IC-OUM-09001_Rev1.2_v4_B3.pdf

IC-OUM-09001 Rev 1.2 11/14/2017

Operator User Manual for the Battery Service Center

Date: 14 November 2017

Prepared by: Taylor Lynard

Operator User Manual for the Battery Service Center

CHANGE LOG

CHANGE / REVISION RECORD

Revision Page(s) Description of Change Made By Date Approved By

1.0 All Initial Release

1.1 All Update contract number Taylor Lynard 10/24/17

1.2 All Convert to new format Taylor Lynard

11/14/17 James

DePersis

Table of Contents

1. Introduction

1.1 General Information

1.1.1 Scope

1.1.2 Safety

1.1.3 Security

1.1.4 List of Abbreviations/Acronyms

1.2 Equipment Description

1.2.1 Equipment Characteristics, Capabilities, and Features

1.2.2 Equipment Data

1.3 Principles of Operation

2. Operating Instructions

2.1 Description and Use of Operator’s Controls and Indicators

2.2 Operation under Usual Conditions

2.2.1 Preparation for Operation

2.2.2 Operation

2.2.3 Termination

2.2.4 Removal

2.2.5 Preparation for Storage

2.2.6 Preparation for Shipment

2.3 Operation under Unusual Conditions

2.3.1 Unusual Environment

2.3.2 Emergency Procedures

3. Operator Maintenance Instructions

3.1 Troubleshooting

3.2 Maintenance Procedures

4. Special Tools/Installation Equipment

5. Appendix

Operator User Manual for the Battery Service Center

Table of Figures Figure 1. Inside view of BSC from perspective of roll up door Figure 2. Circuit Breaker Panel Figure 3. Charging Rack with switches off and no batteries Figure 4. EDI and FREDI Batteries and Charging Bays Figure 5. EDI Batteries Charging Figure 7. Master Disconnect Power Shut off Switch Locations

Operator User Manual for the Battery Service Center

1. Introduction

1.1 General Information

1.1.1 Scope

The operator’s manual for the Battery Service Center (BSC) focuses on the functionality of the BSC system within the FlexTrain system.

1.1.2 Safety

Use caution when handling or operating the BSC, which contains sensitive electronic components.

1.1.3 Security

Not Applicable

1.1.4 List of Abbreviations/Acronyms

AED Automated External Defibrillator

BSC Battery Service Center

COTS Commercial Off The Shelf

EDI Enhanced Dismount Instrumentation

FREDI First Responder Enhanced Dismount Instrumentation

HVAC Heating Ventilation Air Conditioning

IE

LED

MBITR

Inspired Energy Light Emitting Diode Multiband Inter/Intra Team Radio

1.2 Equipment Description

1.2.1 Equipment Characteristics, Capabilities, and Features

The BSC is a dual purpose semi-trailer used to charge the FlexTrain System Lithium Ion and MBITR Batteries that provide power for the Enhanced Dismount Instrumentation (EDI) and First Responder Enhanced Dismount Instrumentation (FREDI).

1.2.1.1 Functions of the Battery Service Center

The BSC has battery charging racks located on both left and right sides of the trailer interior. The BSC has the capability of simultaneously charging quantity 1,024 NL2024 family batteries by Inspired Energy

(IE)

Operator User Manual for the Battery Service Center and quantity 1,920 MBITR batteries. The BSC charging racks can be interchanged allowing the user to customize the ratio of NL2024 and MBITR batteries. The BSC has a fifth wheel coupling that allows it to be moved by your standard tractor truck allowing it to be placed at any training area and powered with generators to conduct charging operations. The BSC can be packed up and ready for movement to next location in one hour. When the Trailer is in the setup mode, access can be gained from side door. A lift gate is located on the rear of the trailer to ease in loading and off-loading battery pallets. The BSC is also used to transport all the EDI and FREDI batteries.

Figure 1. Inside view of BSC from perspective of roll up door

1.2.2 Equipment Data

Not Applicable

1.3 Principles of Operation

The BSC has 28 custom charging racks. Each rack is able to hold 8 each COTS battery-charging modules.

Every rack is also outfitted with a fire suppression system, an auxiliary fan unit and a plenum system to duct cold air from the trailer’s HVAC unit. The BSC is setup to operate through a power distribution system that is powered by two external 208V, 3-phase AC generators. The BSC is equipped with an emergency shutdown system. Each BSC is equipped with Fire Extinguishers and an Automated External Defibrillator (AED).

2. Operating Instructions

2.1 Description and Use of Operator’s Controls and Indicators The BSC may be accessed via an external electric lift gate and roll door or a side staircase leading to a personnel door. The personnel door staircase is secured in a compartment underneath the side access door during transport. After the BSC is deployed, the staircase and associated hand rails shall be properly secured to the attachment points on the exterior of the trailer prior to any personnel utilizing this entry point.

