83

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1. Introduction
1.1 System overview
This manual will give you all the information you need to install the iBOS®battery management system.
Once installed this system will help create a smooth running battery room and provide valuable
management information on the batteries and chargers. Before getting into all the details of installation, a
quick overview of how the system works may be helpful.
Once the system is installed, every charger will have a small monitoring device attached to it called a
Sentinel™that works on all voltages (12-80v). The Sentinel’s™basic function is to detect when the
charger finishes charging and to tell the Control Box that a fully charged battery is now available for use.
The Sentinel™also detects when a battery is connected without the charger starting. After 24 hours in this
state, the Sentinel™will terminate and return the battery to the rotation, even though the battery was not
charged, to avoid stranding the battery indefinitely. A charger no-start record will appear on the iBOSworld
Web Service website indicating charger #, date and time.
All Sentinels™are wired via a daisy chained bus into the Control Box which keeps track of all the charged
batteries. The chargers are grouped into pools, one pool for each type/size of battery in the facility. One or
more scrolling LED displays, mounted on the wall, or a wireless display, mounted on the battery changer,
tells the operator which battery to pick next. The battery that is fully charged and that has been cooled
down the longest will appear on the display, assuming there are no “charger no start” batteries. There is
also a built-in shouter which announces a message in one of seven languages telling the operator when
they have picked an incorrect battery. This enables the system to ensure proper battery rotation.
The procedure for the operators is:
When a truck comes in for a new battery, the operator looks at the display for that pool.
It will tell him/her which battery to take. For example they may see a message like: “Take next
REACH TRUCK battery from charger 102.”
The operator goes to the slot marked “102” to get the battery for that type of truck.
The Control Box is also capable of sending data to a website where it can be analyzed and reports are
generated. These reports contain information necessary for keeping the battery selection process running
smoothly and can be used to predict when a drift in process is due to too many/too few batteries,
malfunctioning chargers, and operators following instructions improperly. The connection to the internet is
either a standard direct network Ethernet or via cellular modem. The Ethernet method saves money over
the cellular service but requires IT department approval and installation. The cellular modem requires a
signal to a cell tower but can be a quick and reliable alternative.
Once data is being sent out, users who have the proper login permission can log into the website and see
information about the performance of the battery room. This information can help determine if the site is
running short of batteries or has too many, if all the chargers are working properly, and if the operators are
correctly following the instructions.
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. This section is simply to help you get familiar with what the
various parts of the system are and what they look like.
Section 3 –Planning the job. When you are specifying a job there are some useful guidelines that
we have found to be helpful in initially specifying the system.
Section 4 –Pre-installation. You have ordered the system and are ready to go on the installation
trip. The steps in this section are invaluable in preparation for when you are on site. Our goal is that

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you only need to make one trip to complete the installation.
Section 5 –Installing the hardware. Finally, the actual installation steps to get everything mounted
and wired.
Section 6 –Configuring the software. This is how you tell the Control Box the names of the pools,
the charger numbers and other configuration information.
Section 7–Final Inspection and testing
Section 8–Troubleshooting
Appendixes- on various topics to support the installation and your system understanding.
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.
188 Oxford Grove
Bolton BL13BH
England
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]
1.4 Installation Outline
Once you get on site, the installation can be divided into three basic stages.
I. Control Box and peripherals –This stage requires some knowledge of battery rooms and can
involve some customer input.
a. Mount Control Box
b. Mount Scrolling Displays or Wireless Display
c. Mount External Shouter alarm (Optional)
d. Connect Ethernet (Installed prior to iBOS®installation, preferably) or cellular modem
e. Review battery pools and charger/battery slots
II. Connecting chargers –This takes the longest time, is repetitive, and someone who is familiar with
general electrician-type work can be trained fairly quickly.
a. Wiring bridge from the Control Box to the 1st Sentinel™of each bus.
b. Mounting Sentinels™on each charger
c. Running the Sentinel™Data Cable between Sentinels™
d. Label chargers and battery bays
III. Testing and configuring the system –This step is probably the quickest (unless problems with
wiring are found and have to be fixed). It is also the most iBOS®specific.
a. Name pools
b. Configure chargers
c. Test upload capability
d. Set system for operations or running dark period
e. Operator Training

