Parente Fireworks Srl FIREMASTER4KT Firemaster IV Base Station User Manual 5

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Document ID	1064568
Application ID	i2UHDemryLSWDvKVhsLVMA==
Document Description	Users Manual VII
Short Term Confidential	No
Permanent Confidential	No
Supercede	No
Document Type	User Manual
Display Format	Adobe Acrobat PDF - pdf
Filesize	32.75kB (409366 bits)
Date Submitted	2009-02-04 00:00:00
Date Available	2009-02-04 00:00:00
Creation Date	2008-12-28 16:26:22
Producing Software	Acrobat Distiller 7.0 (Windows)
Document Lastmod	2009-01-15 14:54:51
Document Title	5
Document Creator	Acrobat PDFMaker 7.0 for Word
Document Author:	Lucio G. Cizza

FIREMASTER IV "MillenniumThree" radio shooting system
User’s manual
5.0 BPK-48A EMERGENCY BATTERY PACK
5.1 CASE AND FRONT- PANEL DIAGRAM
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1. IP67 Ultra-High Impact Copolymer Polypropylene case. 34 x 29.5 x
15.2 cm
2. Double-step latches
3. Stainless steel reinforced padlock protector
4.
Waterproof 7-pole DIN connector for external emergency battery.
WARNING: the metallic contacts of this connector carry directly
the batteries voltage and NO FUSE PROTECTION IS PROVIDED!
AVOID ABSOLUTELY ANY ACCIDENTAL CONTACT OF
THESE PINS EACH OTHER OR WITH OTHER METALLIC
PARTS: THE CONTACTS WILL BE FUSED AND THE
BATTERIES COULD BE PERMANENTLY DAMAGED!!! USE
ONLY THE SPECIAL CONNECTION CABLE (IP65) SUPPLIED
WITH THIS UNIT. Exercise also the maximum care to maintain
these contacts always PERFECTLY CLEAN AND DRY.
5. Protection cap for the DIN connector.
6. Fold-down and rubberized handle
7. Automatic pressure equalization valve
8. Polycarbonate, silk-screen printed front-panel
9.
zz
BATTERY 1 – SYSTEM (red/green). This bi-colour indicator
LED blinks GREEN during the normal charging process and turns ON
RED (steady) if the relative battery doesn’t pass the initial test or the
charging process is terminated with a FAULT condition.
10. zz BATTERY 2 – FIRE (red/green). This bi-color indicator LED
blinks GREEN during the normal charging process and turns ON RED
(steady) if the relative battery doesn’t pass the initial test or the charging
process is terminated with a FAULT condition.
11. zz BATTERY 3 – FIRE (red/green). This bi-color indicator LED
blinks GREEN during the normal charging process and turns ON RED
(steady) if the relative battery doesn’t pass the initial test or the charging
process is terminated with a FAULT condition.
12. z TEST OK/FAULT LED (yellow). This indicator LED blinks during
the initial test of the internal batteries before the charging process takes
place. The TEST LED is turned OFF if the TEST is passed for all the
batteries and the charge starts normally. This LED is turned ON
(STEADY, with the “FAULT” meaning) if otherwise one or more
battery doesn’t pass the initial test.
13. z CHARGE LED (red). This indicator LED turns ON after all the
internal batteries have been successfully tested and the charging process
is running.
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14. OPTIONAL CONNECTOR for the EXTERNAL Battery Pack. 7-pole
DIN connector male. Normally this connector IS NOT MOUNTED on
the front-panel of the BPK-48A units: it is placed outside on the CASE
front (see case diagram, point 4).
15. Insulated bipolar receptacle for the mains supply cable. WARNING: the
Unit is NOT PROVIDED WITH A GROUND CONNECTION (this
condition is marked with the specific symbol). The user's protection is
obtained using components with a DOUBLE INSULATION.
16. z Line LED (blue). This LED indicator turns ON whenever the Unit is
connected to a suitable MAINS receptacle for battery charging. The
charging process takes place automatically when the MAINS cable is
plugged into a suitable line socket (110 – 240Va.c. 50 – 60Hz). No power
switch is provided: the batteries are disconnected automatically from the
external circuits during the charge process.
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5.2 GENERAL DESCRIPTION
The Emergency Battery Pack BPK-48A is an autonomous Unit containing the
following elements:
TWO Batteries for the fire lines: 12V 1,2Ah. Lead-acid type, sealed with
gel-immobilized electrolyte.
