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Eagle Eye BC-2500 User Manual
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Eagle Eye BC-2500 User Manual

Eagle Eye BC-2500 User Manual

Modular switch mode utility battery charger / power supply
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MODULAR SWITCH MODE UTILITY
BATTERY CHARGER / POWER SUPPLY
USER'S MANUAL
Important Safety,
Installation,
Operation, and
Maintenance
Instructions

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Summary of Contents for Eagle Eye BC-2500

  • Page 1 MODULAR SWITCH MODE UTILITY BATTERY CHARGER / POWER SUPPLY USER’S MANUAL Important Safety, Installation, Operation, and Maintenance Instructions...
  • Page 2 Visual Inspection ................................52 TROUBLESHOOTING AND SERVICING ......................52 13.1. Charger Troubleshooting Chart ............................53 13.2. UIM Replacement Information ............................56 13.3. Service Parts List ................................57 CHARGER WIRE DIAGRAMS ..........................59 SPECIFICATIONS ..............................63 BC-2500 2 of 64 User’s Manual...
  • Page 3 CONDITION. DO NOT USE CONNECTORS THAT ARE CRACKED, CORRODED OR DO NOT MAKE ADEQUATE ELECTRICAL CONTACT. USE OF A DAMAGED OR DEFECTIVE CONNECTOR MAY RESULT IN A RISK OF OVERHEATING OR ELECTRIC SHOCK. WARNING: HAZARD OF ELECTRIC SHOCK. BC-2500 3 of 64 User’s Manual...
  • Page 4 Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. BC-2500 4 of 64 User’s Manual...
  • Page 5 As is illustrated in Figure 1-1, a BC-2500 system includes a chassis. The chassis has an access panel near the top for access to the User Interface Module (UIM) that serves as the system controller and for access to the AC input and DC output terminals.
  • Page 6 Proper installation of the charger is important to achieve good charger performance and to prevent damage to the charger and batteries. When a charger is received, a check for possible in-transit damage should be made. If any damage is found, it should be reported as a claim to the carrier. BC-2500 6 of 64 User’s Manual...
  • Page 7 40 in-lb. If other sizes and/or types of fasteners are used, the quantity, location and tightening torque should be designed as recommended by the rack manufacturer to be at least as strong as the above recommendation. BC-2500 7 of 64 User’s Manual...
  • Page 8 11 1 4 " 1 3 8 " 2 3 32 " 16 " 18 5 16 " 14 7 16 " SHELF MOUNT BRACKET Figure 3-1: Dimensions for 8-Slot Chassis and Mounting Brackets BC-2500 8 of 64 User’s Manual...
  • Page 9 1 5 8 " 9 1 2 " 1 9 16 " UNITS 18" 12 11 16 " 18 5 16 " SHELF MOUNT BRACKET Figure 3-2: Dimensions for 4-Slot Chassis and Mounting Brackets BC-2500 9 of 64 User’s Manual...
  • Page 10 18 1 16 " 1 13 11 1 4 " 1 13 16 " 32 " 18 11 14 15 32 " 32 " SHELF MOUNT BRACKET Figure 3-3: Dimensions for 16-Slot Chassis and Mounting Brackets BC-2500 10 of 64 User’s Manual...
  • Page 11 90-264 volts, 45-205 hertz. Below 100 volts, the charger may reduce output power. The 16-slot charger (130V only) has an AC input rating of 208-240 volts, 50-200 hertz, single-phase with an AC operating range from 190-264 volts, 45-205 hertz. BC-2500 11 of 64 User’s Manual...
  • Page 12 240V or 208V Wye transformer secondary wired as single-phase to the charger AC input. Figure 4.1-1: 3-Phase 240V or 208V Delta Transformer Secondary Wired as 1-Phase to Charger AC Input Figure 4.1-2: 3-Phase 240V or 208V Wye Transformer Secondary Wired as 1-Phase to Charger AC Input BC-2500 12 of 64 User’s Manual...
  • Page 13 If the DC polarity is reversed, the main DC output circuit breaker will protect the charger from internal damage. Correct the reversed wires and reset the circuit breaker. Close the access door after tightening the DC cable connections. BC-2500 13 of 64 User’s Manual...
