Philadelphia Scientific iBOS Plus 6 Series User manual

DOC0024
Installation Manual
iBOS®Plus 6 Series
August 2018
Version 1.4

Philadelphia Scientific® iBOS®Plus 6 Series Installation Manual
Page 2 of 43
Table of Contents
iBOS®Plus 6 Series
1. Introduction..............................................................................................................................................3
1.1 System Overview...............................................................................................................................3
1.2 Instruction Manual Organization.........................................................................................................3
1.3 Contact Information............................................................................................................................4
1.4 Installation Outline .............................................................................................................................4
2. System Components................................................................................................................................5
2.1 Individual Components.......................................................................................................................5
3. Planning / Specifying Job.........................................................................................................................8
3.1 Pools..................................................................................................................................................8
3.2 Chargers in each Pool........................................................................................................................8
3.3 Control Box........................................................................................................................................8
3.4 Data Cable Requirements..................................................................................................................8
3.5 Installation and Commissioning Services...........................................................................................9
4. Pre-Installation.......................................................................................................................................10
4.1 Checklist..........................................................................................................................................10
4.2 Control Box Dimensions...................................................................................................................10
4.3 Data Connection Availability.............................................................................................................11
4.4 Power Availability.............................................................................................................................11
4.5 Useful Tools.....................................................................................................................................12
5. System Installation.................................................................................................................................13
5.1 Control Box Installation....................................................................................................................13
5.1.1 Mounting the Control Box: .........................................................................................................13
5.2 Installing the Battery Backup (Recommended) ................................................................................13
5.3 Sentinel™ Wiring and Charger Mounting .........................................................................................13
5.3.1 Sentinel Wiring:..........................................................................................................................13
5.3.2 Mount to Charger (or secure location as desired): .....................................................................14
5.3.3 Sentinel™ LEDs: .......................................................................................................................14
5.3.4 Repeat steps 5.3.1 through 5.3.3 for the remainder of batteries & chargers in the pool. ..........15
5.4 Battery Charger and Battery Bay Labels..........................................................................................15
6. System Configuration and Settings........................................................................................................16
6.1 Language Setting.............................................................................................................................16
6.2 Date and Time Setting .....................................................................................................................17
6.3 Configuring Pools and Chargers......................................................................................................20
6.4 Configuring Internet Connections.....................................................................................................24
6.5 Password Settings...........................................................................................................................29
6.6 Display Pools...................................................................................................................................30
6.7 Volume Adjustment..........................................................................................................................30
6.8 Sentinel Outputs ..............................................................................................................................30
6.9 Message Length ..............................................................................................................................31
6.10 Linked Pools..................................................................................................................................31
6.11 Home Screen Display ....................................................................................................................32
6.12 Running System Dark....................................................................................................................32
7. Final Inspection and Testing..................................................................................................................33
7.1 Sentinels™ ......................................................................................................................................33
7.1.1 Status........................................................................................................................................33
7.1.2 Quarantine.................................................................................................................................34
7.1.3 Sentinel List...............................................................................................................................36
7.1.4 System Information....................................................................................................................37
7.2 Shouter............................................................................................................................................37
7.3 Check Data Upload to Web..............................................................................................................38
Appendix A: Data Cable Reference Diagram (RJ12, 6-wire)......................................................................41
Appendix B –Internet Connection Requirements.......................................................................................41