The rear electric lift gate is powered by a pair of automotive 12v batteries located underneath the trailer.

The lift gate control panel is located adjacent to the rear lift gate. After the lift gate has been lowered, the rear roll up door may be unlatched and opened to grant access to the rear cargo hold of the BSC Stay clear of the lift gate when it is in operation.

2.2 Operation under Usual Conditions

2.2.1 Preparation for Operation

1. The BSC must be connected to the power source by a certified electrician.

2. The rear lift ramp should be deployed and in the down position or retracted and in the down position on rear of BSC when not in use.

3. The roller door should be open ¼ of the way or fully open position.

4. Open and secure side door on right front of BSC and install the stairs, platform, and all safety handrails for the side door entrance.

5. Enter the trailer and turn on both Emergency Lights located in the front and rear of the trailer.

6. Check that all portable fire extinguishers are tagged and seals not broken.

7. Check fire T handle on each bank of chargers for missing seals and safety pins.

8. Check that both the front and rear Master Electrical Shutoff switches are Reset/On. (Turn the red knob clockwise until it pops out to the Reset/On position.)

9. Locate the four circuit breaker panels and insure that all main and branch circuit breakers are in the OFF position.

10. Check and ensure that both red emergency shutdown switches on each charging module are in the ON position on all modules to be used.

2.2.1.1 Installation of the Battery Service Center

The BSC should be delivered and placed on level, firm ground near the Instrumentation Warehouse unless the mission requirements dictate otherwise. All entrance stairways and handrails should be securely setup before extended operations inside the BSC.

2.2.1.2 Power-up and Initialize

1. Ensure both circuit breakers on each of the two ground load-center panels located near the generators are in the ON position.

2. Conduct a Preventive Maintenance and Service Check on all generators by checking oil, antifreeze, and fuel levels to ensure they are within limits.

3. Check that all ground and electrical connections are secure.

4. The main circuit breaker on each generator should be in the OFF position.

5. Conduct a visual inspection of the Emergency Shutoff switch on each generator is in the Reset/On position.

6. Follow all Generator operators start and stop procedures provided with the generator.

7. After starting the generator and waiting for two minutes for warmup, verify the correct voltage for each of the 3 phases indicates 208V.

8. Switch the main circuit breaker on each generator to the ON position.

9. Switch the main breaker, located inside the BSC, on each of the four circuit breaker panels to the ON position.

Figure 2. Circuit Breaker Panel

10. Turn on all remaining branch circuit breakers on each of the four circuit breaker panels inside the trailer.

11. Check each of the individual charging units (with or without batteries) and insure the red light in each switch is illuminated.

Figure 3. Charging Rack with switches off and no batteries

Main Circuit Breaker

12. Check that the green LED light on the fire suppression (Fire Boy system) unit in the bottom of each of the charging racks is on.

2.2.2 Operation

When external power generators are used to supply power to the BSC, the following procedures should be followed.

1. Insert batteries as necessary and monitor the charging process.

Inspired Energy Battery (EDI) MBITR Battery (FREDI)

IE Batteries in Charging Bay MBITR Battery in Charging Bay

Figure 4. EDI and FREDI Batteries and Charging Bays

Operator User Manual for the Battery Service Center

i. Charging Inspired Energy EDI Batteries

Insert batteries into the charging slot with the battery contact side up.

Gently press the battery in until the contacts are seated with the battery charging slot prongs. Do not force the battery into the slot. Damage and electrical hazards can occur.

When the battery is charging the green lights flash on and off. When the battery is fully charged the green indicator light stops flashing and remains

on. If the red indicator light turns on it means the battery is not taking a charge.

Figure 5. EDI Batteries Charging

ii. Charging MBITR FREDI Batteries

To charge the MBITR battery insert the battery into the MBITR battery charging unit with the battery charging contacts down.

Figure 6. MBITR Charger Indicators

Operator User Manual for the Battery Service Center

2. As batteries become fully charged, remove the charged batteries and insert batteries yet to be charged.

3. Monitor the temperature inside the BSC with a thermometer. If the temperature exceeds 90 deg. F due to an extreme outdoor temperature shutdown the appropriate amount of charging bays to control the temperature inside the BSC. If the temperature exceeds 90 deg. F inside the BSC during normal outside temperatures troubleshoot the BSC HVAC (see section 3.2)

2.2.3 Termination

1. Turn off the main and all branch circuit breakers in the four circuit breaker panels inside BSC.

2. Turn off both emergency lights located in the front and rear of the trailer.

3. Shutdown the cooling system by placing the Start/Run switch (On/Off) located on the system control panel to the OFF position.