  • Page 14 One end of the temperature sensor cable has a three-pin plug that plugs into a connector labeled “BATTERY TEMP SENSOR” on the UIM (see Figure 7.1-1). The other end of the cable has the temperature sensor sealed in a ring terminal. BC-2500 14 of 64 User’s Manual...
  • Page 15 Can be connected to a battery temperature sensor to temperature compensate the charge profile. Enabled/disabled, compensation value, min compensation limit, and max compensation limit configurable via the web server. The reference temperature for compensation is 25ºC or 77ºF. BC-2500 15 of 64 User’s Manual...
  • Page 16 The UIM also drives three LEDs located on the front panel of the unit to indicate basic functionality. These LEDs duplicate the functionality of the "UIM Status LED", "Alarm LED", and "AC Present LED" as explained above and illustrated in Figure 7.2-1. BC-2500 16 of 64 User’s Manual...
  • Page 17 UIM and also includes individual LED indication when an alarm occurs. The Alarm Relay System can be remote or built into a charger. Figure 7.6-1 illustrates the Remote Alarm Relay System. Mounting and connection instructions are included with this option. BC-2500 17 of 64 User’s Manual...
  • Page 18 Figure 7.6-3. The Built-in Alarm Relay System is a standard feature of the 4-slot compact chassis. Figure 7.6-2: Built-in Alarm Relay System, Remote LEDs Figure 7.6-3: Built-in Alarm Relay System, Terminals BC-2500 18 of 64 User’s Manual...
  • Page 19 TOP. ARCING OR EXPLOSION OF THE BATTERY CAN RESULT! WARNING: DO NOT DISCONNECT THE CHARGER DC OUTPUT FROM THE DC WIRING WHILE A CHARGE CYCLE IS IN PROGRESS. THE RESULTING ARCING AND BURNING COULD CAUSE THE BATTERIES TO EXPLODE. BC-2500 19 of 64 User’s Manual...
  • Page 20 No alarms or faults are active. At least one alarm is active with a Alarms & priority of “Major” or “Minor”. Faults Solid Alarms configured with a priority of “Warning” do not activate the “Alarm” LED. BC-2500 20 of 64 User’s Manual...
  • Page 21 Note: Enable JavaScript within the Internet browser you plan to use per the browser instructions (JavaScript is typically enabled by default). The Internet browser must also support HTML5, which all popular modern browsers do (Internet Explorer is not recommended) . BC-2500 21 of 64 User’s Manual...
  • Page 22 Select “Use the following IP address:” • Enter an “IP address:” of “10.10.10.XXX”, where “XXX” is any 3-digit number other than “210” (for example, “10.10.10.220”) • Enter a “Subnet mask:” of “255.255.255.0” • Press the “OK” button BC-2500 22 of 64 User’s Manual...
  • Page 23 Only one user is allowed at a time. A refresh of the webpage after the other user has logged out will allow a new login. BC-2500 23 of 64 User’s Manual...
  • Page 24 Figure 10.3-2: Accessing the Internal Charger Web Server via a Standard Internet Browser Figure 10.3-3: All User Slots are Allocated BC-2500 24 of 64 User’s Manual...
  • Page 25 SNMP destinations IP addresses. The UIM serial number and firmware version traps are the information sent when this is active. Setting this value to zero (0) disables the heartbeat message. BC-2500 25 of 64 User’s Manual...
  • Page 26 Mode. In order to do so, first follow the instructions in Section 10.3 to directly connect a laptop or desktop computer to the charger. Then, navigate to the “Ethernet Port” section on the “Configuration >> Ethernet Settings” page and change the “Address Mode” setting value to “Automatic (DHCP)”, as shown in Figure 10.5-1. BC-2500 26 of 64 User’s Manual...
  • Page 27 PRESENCE” button until the charger completes booting up (UIM LED startup sequence has finished.). • The “Ethernet Port” settings have now been restored to the factory-defaults. • Follow the steps in Section 10.3 again. BC-2500 27 of 64 User’s Manual...
  • Page 28 DC voltage at end of DC cable or the remote battery sense cable. DC Output Current Total DC output current of the system. DC Output Power Total DC output power of the system. AC Input Voltage AC input voltage. BC-2500 28 of 64 User’s Manual...
  • Page 29 Below are the items displayed in the “iPMs” section of the “Dashboard” page for each active iPM in the system. • Slot ID • Model • Serial Number • Firmware • Current • Power BC-2500 29 of 64 User’s Manual...