ONE Battery for the System supply: 12V 5,7Ah. Lead-acid type, sealed
with gel-immobilized electrolyte.
Universal Line power supply (110 - 240Va.c 50-60Hz for the re-charge
system.
Automatic charging circuit, supervisor and battery status manager,
controlled by a dedicated microprocessor.
Highly impact-resistant plastic polymer case.
Front-panel with LED indicators for the batteries charge status.
7-pole waterproof DIN connector to carry power to the external Units.
The Battery Pack can verify the charge status of all batteries (both System
and Lines), to provide an optimal recharge of the batteries and to signal
accurately any inconvenience detected during the charge or the test.
5.2.1 USE
The BPK-48A Emergency Battery Pack is intended to be used IN
EMERGENCY when the INTERNAL BATTERIES of both TX5000 or
RX48 Units should fail to pass the initial test or when the charge level is
considered too low to grant a reliable performance during the whole show.
The BPK-48A Emergency Battery Pack can be immediately connected to
the corresponding socket (placed OUTSIDE on the case near to the handle)
of any TX5000 or RX48 Unit. Since all connectors are placed
EXTERNALLY and the special cable supplied for the connection is
WATERPROOF (IP65), all the Units can be used with the COVERS
CLOSED AND LATCHED, thus maintaining a complete protection of the
whole system against water penetration.
BEFORE CONNECTING the BPK-48A Emergency Battery Pack to any
Unit (TX5000 or RX48), MAKE SURE THE POWER SWITCH OF THE
UNIT IS PLACED ON THE OFF/EXT position in order to AVOID
POSSIBLE CONFLICTS BETWEEN THE INTERNAL BATTERIES
AND THE POWER SUPPLIED BY THE BPK-48A.
WHEN THE BPK-48A IS CONNECTED TO AN EXTERNAL UNIT,
THE LINE CORD MUST REMAIN DIS-CONNECTED (i.e.: the
charge process IS NOT ALLOWED)
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5.3 OPERATION DESCRIPTION
5.3.1 TEST
The INTERNAL BATTERIES of the BPK-48A are tested by the circuits of
the RX48 Unit when the connection is made. The BPK-48A doesn’t have
any internal circuit to detect the charge status of its batteries: it will be
User’s care to maintain always WELL CHARGED the batteries of the BPK48A unit or to connecting it time to time (when not in use) to a RX48 Unit
to monitor the residual battery charge.
5.3.2 TEST (UNIT CONNECTED TO MAINS)
When the mains cord is connected to a line receptacle, the BPK-48A
internal circuits perform a minimum of test on the internal batteries before
the charging cycle is started:
The batteries must be present and have a minimum residual voltage
(below a preset voltage or when NO VOLTAGE is detected, the battery
is considered PERMANENTLY FAILED or ABSENT and the charging
cycle WILL BE NOT INITIATED).
The line voltage must be within the specified values (110 to 240Va.c.)
otherwise the test and charging cycle will be INHIBITED.
5.3.3 TEST CONDITIONS
The test conditions are summarized in the table below:
PARAMETER
TYPE
Nominal voltage
Charge capacity
CHARGE voltage
CHARGE limit current
FAILED Battery voltage
Battery “having to be charged” voltage
Battery “CHARGED” voltage
END-OF-CHARGE current
Max time with LIMIT CURRENT
Max charging time
OPEN-LOAD Percentage (TEST)
OPEN-LOAD Percentage (after charging)
SYISTEM Battery
LINE Battery
Sealed- Lead-acid
12V
5.7Ah
13.9V
700mA
≤8.0V
≤11.5V
≥12.3V
≤75mA
∞
12h
≤15%
≤10%
Sealed- Lead-acid
12V
1.2Ah
14.2V
300mA
≤8.0V
≤11.5V
≥12.3V
≤18mA
30'
12h
≤20%
≤12%
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5.3.4 CHARGE
The BPK-48A Battery Pack must be first connected to the mains with the line
cord: the blue LINE LED will turn immediately ON and the TEST
OK/FAULT yellow LED will start to blink. The BATTERY#1 (SYSTEM)
LED will turn ON (green): during 10 seconds the battery is tested (the
corresponding green LED is steady). If the battery is present and its voltage is
above the minimum required voltage, the charge will start (the corresponding
LED will start to BLINK). If otherwise the battery is NOT PRESENT or its
open-circuit voltage is BELOW the minimum allowed limit, the LED will turn
RED and this battery will be DISCONNECTED (the battery is not present or
is failed and requires service).