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2. System Components
2.1 Individual Components
The iBOS®Pro 6 Series Control Box is manufactured in two versions:
- BOS-CB6700 –can hold up to 200 Sentinels™with Scrolling Displays or wireless display
- BOS-CB6710 –can hold a max of 350 Sentinels™with wireless display
Wireless Display
Control Box
Built in Speaker
Mounting Feet
Sentinels™
External Shouter
Cellular Modem
Touch Screen
Interface
Locking Tab

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2.2 Control Box
Battery Backup
Compartment
Wireless Radio
Modem Mounting
location (used with
Wireless Display)
Cable Tray
Power Socket
Connection to
Control Box
2 Wiring Ports
(3/4” ID and 1 ½”
OD)
Wireless
Radio
Antenna
Mount
Connection
Port Interface
Mother Board
Panel Cover (Do
not remove)

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2.3 BOS-CB6700 Ports
2.4 BOS-CB6710 Ports
No Scrolling Displays
Programming
Wireless
Display
Connections
1st and 2nd
Ethernet
Accessory
Scrolling
Displays (x3)
Sentinel™Bus
(x4) –Max 50
Sentinels™/ bus
USB
Ports
External
Shouter
Sentinel™ Bus (x7) –
Max 50 Sentinels™/ bus
Programming
Ethernet
Accessory
USB
Ports
External
Shouter
Wireless
Display
Connections
1st and 2nd

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2.5 Control Box Rear of Front Door
SD Card
for Touch
Screen
Front
Locking
Slot
Internal
Shouter
Power
(12v) to
Display
Audio to
Shouter
Closure
Screws
Closure
Screws

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2.6 Sentinel™BOS-SU6000 Anatomy
Reverse Side –
Slotted
End Cap
Enclosure
24” (.61m)
Sensing
cable
Quick
Tap
Sentinel™
Board
Sentinel™
End Cap
Shipping Tubes
(discard)
Data
Sockets (2x)
Software Version
Serial Number of Sentinel (SN)

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2.7 System Components
Sentinel™
BOS-SU6000
Scrolling Display
BOS-DSPT
Wireless Display
BOS-WD6000
Sentinel™Data Cable
and Coupler 25’ (7.6 m)
BOS-143
Sentinel™Data Cable
and Coupler 100’ (30.5 m)
(CAT3)
BOS-161

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Peripheral Data Cable
(CAT5e) and Coupler 50’
(15.2 m)
BOS-200
Wireless Display Antenna
Extension Cable
BOS-163
External Shouter
BOS-SH6000

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Custom Sentinel™Data
Cable Kit
BOS-159

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2.8 Wireless Display System Diagram
Wireless Display
External Shouter
Sentinel™
Control Box:
4 Buses
Max 50 Chargers
per Bus
Audio Cable
50’(15.2 m)
included
Bus Sentinel Data
Cable (CAT3)
(100’ (30.5 m) included)
Available in 25’ (7.6 m)
and 100’ (30.5 m)
lengths w/ coupler
7’ (2.1 m) Sentinel
Data Power (CAT3)
Cable
included with each
Sentinel
Battery Backup and Surge
Protector

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2.9 Scrolling Display System Diagram
Shouter
BOS-
SH6000
Sentinel™
Scrolling Display
(Max 9 Displays)
Control Box:
4 Buses
Max 50 Chargers
per Bus
Battery Backup and
Surge Protector
Scrolling Displays
use Standard
Cat5e cable
1x 50’ (15.2 m)
included for each
display (up to 3)

