Philadelphia Scientific iBos Charger-Splitter User manual

DOC0015
April 2018
Version 2.0
Installation Manual

Installation Manual
Philadelphia Scientific® Charger-Splitter™ Installation Manual
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Table of Contents
1. INTRODUCTION...................................................................................................................................3
1.1. SYSTEM OVERVIEW ...........................................................................................................................................3
1.2. TYPICAL BATTERY ROOM LAYOUTS AND CONFIGURATIONS ........................................................................................4
1.2.1. SINGLE LEVEL RACK WITH FRONT-MOUNTED SPLITTER BRACKET ...................................................................4
1.2.2. MULTI-LEVEL RACK WITH REAR-MOUNTED SPLITTER BRACKET......................................................................5
1.2.3. MULTI-LEVEL RACK WITH FRONT-MOUNTED SPLITTER BRACKET,OPTION A ....................................................6
1.2.4. MULTI-LEVEL RACK WITH FRONT-MOUNTED SPLITTER BRACKET,OPTION B ....................................................7
2. SYSTEM COMPONENTS..................................................................................................................... 8
2.1. CHARGER-SPLITTER™KIT (PART NUMBER BOS-258)..............................................................................................8
2.2. BATTERY EXTENSION CABLE ................................................................................................................................9
2.3. UNISTRUT®OR SIMILAR METAL FRAMING CHANNEL ................................................................................................9
3. REQUIRED TOOLS............................................................................................................................10
4. INSTALLATION..................................................................................................................................11
4.1. CHARGER-SPLITTER™BRACKET INSTALLATION ......................................................................................................11
4.2. BATTERY EXTENSION CABLE ..............................................................................................................................13
4.3. RETAINING CHAIN ...........................................................................................................................................15
4.4. CONNECT SENTINELS™.....................................................................................................................................15
5. CHARGER-SPLITTER™ SETUP.......................................................................................................16
5.1. ADDING CHARGERS FOR THE CHARGER-SPLITTER™CONFIGURATION.........................................................................16
5.2. SENTINEL™OUTPUTS ......................................................................................................................................16
6. FINAL INSPECTION AND TESTING.................................................................................................18
7. TROUBLESHOOTING........................................................................................................................19
8. CONTACT INFORMATION ................................................................................................................20

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1. Introduction
This manual will provide information needed to install the Charger-Splitter™. The
Charger-Splitter™ is to be used in conjunction with an iBOS®battery room
management system.
1.1. System Overview
The Charger-Splitter™ add-on feature enables a site to reduce the number of
chargers needed in half. With the Charger-Splitter™ add-on, two battery
positions are paired to a single charger. When the first battery is fully charged,
the iBOS®battery room management system will alert the operator with a
white flashing LED to switch the charger to begin charging the second battery.

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1.2. Typical Battery Room Layouts and Configurations
The iBOS®Charger-Splitter™ is a modular system that has been designed to
operate in various battery room layouts. Although several different battery
room configurations exist, this section will provide examples of the more
common ones.
1.2.1. Single Level Rack with Front-Mounted Splitter Bracket

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1.2.2. Multi-Level Rack with Rear-Mounted Splitter Bracket

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1.2.3. Multi-Level Rack with Front-Mounted Splitter Bracket, Option A

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1.2.4. Multi-Level Rack with Front-Mounted Splitter Bracket, Option B

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2. System Components
2.1. Charger-Splitter™Kit (Part Number BOS-258)
Each Charger-Splitter Bracket Kit includes:
2x
4x
Charger Splitter Bracket and Retaining Chain
1x 7ft. (2.13 m) Data Cable
1x 1ft. (30.48 cm) Data Cable
Splitter Enabled Sentinel
4x

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2.2. Battery Extension Cable
2.3. Unistrut®or Similar Metal Framing Channel
Unistrut®or similar metal framing channel is used to mount the
Charger-Splitter bracket to the battery racks. It is cut to length
to mount to the rack supports.
One battery extension cable is required per battery position. A
battery extension cable consists of one positive and one
negative cable with crimped-on connectors.
Battery cables, connectors and Unistrut®or similar metal framing
channel are not included with the Charger-Splitter™ kit and must be
supplied by the customer.
Positive and Negative cables
SB Connectors

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3. Required Tools
Philadelphia Scientific®recommends using the following tools for installation:
Drill
Anchors
Phillips Head Screw Driver
7/16 Wrench
Battery Cable Cutter
Battery Cable Crimper

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4. Installation
4.1. Charger-Splitter™ Bracket Installation
1. Slide two (2) Spring Nuts into the channel about 10” apart.
2. Using the Spring Nuts as a guide, fasten the Charger-Splitter bracket to
the Unistrut or metal framing channel with the included hex bolts.