Philadelphia Scientific® iBOS®Plus 6 Series Installation Manual
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1. Introduction
1.1 System Overview
The purpose of this manual is to relay all necessary information regarding the installation of the iBOS®Plus
6 Series battery room management system. Once installed, this system will help streamline the process of
selecting batteries and provide valuable management information on the batteries and chargers.
A fully installed system will have a monitoring device mounted on each charger. This monitoring device is
referred to as a Sentinel™. The Sentinel’s™primary function is to detect when the charger finishes
charging and send this information to the Control Box. The Control Box is wired to all Sentinels™and uses
information received from these Sentinels™to keep track of all charged batteries. Sentinels™/chargers
are grouped into units called “Pools”. Each Pool is dedicated to a specific type/size of battery in the facility.
The Control Box’s other function is to inform the operator of which battery to pick to ensure maximum
efficiency. This information is relayed through a display mounted on the control box, a “Shouter” that
announces messages to the operator, and colored LEDs mounted on the Sentinels™.
The procedure for the operator is as follows:
1) Operator looks at the display for the pool that corresponds
to the specific battery type he/she is seeking:
a. The display will tell the operator which battery to
take: An example message would be “REACH -
203”.
2) Operator follows the message displayed on the Control
Box’s iDisplay™or the Sentinel’s™flashing blue light to
the charger specified and selects the battery.
The Control Box is also capable of sending data to a website to
generate management reports. These reports contain information
necessary for keeping the battery selection process running
smoothly and can be used to predict when drift in process is due
to too many or not enough batteries, malfunctioning chargers, and
operators following instructions improperly.
1.2 Instruction Manual Organization
•Section 1 - System Overview. Introduction and overview of the iBOS®Plus 6 Series System and
outline of this installation manual.
•Section 2 - System Components. Various parts of the system are documented / pictured to assist
in familiarizing the installer and operator with the iBOS®Plus 6 Series System.
•Section 3 - Planning/Specifying the Job. Installation planning and strategies are highlighted.
•Section 4 - Pre-Installation. On-Site preparation steps are listed to ensure a smooth installation.
•Section 5 - Installing System Components. Hardware installation is highlighted to aid in the
mounting and wiring of the Control Box and Sentinels.
•Section 6 - System Configuration. Instructions to naming the pools and chargers with the Control
Box as well as correct wiring verifications are captured.

Philadelphia Scientific® iBOS®Plus 6 Series Installation Manual
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•Section 7 - Final Inspection and Testing. A final checklist for the installer is included.
•Section 8 - Operating System Overview. Settings Screen anatomy, Maintenance Mode options,
and Status Screen are highlighted.
•Section 9 - Operating Instructions. Operator instructions are listed and pictured.
•Section 10 - Appendix. Additional references are listed and pictured.
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]
1.4 Installation Outline
On-Site Installation can be divided into three stages:
1) Control Box and Peripheral Installation
a. Control Box
b. Ethernet Connection/Wireless Cellular Modem (Optional)
2) Sentinel Wiring Connections
a. Wiring from Sentinel to Sentinel
b. Wiring to the Control Box
c. Mount to Chargers
d. Labeling the Chargers/Battery Bays
3) Charger Configuration/Final Testing
a. Configure Pools
b. Configure Chargers
c. Testing Upload Capability
d. Operator Training

Philadelphia Scientific® iBOS®Plus 6 Series Installation Manual
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2. System Components
2.1 Individual Components
Control Box - 100 Sentinels Max
iDisplay
Touch
Screen
Ethernet
No Scrolling Displays
USB
Port
Internal
Shouter
Cellular Modem
Power Connection
to Control Box
Sentinel Bus (x2)
*MAX 50 Sentinels per Bus
data cable connection
Mounting
Feet

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Sentinel™
BOS-SU6000
Sentinel™
Data Cable connection to Bus -
cable is live 24V - DO NOT CUT!

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Optional Accessories:
25’ (7.6 m) Data Cable and Coupler
BOS-143
100’ (30.5 m) Data Cable and
Coupler
BOS-161
Custom Data Cable Kit
BOS-159
UPS Backup and Surge Protector
BOS-150