The process described above is repeated for the BATTERY#2 and
BATTERY#3 (FIRE batteries). When all batteries have been tested, all the
battery LED should BLINK GREEN, the TEST OK/FAULT yellow LED is
turned OFF and the red CHARGE led is turned ON. From this moment
begins the charge cycle of 12 hours.
The charge cycle (independently for each battery) can terminate in two possible
ways:
The charging current remains BELOW the preset limit (preset end-ofcharge minimum current) for at least 1 minute.
The charge is terminated ANYWAY after 12 hours (even if the end-ofcharge minimum current is not reached)
While the first case is the correct way to terminate the charge cycle, the second
case should be regarded as quite irregular. In any case if a battery doesn’t reach
the end-of-charge minimum current within the allotted period of 12 hours, not
necessarily this battery should be regarded as FAILED one. It is quite
common for this type of batteries, after a long use and several charging cycles,
TO HAVE THE CHARGE CAPACITY REDUCED: this battery can be still
used but it will be User’s care to replace this battery as soon as possible with a
NEW ONE. Remember as a sealed Lead-Acid battery has a reliable mean life
of TWO YEARS and it should be replaced ANYWAY after this period (even
if apparently still efficient).
Since the BPK 48-A Unit IS NOT PROVIDED with a LINE SWITCH,
the Unit itself, during the charging process, must be suitably placed in
order to allow the easy removal of the LINE CORD at any moment, in
case of emergency.
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5.3.5 ERROR CONDITIONS LISTING
The table below resumes all the possible error conditions and the way they
are indicated by the LED lamps on the front-panel of the Battery Pack. The
same information is printed on the front-panel itself.
LED "TEST OK - FAULT" (YELLOW)
CONDITION
BLINKING
STEADY
MEANING
Test in progress
Test OK
LED B#1 - B#2 - B#3 (Bi-color)
CONDITION
GEEN STEADY
GREEN BLINKING
RED STEADY
MEANING
Battery under test
Test OK - Battery under charge
Charge NOT in progress: the pre-charge test FAILED
LED "CHARGE” (RED)
CONDITION
OFF
STEADY
MEANING
Test in progress
Test OK – CHARGE IN PROGRESS
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5.4 BATTERIES
All batteries used by the FIREMASTER IV "Millennium Tree" SYSTEM,
are of SEALED lead-acid type with GEL solid electrolyte. These are very
reliable batteries requiring very little precautions and need PRACTICALLY
NO SERVICE.
Considering however as the good result of a pyrotechnic show of several
thousands dollars value, depends for a large extent by the good battery
behavior, it seems adequate to insist on the absolute necessity of
ACCURATE AND FREQUENT CONTROLS of the battery situation. In
particular:
1) Avoid exposing the battery to extreme temperatures (below
0°C or OVER 45°C) for long periods.
2) When the SYSTEM is NOT IN USE, provide to charge regularly
the batteries: the lead-acid batteries have a much longer life if
maintained ALWAYS FULLY CHARGED. It is suggested a
charge cycle of 12 hours every 30 days. The internal
microprocessor system will take care to maintain the optimum
charge level in any condition.
3) When the System is NORMALLY USED (periodic duty), it is
suggested to have a 12-hour charge before all shows.
4) If the batteries have been DEEPLY DISCHARGED it is
suggested to have a full charge for at least 24 hours (eventually
repeat TWICE the automatic charge cycle).
5) Make periodic controls of the battery status at least every 6
months by visual inspection after removing it from the container:
if any swelling, spot, salt or liquid spills are noticed, DISCARD
IMMEDIATELY THE SUSPECT DEVICE even if apparently it
does still give energy enough.
6) If measured OPEN CIRCUIT (without any load applied) all leadacid batteries, when a common voltmeter (tester) is used, always
give 12V even if quite completely discharged . It will be then
necessary to always measure the battery voltage while a suitable
load is applied. To do that, REMOVE the batteries from the Unit
case, measure the voltage across the terminal with a voltmeter
and connect momentarily a load sinking about 1A current. For
a 12V battery a common wire-wound resistor rated 10ohm 10W
can be used or optionally a 12V car bulb (e.g.: the one used for
the headlight). The DIFFERENCE between the voltage measured
OPEN CIRCUIT and UNDER LOAD shouldn't be MORE
THAN 10% - 15%. E.g.: if a battery measured OPEN CIRCUIT
gives a reading of 12,2V and, when LOADED with the resistor
or the lamp, the reading decreases to 11,5V, it can be still
regarded as a GOOD ONE. On the contrary, if the voltage
measured UNDER LOAD should fall below 11V (or less), it will
be then necessary to have a full charge for at least 12 hours and
then the test will be repeated. If, after the charge, the test above is
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User’s manual
passed, OK: the battery was just discharged and can be still used.