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3. Hand-tighten both sides.
4. Tighten the bolts using a 7/16 wrench.
The Retaining Chain should hang below the bracket.

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4.2. Battery Extension Cable
Assemble the battery extension cables according to local electrical
code.

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Fasten the SB Connectors to the bottom of the Charger-Splitter bracket
using the attached hex bolts and nuts.

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4.3. Retaining Chain
Connect the chain to the charger connector using the attached screw and
lock nut. Insert the screw through the top side of the charger connector so
that the chain hangs under the assembly.
4.4. Connect Sentinels™
The retaining chain must remain in place during operation to avoid
incorrectly pairing with the wrong charger.
Refer to the iBOS Installation Manual for “Installing the Sentinels”
instructions.

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5. Charger-Splitter™ Setup
5.1. Adding Chargers for the Charger-Splitter™Configuration
For each charger, enter the desired charger ID followed by an “A” or “B”
(no spaces). Repeat steps for the remainder of batteries and chargers in
the pool
5.2. Sentinel™ Outputs
1. From the Home screen press the Settings button.
2. The passcode entry screen will appear. Enter the site or default
passcode (919191). Press OK.
3. Press the on the Settings screen to get to the second page.
The following instructions are specific to the Charger-Splitter
configuration where two batteries are paired with each charger.
Refer to the iBOS Installation Manual for “Configuring Pools and
Chargers”instructions.
101A, 101B

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4. Press the Sentinel Outputs button.
5. The Sentinel Outputs screen will appear. Use the buttons to
select “Pick” for the Blue Light and “Switch” for the Output Relay
(white LED). The system will automatically save the settings.
6. Press the button to return to the Home screen.

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6. Final Inspection and Testing
Task
Status
Battery cable connectors are secured to the bracket.
Unistrut® or metal framing channel is secured to mounting
surface.
Verify there is sufficient cable to reach both the A and B sides of
the Charger.
Reset the Maintenance screen to the default password (“11111”)
or Settings screen to the default password (“919191”) when
leaving the box if it was changed during installation.
Close the control box and fasten the screws (locking is optional).

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7. Troubleshooting
Use the following chart to help identify solutions to the most common issues.
Issue
Possible Solution
No White Light
•The white LED on a Sentinel™ flashes to
alert the operator to disconnect a charger
from a battery and plug it into a paired
battery. If both batteries are charged, no
white light will be on.
•Check the Sentinel™Outputs screen to
ensure that the Output Relay is set to
“Switch”.
•Use the buttons to scroll
through the options under Output Relay.
•Select the “Switch” option.
Power and Data
Connection Issues
Green LED –Communication status
•Off –No power to the Sentinel™.
•Solid –Sentinel™ is communicating properly with
Controller.
•Flashing –Sentinel™ is not communicating
properly with the Controller.
Amber LED –Charging status
•Off –No battery connected.
•Solid –Battery is connected.
•Solid –No battery connected. Check the charger
for a voltage leak to the DC cables.
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 next.
White Light is on for a
long time
•During normal operation, the white light will
go off after connection and charge start.
oIf the charger is still charging, leave
it connected.
oTroubleshoot charger if there is a
charger fault.

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8. Contact Information
https://www.phlsci.com/
© 2018 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.
Philadelphia Scientific LLC
207 Progress Drive
Montgomeryville, PA 18936
USA
Phone: [phone]
Fax: [phone]
Email: [email protected]
Philadelphia Scientific UK Ltd.
Atlas Mill,
Mornington Road,
Bolton, BL1 4EZ
England
Phone: [phone]
Fax: [phone]
Email: [email protected]
Philadelphia Scientific-
Asia/Pacific
2/17 Norman Street
NSW, 2225
Australia
Phone: [phone]
Fax: [phone]
Email: [email protected]