Philadelphia Scientific® iBOS®Plus 6 Series Installation Manual
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3. Planning / Specifying Job
3.1 Pools
Batteries in a facility should be grouped by type in a unit called a “Pool” to utilize the iBOS®battery
organizing system. An example of this organization would be to consider all of the Reach truck batteries in
a facility that use the same type of batteries, in voltage and size, (e.g., 18-125-15) to be one pool and all of
the Pallet Jack batteries to be in another pool.
As a basic rule of organizing batteries, there will always be at least one pool per type of battery in the
facility. There are some scenarios where it would be preferable to have more than one pool per type of
battery. An example of this circumstance would be if the facility had two battery changers per one type of
battery. An example organization in this circumstance would be to have two separate pools: one per the
battery changer on the right and one per the battery changer on the left. The iBOS®Plus 6 Series has a
max of 9 pools.
*Note: The Pool names must be 13 characters or less.
3.2 Chargers in each Pool
One Sentinel™is needed per charger. Chargers in a given pool all have the same voltage. Sentinels™
are universal and can be used for any voltage between 12V to 80V.
3.3 Control Box
The Control Box is used to relay battery selecting information to the operator as well as control the
process. The mounted location is critical for the operator to view the next battery and shortest distance to
first Sentinel™for each bus.
Some guidelines for mounting the Control Box include:
•Mount in a visible area, free of obstructions.
•Keep the component away from water sources such as emergency showers and sinks.
•The Control Box requires a 100 - 240V power source.
•Be aware of the substrate that the component is being mounted to. Use appropriate anchors as
necessary to support the Control Box (15 lbs. (6.8 kg)).
3.4 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. The iBOS®Plus 6 Series System has 2 Buses with a system max of 100 Sentinels.
•7’ (2.1 m) Data Cables (supplied with each Sentinel™)
•25’ (7.6 m) Data Cables (must be ordered) BOS-143
•100’ (30.5 m) Data Cable (must be ordered) 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. Two
examples of Bus cabling are shown in the picture below:
Bus 1: 50’(15.2 m) of cable needed even though it was only 10 ft. from the Control Box to the first
Sentinel™.
Bus 2: 100’ (30.5 m) of cable needed as it was located on the other side of the aisle to the first Sentinel™.

Philadelphia Scientific® iBOS®Plus 6 Series Installation Manual
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3.5 Installation and Commissioning Services
The iBOS®Plus 6 Series System is designed to not require commissioning by Philadelphia Scientific®, but
if assistance is required, it is offered by request. Installation videos are also available online.
Contact Philadelphia Scientific®to receive assistance.
Phone: [phone] and ask for Customer Service

Philadelphia Scientific® iBOS®Plus 6 Series Installation Manual
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4. Pre-Installation
4.1 Checklist
Task
Status
Plan for location of Control Box:
•Power for Control Box
•Near chargers
•Plan for data cable run to the 1st Sentinel™in each bus
Gather all required tools and equipment:
•Ladders and/or Scissor Lifts.
•Power Tools –for mounting Control Box, etc.
•Hand Tools –wire cutters, Phillips-head screwdriver.
•Extension cords for temporary power.
•Anchors for mounting components based on mounting wall.
Review
•UPS Battery Backup System for the Control Box (Optional).
4.2 Control Box Dimensions
Be sure that there is adequate clearance around the control box to connect cables. (Power, Ethernet, etc.)

Philadelphia Scientific® iBOS®Plus 6 Series Installation Manual
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4.3 Data Connection Availability
To give the iBOS®Plus 6 Series the ability to gather data and generate reports, the customer must provide
a means for the iBOS®Plus 6 Series system to connect to the internet. All communication is initiated by
the Control Box. The ability to remotely initiate a communication session from the outside is not enabled.
See Appendix B –Internet Connection Requirements for details.
4.4 Power Availability
Layout planning restrictions to consider:
•Extension cords can be used temporarily but Surge Protection is highly recommended for the
Control Box.
iBOS®Plus 6 Series Component Power
Requirements
Component:
Voltage:
Amperage:
Control Box
100-240 VAC
1.3 A
Cellular Modem
100-240 VAC
0.6 A

Philadelphia Scientific® iBOS®Plus 6 Series Installation Manual
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4.5 Useful Tools
Drill
Level
Drill
Extensions
Anchors
For mounting
Control Box
For mounting
Control Box
Suitable for the mounting
surface present
Optional -
could be useful
Wire
Snips
For installing
Sentinels

