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Airpax Dimensions, Inc. 1









ISO 9001:2000 Certified Company
Airpax Dimensions, Inc.

LED Signal Battery Backup System
Installation, Operation and Maintenance Manual

ADI-48M17






























Form: 122004C
March 2007 2
Table of Contents

Section Description Page
1.0
Safety Instructions ..
3
1.1
Warning Symbols ..
3
2.2
Battery backup System Precautions
4



2.0 Glossary
5



3.0 General
Description
. 7
3.1 Introduction
. 7
3.2
BBS Physical Description
8



4.0
General Characteristics ..
12



5.0
BBS Components ..
13
5.2
Mounting the BBS .
14
5.3
Wiring the BBS
20
5.4 Dry-Relay
Contact
Wiring .
24



6.0 Adjustments
26
6.1
Remaining Battery Capacity Adjustment ..
26



7.0 Communications
27
7.1
Connecting the RS232 Port ..
27
7.2
Terminal Setup
27
7.3
Using the BBS Communication Interface .
30



8.0
Theory of Operation .
32
8.1 System
Description ..
32
8.2
Startup Procedure .
35



9.0 Maintenance
36
9.1 Preventive
Maintenance .
36
9.2
Trouble Analysis .
37



10.0
Parts List ..
40



11.0
Electrical Interconnection .
41



12.0 Appendix
.. 43



13.0
Limited Warranty ..
45








3
Safety Instructions


Section 1

1.1 Warning Symbols:


*** Save This Manual ***

Read this manual before installation or maintenance, it contains important
safety installation and operating instructions. Keep it in a safe place.




All wiring must follow the National Electric Code, Provincial or other codes
in effect at the time of installation, regardless of suggestions in this
manual. All wires should be copper conductors.



To reduce the risk of electrical shock and to ensure the safe operation of your
Dimensions Battery Backup System, the following symbols are used throughout the
manual.






ATTENTION: Important operating instructions. Follow them closely







DANGER: Risk of electrocution exists in this area. Use extreme caution.












4
2.2 Battery Backup System Precautions:

2.2.1 Battery Backup System Module:

Battery Backup System modules produce hazardous voltages; to avoid risk of harm
or fire the unit must be properly installed.
There are no user serviceable parts inside, do not remove the cover.
The battery backup module should not be mounted in a location that may be
exposed to rain or spray.
The battery backup module should not be installed in a zero clearance enclosure.
Damage to the battery backup module will occur if correct polarity is not observed
when installing the DC input cables.
Damage to the battery backup module will occur if an external AC power source is
applied to the battery backup modules AC hardwire output.
The battery backup module contains a circuit breaker and capacitor that may
produce a spark. Do not mount in a confined battery or gas compartment.
Be sure both the battery backup module and, if used, the external AC input circuit
breaker or fuse are turned "OFF" during installation.

2.2.2 Battery Precaution:

Working in the vicinity of lead-acid batteries is dangerous. There is a risk of acid
exposure.
Batteries generate explosive gases during operation. Do not open the batteries.
There is also a risk of high current discharge from shorting the battery that can
cause fire and explosion.
Limit access to authorized personnel only.
Read all instructions and specifications prior to performing work on the batteries.
Do not smoke, light matches or cause sparks near any storage batteries.

Remove all metal objects from your person like rings and watches.
Use tools with insulated handles.
Wear rubber gloves and boots.
Do not allow a metal tool to contact two battery posts.
Disconnect the charging source prior to connecting or disconnecting battery
terminals.
Carefully disconnect battery cables, protecting against short circuits.
Make sure installation is in accordance with engineering instructions prior to battery
start-up.
Follow all regulations when disposing of batteries. 5
Glossary





Section 2

AGM: (Absorbent Glass Mat) A lead-acid battery that incorporates a sponge glass mat
separator to immobilize the electrolyte. Because of the immobilized electrolyte, AGM
batteries will not leak or spill.
Ambient Temperature: The surrounding temperature usually refers to room
temperature.
Alternating Current: A pulsating electric current in which direction of flow is rapidly
changed, so the terminal becomes in rapid succession positive, then negative.
Abbreviated AC.
Ammeter: An instrument for measuring electrical current.
Ampere-Hour: It is used to express battery capacity and the number of ampere-hours
that can be delivered by a storage battery under specified conditions as to temperature,
rate of discharge and final voltage.

Capacity: The ability of a fully charged battery to deliver a specified quantity of
electricity (Amp-Hr, AH) at a given rate (Amp, A) over a finite period of time (Hr) is
defined by its capacity. The capacity of a battery depends upon a number of factors
such as: active material weight, density, adhesion to grid, number, design and
dimensions of plates, plate spacing, design of separators, specific gravity and quantity of
available electrolyte, grid alloys, final limiting voltage, discharge rate, temperature,
internal and external resistance, age and life history of the battery.
Charging: The procedure to convert the chemicals in a storage battery to their original
conditions by passing a higher voltage electrical current through the plates and
electrolyte. Charging reverses the discharge of a battery and attempts to restore it to a
useful state of charge.
Continuity: The indication that a circuit is complete between two points.
Corrosion: The chemical action of electrolyte on a metal that forms a new compound;
e.g., dilute sulfuric acid on steel forms the corrosion compound, rust. Battery terminals
can be subject to corrosion.
Current: The time rate of flow of electricity, normally expressed as amperes, like the
flow of a stream of water.
Cycling: The repeated charge/discharge cycle of a storage battery. Some batteries are
rated as to their ability to withstand repeated, deep discharge cycles.

Deep Cycle Batteries: Batteries that are designed to withstand repetitive deep cycling
and continue to provide their rated capacity even after hundreds of cycles. They are
used primarily in Marine/RV applications.
Deep Discharge: Removal of up to 80% of the rated capacity of a cell or battery.
Direct Current: A single-direction current. Abbreviated DC.
Discharge: Conversion of a battery's chemical energy into electrical energy.

Electricity: The flow of electrons through conductive materials and devices.

Fuse: A component of a circuit placed in series and designed to melt "open" at a
specific level of current. Fuses protect circuits from dead shorts and/or a rapid increase
in circuit current.
6
Gel Cell Battery: A lead-acid battery in which the electrolyte is immobilized by adding
a gelling agent. This battery has the advantage of being non-spillable. A gel cell
battery is totally sealed, valve regulated, with no possible access to the cells.
Glass Mat: Fabric made from glass fibers with a polymeric binder such as styrene or
acrylic, which is used to help retain positive active material.

Hydrometer: A device used to measure density or specific gravity of electrolyte
solutions.