introducing the new SMART diagnostics board

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1 introducing the new SMART diagnostics board

2 2. OPERATI The diagnostic/charger is a fully self-contained. Fully automatic micro-controller based system. The use of a high power, 8 bit microcontroller enables us to provide the customer with one of the best charger/diagnostic systems on the market.all operations are automatic and the installation is no more complicated than a standard unit. When the installation is completed and the unit is powered, the system is automatically functional. There is no need to have the AC present at this time, only the battery needs to be connected. The unit goes directly in lockout mode and waits for AC to be restored. The design is also based on field proven techniques that are well known for it s high quality and long life reliability, such as the PULSE PL temperature compensated charger and the high quality sealed lead and sealed lead-calcium batteries. 2.1 STANDARD FEATURES GENERAL High power 8-bit microcontroller (MCU) Lockout mode Annual test sequence Standard 10 minutes time delay Selectable accelerated lamp test Variable time forced test CHARGER 120/347 volts 60 Hz input standard Pulse charger under MCU control Temperature compensated Charger indicator lamp AC pilot lamp TRANSFER Sealed relay Automatic and instantaneous Low voltage battery disconnect Fused output circuits Brownout detection Lockout DIAGNOSTIC Audible alarm and high efficiency red LED s Battery failure/1 minute test ( & ) Battery disconnect / 5 minutes test ( & ) Charger failure/30 minutes test () 10 minutes () Lamp failure/60 minutes test () 20 minutes () Service alarm (removed if required) AC on Charger on 2.2 SYSTEM OPERATI The microcontroller provides decisional logic and output drivers for the monitoring and control of the battery, the charger, the lamp circuit, the transfer circuit, and all the alarm visual and audible indicators. Power line (AC) present indicator is also provided. Any fault condition produces an audible warning that consists of an intermittent beep, one second on, one second off. When alarm is initiated, the audible warning is energized and the indicator associated with the fault is illuminated continuously. Alarms are acknowledged by pushing the switch less than one half second. This action turns off the audible alarm and changes the alarm indicator status from continuous to intermittent (flashing). Alarm indications can only be restored by correcting the fault or by a system re-initialization. System initialization is done by activating the internal, on board, RESET push button or by removing all power sources, battery and AC power. Manual forced tests are initiated by pushing and holding the switch more than one half a second. Releasing the switch initiates the test duration shown by the indicator. Pushing on switch while in test, abort the test. During a prolonged power outage, alarm status and lamp circuit data are memorized. When power is restored, all functions and alarm conditions resume operation in the same way they were before the power failure. Each time the MCU is initialized or when it leaves the stop mode, the audible alarm is sounded for about 200mS. This tells the user that the MCU has successfully been restored to normal operation CHARGER The charger is a hysteresis type CHARGER MITORING CHARGER FAILURE indicator is illuminated if the charging current does not fall within limits corresponding to the charger command state. *The 10 minute time delay duration can be modified by the end user to: minutes or deactivated completely.

3 OPEN BATTERY CIRCUIT BATTERY DISCNECT indicator is illuminated if the charger output voltage is over a certain limit which indicates an open circuit BATTERY FAILURE This is a multi-function indicator all related to battery condition. This indicator will be illuminated when a wrong battery (ex: 6V battery on a 12V system) or a completely depleted battery (battery voltage less than 65% of nominal ) is connected to the circuit, it will also be illuminated if the charger s output is shorted or a battery has failed a timed or forced test (reached LVD level before the end of the test). When a wrong battery is detected, the charger will self-protect and it won t try to recharge the battery. 3.1 AUTOMATIC UNIT (30 day test) Every 30 days, while in charging mode, the sequence generator will generate a command to energize the transfer relay on the emergency lighting circuit for a variable test period depending of the yearly sequence. All monthly test duration are 1 minute except for the 6th and 12th month which are 30 minutes () or 10 minutes () and 90 minutes () or 30 minutes () respectively. During the test period the charger is disabled and the battery and charger monitoring functions are suspended. An external link on the printed circuit board marked BATTERY EXERCISER - see diagram - selects the or the Canadian test time schedule. If the battery fails to complete the discharge test, the BATTERY FAILURE indicator will be illuminated and the test aborted. The 30 days automatic test sequence is reset every time the lamps have been turned on LAMP CIRCUIT (incandescent only) The test is done once a day for a board with one output lamp circuit and once every two days for a board with two output lamp circuits. The test is fully automatic and because of that, there are some precautions. To maintain accurate data, some conditions are to be fulfilled prior to acquiring values from an all-good lamp circuit. One of the major requirements is that the battery be at or near full power. The program will delay data capture for a minimum of 48 hours following any discharge or reset. The charger will also wait for the charger to be in hysteresis mode. Both conditions must be fulfilled CAPTURE SEQUENCE (lamp test start) The capture sequence is initiated only by a reset of the system. This is done by pushing the RESET push-button located on the board or by disconnecting the battery and the power (AC). The reset also initializes the main counter. After 12 periods of 30 days, lamp capture data is renewed. This renewal takes place to compensate for system variations when the unit ages. Renewal is not allowed if there is a lamp failure alarm TRANSFER MODULE The transfer module consists mainly of a power relay. The transfer relay is activated by the MCU when there is a power failure, a brown-out condition, the test switch has been activated for more than half a second or when a 30 day test is initiated. When a transfer is initiated (brown-out, manual test or auto-test), and the system fails to energize the lamp circuits, a system failure is detected and the Service Alarm indicator is illuminated. 3.2 TRANSFER TIME DELAY This function is standard and is activated through an external link on board. When activated, this option will keep the power on the emergency lights for a period of 15 minutes (A) or 10 minutes () after the AC power is restored. If the battery goes into LVD before the end of the delay, the power to the lamps is removed and all functions restored. The time delay is activated by a brown-out condition or a power failure. 3.3 ACCELERATED LAMP (Option) This option is provided to help the user during installation of the unit. In this mode of operation, the lamps are tested every minute for a single output circuit board and every two minutes for a double output circuit board. All other features remain the same. By enabling this option, the user can ascertain proper operation of the system very quickly. To notify the user that the system is not in normal operation, (accelerated lamp test is for that specific purpose only) the SERVICE ALARM LED indicator is put in flashing mode. To go into accelerated lamp test mode, the user moves the selection jumper - See diagram and pushes reset. To go back to normal operation, the user has to change the selection jumper - See diagram back to the original position and activate again the reset push-button. 3.4 LAMP DISCNECT (Battery Energy Saver) Used when emergency light is not needed at the moment of a power fail-ure, but lighting will be useful later. When in transfer, because of a power failure or a brown-out condition, lamps can be turned by pushing the push-button switch. If LVD has not been detected, lamps can be turned back by again pushing the push-button. Activating the LAMP DISCNECT feature will not change the normal operation of the unit.