  • Page 30 Manual Control Priority list from highest to lowest priority: 1) Output Control: Output OFF 2) Start Manual Battery Load Test 3) Start Manual Continuity Test 4) Start Manual Equalize Charge BC-2500 30 of 64 User’s Manual...
  • Page 31 Figure 11.1-2: Manual Control Section of the Dashboard Page Figure 11.1-3: Dashboard Showing Equalizing BC-2500 31 of 64 User’s Manual...
  • Page 32 °C or °F The selected temperature units are used throughout the web server. Start Delay minutes 0-1440 When AC input power is applied to the charger, the start of the charge cycle will be delayed by BC-2500 32 of 64 User’s Manual...
  • Page 33 "00". 12 cells: 1.00-3.00 Ni-Cd: Setting Limits = 1.00 - 3.00 18 cells: 1.00-2.22 19 cells: 1.00-2.10 20 cells: 1.00-2.00 48V (30.00-61.00Vdc) Lead-Acid: 20 cells: 1.50-3.00 21 cells: 1.43-2.90 22 cells: 1.37-2.77 BC-2500 33 of 64 User’s Manual...
  • Page 34 Maximum settable 130V value changes with 4.0A per iPM number of valid iPMs per chassis Automatic Equalize None Disabled or Enabled When "Enabled" is selected, automatic equalization charge cycles occur using the settings below. BC-2500 34 of 64 User’s Manual...
  • Page 35 Continuity Test Days 1-255 The interval in days for the automatic Interval continuity test to occur. For example, entering a value of "1" would trigger an automatic continuity test cycle every day. BC-2500 35 of 64 User’s Manual...
  • Page 36 If the battery voltage is above this value, after one (1) minute the charger will shutdown and not restart to protect the batteries. After the high voltage issue has been resolved, the charger can be restarted by switching off all AC and DC breakers on the unit and then switching them back on. BC-2500 36 of 64 User’s Manual...
  • Page 37 Fault None iPM Communication Lost None iPM Incorrect DC Voltage None UIM Fault None Battery Temp Sensor Fault None Remote DC Voltage Sensing Fault None Ground Fault Detection 1.50-4.00 Continuity Fault/Battery Load V/cell 0.80-4.00 BC-2500 37 of 64 User’s Manual...
  • Page 38 “Date and Time” control. This control can be used to manually change the system date and time. Optionally, the system date and time can be synchronized with a network (NTP) time server by setting the “Network (NTP) Time Server Address”, “SNTP Update Interval”, and “Time Zone” controls. BC-2500 38 of 64 User’s Manual...
  • Page 39 Figure 11.5-1: Configuration >> Date and Time Settings Page 11.6. Configuration >> Ethernet Settings >> Ethernet Port The “Ethernet Port” section on the “Configuration >> Ethernet Settings” page is shown in Figure 11.6-1. See Section 10 for details. BC-2500 39 of 64 User’s Manual...
  • Page 40 Figure 11.6-1: Ethernet Port Section of the Configuration >> Ethernet Settings Page BC-2500 40 of 64 User’s Manual...
  • Page 41 System Charge Alarm Date Ethernet User Upgrades Settings Settings Settings Settings Accounts Time Settings Administrator Power User User Guest Read (Does NOT Include Pressing Buttons) Write (Includes Pressing Buttons, Does NOT Include Deleting) BC-2500 41 of 64 User’s Manual...
  • Page 42 Figure 11.8-1: Configuration >> User Accounts Page Figure 11.8-2: Options Available When Editing a User Account BC-2500 42 of 64 User’s Manual...
  • Page 43 Firmware column. The UIM Firmware can be upgraded by (1) selecting a firmware file and uploading it into a bank using the appropriate “Upload Into Bank” button, (2) selecting the “Bank #” with the desired “Firmware”, and (3) pressing the “Upgrade and reboot” button. BC-2500 43 of 64 User’s Manual...
  • Page 44 The total number of available records is listed in this sub-section. The charger can store over 10,000 records. When the record storage is full, the oldest 300 records (approximately) will be permanently deleted to make room for new records. BC-2500 44 of 64 User’s Manual...