If otherwise the battery still exhibits an excessive voltage
reduction under load, then it MUST BE IMPERATIVELY
DISCARDED AND REPLACED WITH A NEW ONE.
NOTE: all batteries installed inside the RX48 Units, are
AUTOMATICALLY TESTED with the above method.
7) The MEAN LIFE of a lead-acid battery is ABOUT 2 YEARS or
500 charging cycles (whichever is less). It is thus suggested, in a
prudential way, to CHECK YEARLY with great care all batteries
and to replace all devices giving test results LESS THAN
PERFECT (even if apparently acceptable). The recovered
batteries, if still passing the load test, can be used as
EMERGENCY EXTERNAL BATTERIES.
8)
We recall here the RECYCLING RULES concerning
the battery disposal: it must absolutely avoided to dispose the
failed batteries with the common garbage, call instead a
specialized collecting center enabled for the recycling of this
polluting waste!
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5.5 INTERNAL BATTERIES REPLACEMENT
RX 48 – INTERNAL VIEW – BATTERY REPLACEMENT
TX5000 – INTERNAL VIEW – BATTERY REPLACEMENT
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BPK-48A – INTERNAL VIEW – BATTERY REPLACEMENT
When it is necessary to access the internal batteries for a check or
replacement, proceed as follows:
1) If not already done, SWITCH OFF the Unit (Remote or Base).
2) Unscrew the top panel.
3) Remove VERY CAREFULLY the top panel. Disconnect the antenna
coaxial cable and the external battery connection. During the above
operations avoid any internal circuit or component touching the metal
shields.
4) Unscrew the metal plates fastening the batteries
5) Disconnect the batteries from the circuits by removing the cable
connectors (FASTON).
6) Check or replace all batteries needing service.
7) Restore the connections to all batteries RESPECTING THE
CORRECT POLARITY (CHECK MORE THAN ONCE FOR
SAKE OF SAFETY!)
8) Restore the rubber spacers placed between the batteries and the metal
panel. Fasten the batteries with the metal plate and secure all screws.
9) Close the panel securing it to the case with the screws (don't forget the
nylon washers!)
10) When a battery replacement is needed, USE THE ORIGINAL
SONNENSCHEIN - DRYFIT BATTERIES ONLY.
The battery used on the FIREMASTER IV "Millennium Three" are the
following types:
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TRANSMITTER (TX5000): ONE 12V 5,7Ah battery series
dryfit A300 SERIAL 07 191432 00 (optionally it can be used
the same type series A200 SERIAL 07 191432 00)
RICEIVERS (RX48): - ONE SYSTEM BATTERY 12V
5,7Ah series dryfit A300 SERIAL 07 191432 00 (optionally it
can be used the same type series A200 SERIAL 07 191432
00) - TWO LINE (FIRE) BATTERIES 12V 1,1Ah seris
dryfit A300 SERIAL 07 191185 00 (optionally it can be used
the same type series A200 SERIAL 07 190185 00)
WARNING: using battery types DIFFERENT FROM the specified
ones, other than NOT GRANTING a normal working autonomy, could
also require a complete RE-TUNING of the recharge circuits: this
operation requires the manufacturer intervention.
The charging voltage of the Sonnenschein dryfit batteries (limited
current) is 13,9V/14,2V at 20°C: the internal charging circuits are set to
this value. Batteries of different manufacturers, could require different
charging values up to 14,9V.
The dryfit Sonnenschein batteries are SOLID GEL IMMOBILIZED
and can be used without restrictions IN ANY POSITION. Several other
SEALED BATTERY have a LIQUID IMMOBILIZED electrolyte: even
if equivalent from a functional point of view, they CANNOT
OPERATE FOR LONG PERIODS LAID DOWN, or a sudden LOSS
OF CHARGE CAPACITY will be faced. In any case the SYSTEM
BATTERY must be NEVER replaced with such a type, because it
PERMANENTLY OPERATES IN THIS POSITION.
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