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3. Planning / Specifying Job
3.1 Decide on Pools
The first step is to make a list of all the pools in the facility. The groups of different kinds/sizes of batteries
are put into pools. For example all of the reach truck batteries would be considered one pool. All of the
Pallet Jack batteries would be a different pool.
For example, if a distribution center has 12 chargers for pallet jacks, 9 chargers for reach truck batteries,
and 7 for turret truck batteries, we would have 3 pools.
Pool 1 “PALLET JACK” Pool 2 “REACH TRUCK” Pool 3 “TURRET”
As shown in this example there will always be at least one pool for each battery type/size in the facility.
There can be more pools in some situations
If a distribution center has 2 battery changers you may want to configure 2 pools for each battery type.
Assume that each battery changer has 40 chargers for pallet jacks and 25 chargers for reach trucks. You
would probably want to set up 4 pools:
Pool 1 “PALLET (LEFT)” Pool 2 “REACH (LEFT)”
Pool 3 “PALLET (RIGHT)” Pool 4 “REACH (RIGHT)”
NOTE: The names of the pools need to be 13 characters or less.
3.2 Count Chargers in Each Pool
You will need one Sentinel™for each charger. The Sentinels™are universal voltage and work from 12v
to 80v DC.

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3.3 Wireless Display Location
(if applicable for your system)
- Wireless Display (BOS-WD6000) is normally
mounted on the battery changer.
- Power Requirements:
o100 VAC/ 240vAC outlet
Surge protector is recommended. See appendix D-
Display Protection.
- It can also be mounted on a wall or
anywhere that is convenient.

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3.4 Scrolling Display Location
(if applicable for your system)
The Scrolling Display shows which battery to
take. The people who change the batteries
must be able to see the display easily.
Method 1 Grouped: locate all of the
Scrolling Displays together, i.e. at the end of
the battery changer bay. Many installers find
it helpful to install the displays and shouters
on a backboard before going to the site to
make a very professional look and to make
installation easier (Appendix C).
Method 2 Per Pool: If you have two battery
changers, the Scrolling Displays for each
battery changer can be put in the bay for
that changer.
The Scrolling Displays can also be mounted
near the pool for that display.
NOTE: It is highly recommended that each
display is protected with a surge protector (see
Appendix D).
Scrolling Displays mounted together (Method 1)
Displays mounted next to each pool of batteries (Method 2)
3.5 Control Box Location
Locate Control Panel in a clean, dry safe area:
Near battery chargers.
Close to the Scrolling Displays. Ideally less
than a 25’ (7.6 m) run for the display cable.
Less than 12’ (3.7 m) from an AC outlet
Out of the way, so it won’t be damaged by lift
trucks or other moving objects
At a comfortable height for programming on
display
Where it won’t obstruct anything
Where it will be easy to run cable from the
chargers.
Use appropriated anchors as dictated by the wall material you
are mounting the Control Box (35 lbs. (15.9 kg))

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3.6 Sentinel™Data Cable Requirements
Data Cables are required to be run from the Control Box to the first Sentinel™in a pool as well as from
Sentinel™to Sentinel™for the rest of the chargers in the pool in a daisy chain method for a max of 50
Sentinels™per Bus. Model BOS-CB6700 has 4 Buses with a system max of 200 Sentinels™and model
BOS-CB6710 has 7 buses with a system max of 350 Sentinels™. Using non-approved cable may not work
and could void your warranty.
7’ (2.1 m) Sentinel™Data Cables (supplied with each Sentinel™)
25’ (7.6 m) Sentinel™Data Cables w/coupler (must be ordered) BOS-143
100’ (30.5 m) Sentinel™Data Cable w/coupler (1 per Bus is supplied with control box) BOS-161
Custom Cable Kit (must be ordered) BOS-159
You need to purchase enough cable to reach the first Sentinel™for Each Bus you are using.
Here are some sample layouts of a typical battery room layout.
Sample 1: Layout 2 pool on one bus.

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Sample 2: Layout - 3 pools on 4 Buses.
(A) A single Bus can run multiple pools.
(B) One Pool can span across multiple buses.
(C) The distance from control box and the first Sentinel™can vary as required.
(D) Bridges can be installed between different racks with varied distances as required
These samples above show that you can mix voltages and pools on one bus. The limitation is you can
only go up to 50 Sentinels™on one bus.