  • Page 45 New to the History web server page Event Records is the Clear Alarm Events button that allows an Administrator or Power User the ability to clear the event records if necessary. It is recommended to always download all event records before clearing them to prevent loss of this information. BC-2500 45 of 64 User’s Manual...
  • Page 46 User name for logon or logoff. • Performed for any Equalize charge done (if manually stopped record will still be added). • Minutes of the Battery Load Test. • Voltage value for Continuity Test and Continuity Fault. BC-2500 46 of 64 User’s Manual...
  • Page 47 Figure 11.10-1: Event Records Section of the History Page BC-2500 47 of 64 User’s Manual...
  • Page 48 The values will be added together. (Example: Heat sink Temperature High and Over Temperature Shutdown will give you a 256+32=288 ) Figure 11.10-3 iPM Fault Codes BC-2500 48 of 64 User’s Manual...
  • Page 49 The UM received communication from an iPM of a fault condition. See iPM iPM Fault fault codes in Figure 11.10-3 for information about recommended action. BC-2500 49 of 64 User’s Manual...
  • Page 50 If the fault happens again, then verify charger float voltage settings (including temperature compensation if enabled) and alarm settings. Verify the charger output voltage and current levels maintain the battery float voltage under system load. BC-2500 50 of 64 User’s Manual...
  • Page 51 If they do contact the charger, they must be removed. Dust, debris, or moisture will shorten the working life of the charger, if they are allowed to build up. BC-2500 51 of 64 User’s Manual...
  • Page 52 If the steps above do not solve the issue and you are qualified to do additional investigating of the issue, then see the section of BC-2500 Charger Troubleshooting chart (see section 13.1) to assist with the troubleshooting. The charger wiring diagram (see section 14) can also be used to help in determining the cause of the issues.
  • Page 53 DC output current, AC input voltage, iPM information, and manual control information can assist in troubleshooting. See the charger wire diagram in section 14 for additional assistance. BC-2500 CHARGER TROUBLESHOOTING Symptom Possible Cause Recommended Action 1) Are any iPM LEDs on? If iPM LEDs are on, then you have AC power to the charger chassis and the AC circuit breaker is good.
  • Page 54 UIM via the server. Server 3) If unable to access the web server, then see section 10.6 to restore the factory default Ethernet port settings and retry to access the UIM via the server. BC-2500 54 of 64 User’s Manual...
  • Page 55 Power 1) If only some of the iPM’s are in this mode, then the system is in seconds Saving Mode power saving mode and those iPMs are not needed to maintain the BC-2500 55 of 64 User’s Manual...
  • Page 56 Manual Control, Output Control and click on Turn Output On. Charger output should come on and iPM LEDs will come on. With DC battery not connected you can check for proper float voltage at the charger terminal block. BC-2500 56 of 64 User’s Manual...
  • Page 57 42724S Alarm Box + Modbus RS-232 Expansion Kit 42727S Alarm Box + Modbus RS-485 Expansion Kit 42729S Modbus RS-232 Expansion Kit 42726S Modbus RS-485 Expansion Kit 42728S User Interface Module (UIM) 41593-C23S 41593-C33S 41593-C43S BC-2500 57 of 64 User’s Manual...
  • Page 58 Remote Battery Voltage Cable, 10 Ft. 40977S Remote Battery Voltage Cable, 30 Ft. 40978S Terminal Block, Input and Output 43392S iPM, Blank, Cover Plate, 1 per 41838S Drip Shield 43041S Digital Display 42233S GFD ON/OFF Switch 42583S BC-2500 58 of 64 User’s Manual...
  • Page 59 14. CHARGER WIRE DIAGRAMS Figure 14-1: Wire Diagram for 4-Slot Utility Chassis BC-2500 59 of 64 User’s Manual...
  • Page 60 Figure 14-2: Wire Diagram for 8-Slot Utility Chassis BC-2500 60 of 64 User’s Manual...
  • Page 61 Figure 14-3: Wire Diagram for 16-Slot Utility Chassis BC-2500 61 of 64 User’s Manual...
  • Page 62 Figure 14-4: Wire Diagram for 4-Slot Compact Utility Chassis BC-2500 62 of 64 User’s Manual...
  • Page 63 15. SPECIFICATIONS See the BC-2500 datasheet for specifications. NOTES BC-2500 63 of 64 User’s Manual...
  • Page 64 42192 R BC-2500 64 of 64 User’s Manual...