4. Place the main circuit breaker on all generators in the OFF position.

5. Shutdown each generator by placing the Start/Run switch on each generator to the OFF/STOP position.

6. Remove the handrails, stairs, and platform for the side entrance and stow.

7. Close side door and secure.

8. Close rear roller door and secure.

9. Make sure lift ramp is deployed and in the down position, (or fully stowed) on rear of BSC.

2.2.4 Removal

The BSC is removed by a contracted trucking company.

2.2.5 Preparation for Storage

Secure the rear lift gate and ensure it is in the fully closed position. Ensure all latches are secure and locked on the rear roll up door. Properly remove and store the personnel entrance staircase and handrail into the underneath storage compartment. Secure the staircase and handrail with the appropriate locking mechanisms to ensure it does not become loose during transport.

2.2.6 Preparation for Shipment

1. Follow the shutdown procedures section 2.2.3 steps 1 through 5.

2. Disconnect the grounding cable from the grounding rod.

3. Disconnect Prime power cables from power source and secure cabling in storage

Operator User Manual for the Battery Service Center box located in the underbelly of the trailer.

4. Ensure all equipment located inside the trailer is secure to and will not move when the trailer is in transit.

5. If pallets are placed inside trailer ensure the pallet load is secure and will not damage the charging racks.

6. Remove the handrails, stairs, and platform for the side entrance and stow.

7. Close side door and secure.

8. Close rear roller door and secure.

9. Place the rear lift ramp to the Stowed position for travel.

2.3 Operation under Unusual Conditions

Caution should be used when operating the rear electric lift gate in wet or hazardous conditions.

Safe proximity should be kept away from the lift gate whenever it is in operation. When entering or exiting the BSC via the side personnel entrance, take caution that any debris or weather may cause slippery footing both inside and outside the BSC. During severe electrical or lightning storms, operations inside the BSC should be conducted only if necessary.

2.3.1 Unusual Environment

2.3.1.1 Lightning

The BSC and any connected electrical generators should be properly grounded during setup. Avoid working inside the BSC during severe lightning storms unless necessary. If lightning damage is suspected, immediately power down the BSC and any connected generators and thoroughly check for lightning damage.

2.3.1.2 Strong Winds

The BSC is used at ground level and should not be affected by strong wind conditions.

2.3.1.3 Cold

Not Applicable

Operator User Manual for the Battery Service Center

2.3.2 Emergency Procedures

In case of fire, smoke or burnt electrical smell activate the red master disconnect switches by pressing them in and exit the BSC immediately. Notify everyone near the BSC about the emergency instruct them to stay clear of the area around the BSC.

Figure 7. Master Disconnect Power Shut off Switch Locations

Master Disconnect Power Shut Off Switches

Operator User Manual for the Battery Service Center

3. Operator Maintenance Instructions

3.1 Troubleshooting

a. Observation

Electrical outlets are non-functioning. Lights do not work with electricity connected.

b. Solutions

Open circuit breaker panel and check for any breakers in the off or disconnected position. Ensure the power service selector switch is in the proper position, either Generator or Land Power.

Contact a licensed electrician if problems persist

a. Observation HVAC unit does not activate with power connected.

b. Solutions

Open circuit breaker panel and check for any breakers in the off or disconnected position.

Contact a licensed HVAC technician if problems persist.

a. Observation

Toggling the control panel for the rear lift gate does not produce any motion in the lift gate.

b. Solutions

The battery for the rear lift gate has likely run out of charge. Attach an appropriate 12v or car battery charger to the battery and let sit until fully charged. Ensure all electrical connections between the batteries and the lift gate are functioning properly. Check the lift gate fuse.

a. Observation

Charger has power and red LED indicator appears

b. Solutions

Try a different battery, if the problem persists mark the charger with a piece of tape and discontinue use of the affected slot or charging unit. Report to supervisor for repair process. If the other battery takes a charge discontinue use of battery, and fill out the proper maintenance form for the battery.

Operator User Manual for the Battery Service Center

a. Observation

Battery will not seat properly into charging slot.

b. Solutions

Gently twist battery from side to side while trying to insert; Try to insert the battery into a different slot, if battery does not insert to other slots discontinue use of battery fill out the proper maintenance form for the battery; Try to insert a different battery into the slot, if no batteries will properly seat mark the slot with a piece of tape and discontinue use and report to supervisor for repair process.

3.2 Maintenance Procedures

Not Applicable

4. Special Tools/Installation Equipment A T-25 Torx driver may be needed if charging bays need to be removed or re-installed in the charging racks.

An adjustable wrench should be available to secure and tighten the grounding cable connections points.

Fire Extinguishers, AED and First Aid kit should be readily available and secure at the front entry way on the trailer wall with easy access at all times.

A thermometer is needed to monitor the BSC interior temperature during operation.

5. Appendix Not Applicable

1.2.2 Equipment Data

1.3 Principles of Operation

2.3.2 Emergency Procedures