Philadelphia Scientific® iBOS®Plus 6 Series Installation Manual
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5. System Installation
5.1 Control Box Installation
5.1.1 Mounting the Control Box:
•Level the Control Box.
•Secure the Control Box with four or more screws as needed.
5.2 Installing the Battery Backup (Recommended)
•Ensure the battery is connected inside.
•Connect the Control Box’s power cord to an outlet on the ‘Battery Backup’ side of the Battery
Backup.
5.3 Sentinel™Wiring and Charger Mounting
5.3.1 Sentinel Wiring:
•Remove the Sentinel™, Data Cable, and
Mounting Tool (mounting squares and
wire-ties) from the box.
•Remove the slotted end cap from the
Sentinel™and connect the Data Cable
from the previous Sentinel™(for all the
Sentinels™after the first in a pool) as
well as a second Data Cable through the
slotted end cap to either of the ports
(independent of order).
•Squeeze the end cap to open the slot and
allow easier insertion of data cables.
•Remove the tubing from the ends of the
Quick Tap.
•Place the Quick Tap between the cables
on the charger and squeeze.
•Ensure the pins of the Quick Tap fully
penetrate the charger cables and secure
with four wire-ties.
•Slide the end cap back onto the
Sentinel™.
Quick Tap Installation

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5.3.2 Mount to Charger (or secure
location as desired):
•Mount the Sentinel™directly to the
charger using wire-ties (preferred) in a
visible, stable area.
•Secure the mounting squares to the
charger in a visible, stable area and then
wire-tie the Sentinel™to the mounting
squares.
•Secure the upstream data cable to the
wire-tie as shown for strain relief.
5.3.3 Sentinel™LEDs:
•Green LED = Communication Status:
A solid green light indicates a good
connection to the Controller. All
Sentinels™should have a solid green
light. Upon initial connection, the green
light will flash fast, then slower, before
settling at solid green. If the green light
remains flashing fast, check the wire
connection to the Sentinel™.
•Amber LED = Charging Status:
When the amber light is on, the battery is
connected. If the amber light does not
turn on, check the quick tap to ensure
that the pins have fully penetrated the
cables.
•Blue LED = Next Battery to Pick:
A slow, blue flashing light indicated the
next battery to pick in that pool. If you do
not want to use the blue light as a pick
light indicator, it can be turned off in the
settings panel.

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5.3.4 Repeat steps 5.3.1 through 5.3.3
for the remainder of batteries &
chargers in the pool.
5.4 Battery Charger and Battery Bay Labels
The iBOS®Plus 6 Series System communicates with the operator by referencing a charger number. It is
always important to keep the charger numbering system organized to maintain the smooth process of
selecting a battery. When setting up the charger numbering system in the facility it is recommended to
follow a 3 digit format where the first digit references the pool and the second and third digit reference the
battery number in that pool.
•If the customer already has numbers that
they are accustomed to using, they can
be used if they are no longer than 6
characters. It is recommended that a
Pool reference letter be used to
differentiate between Pools.
Pallet
Reach
101
201
102
202
103
203
Pallet
Reach
P1
R1
P2
R2
P3
R3
Clearly labeled battery using 3-digit organization
Example of 3-digit organization
Example of reference letter organization

Philadelphia Scientific® iBOS®Plus 6 Series Installation Manual
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6. System Configuration and Settings
Click “Settings” and you will see these
headings, from which you can set the
following:
Click the down arrow to get to the 2nd
Settings screen
6.1 Language Setting
Set a Language. The language in white
becomes the system language and will
change the audio message and text on
screens.

Philadelphia Scientific® iBOS®Plus 6 Series Installation Manual
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Note: When you change language all
system settings also change to that
language.
6.2 Date and Time Setting
The system time is controlled by this
feature. This should be checked to
ensure the location time is correct. The
default is set at the factory for EST.
(-4 GMT)
The system is currently set to EST Time
Zone.

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Select your local time zone.
Then click ok.
This will take you back to the time/date.
Set Local Time/Date

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Adjust as needed, and then click “Save
and Reboot”.
During system reboot, the touch screen
will become temporarily grey and
inoperable. Please wait for system to
complete the time/date change.
Time/Date is now reset.

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6.3 Configuring Pools and Chargers
After the chargers are connected and labeled, they must be configured at the Control Box. The steps to
follow to correctly configure pools and chargers are outlined below. (Default password is: “919191”)
To configure the chargers, click
“Settings on the Home screen.
Enter Default Password “919191” then
click OK.
Click the “Pools and Chargers” key.