4 4.1 BATTERY FAILURE / 1 MINUTE ( & ) Illuminated with Service Alarm indicator: Indicates a battery failure or a shorted charger output. Action required: Replace battery or check for shorted battery wires. Illuminated alone: Indicates a 1 minute test in progress. 4.2 BATTERY DISCNECTED / 5 MINUTE ( & ) Illuminated with Service Alarm indicator: Indicates that there is no battery connected to the charger. Action required: Connect the battery. Illuminated alone: Indicates a 5 minute test in progress. 4.8 /SILENCE BUTT To shut off the buzzer when there is an alarm, just push and release the button. To activate the transfer, push and hold the button for 1 second which will initiate a 1 minute test. Holding the button down for a longer time will initiate a longer test period as indicated. 4.9 RESET In normal operation, the reset push-button does not need to be activated, however if reset is requested to restart the unit, push on the button. Because the reset push-button is directly on the printed circuit board, the use of metallic tools to push on the switch, such as a screw driver, is not recommended. The tool can slip and create a short circuit. See diagram for location. 4.3 CHARGER FAILURE / 30 MINUTE () 10 MINUTES () Illuminated with Service Alarm indicator: Indicates that there is a problem with the charger circuit. Action required: Have the unit serviced. Illuminated alone: Indicates a 30 minute () test in progress or 10 min-utes () Illuminated with Lamp Failure indicator: Indicates a 90 minute () test in progress or 30 minutes () 4.4 LAMP FAILURE / 60 MINUTE () 20 MINUTES () Illuminated with Service Alarm indicator: Indicates that there is one or more lamps defective. Action required: Replace defective lamp(s). Illuminated alone: Indicates a 60 minute () test in progress or 20 min-utes () Illuminated with Charger Failure indicator: Indicates a 90 minute () test in progress or 30 minutes () 4.5 SERVICE ALARM Illuminated with BATTERY FAILURE, BATTERY DISC- NECT, CHARGER FAILURE AND LAMP FAILURE alarms. Detection of a malfunction of the transfer circuit will trigger the service alarm alone. Service alarm LED will flash if the unit is in ACCELERATED LAMP. Action required: depending on the fault, when illuminated with another alarm. Refer to the corresponding alarm description. When illuminated alone and the circuit is not in accelerated lamp test, check lamp circuit fuse, replace if necessary. If the fuse is good, have the unit serviced. 4.6 AC (green): Illuminated when line voltage is present. 4.7 CHARGER (Yellow): Illuminated when the charger is charging the battery. Off when the charger idles. 5.0 ELECTRICAL SPECIFICATIS Power requirements: 120 or 347 volts 60 hz Output: Fused output circuit 6 volts 50 watts One lamp circuit (56 watts max.) 6 volts 100 watts Two lamp circuits (56 watts each) 12 volts 100 watts One lamp circuit (112 watts max.) 12 volts 200 watts Two lamp circuits (112 watts each) Transfer Dust-tight relay automatically and instantaneously energizes lamp load upon failure of AC supply. Lamp Filament Detection Resolution is 10% of the full-load circuit or 5.6 watts in a 56 watts load (i.e.: one lamp out of ten). No more than 5% voltage drop is allowed in the remote lead wires. See chart for wire size vs. distance and power. LVD Low voltage battery disconnect automatically shuts down lamp load and circuitry when battery reaches 87% of nominal battery voltage preventing deep discharge and permanent damage to the battery. Lockout Labor saving feature that automatically connects battery only after AC circuit is activated. Brownout Close tolerance feature that initiates a transfer when input line voltage dips below 80-85% of nominal voltage. Charger The charger is current limited, temperature compensated and short-circuit proof. The equipment is capable of full recharge in compliance with Underwriters Laboratories std. 924 specifications, and CSA C22.2 no Controls One external test/silence test switch, one reset switch on PCB. Indicators Five high efficiency red LED's for alarms, one yellow LED for CHARGER on and one green LED for AC on. These LED's perform dual duty of indicating forced test in progress and its duration.

5 Wiring Diagram Name Plate

6 Single Output Circuit Board To select one option: 1. Remove all power sources to the board (AC and battery). 2. With long-nose plier, pull on the shunt until it is free from the pins. 3. Put the shunt back in place according to the option selection. 4. Reconnect the AC and battery. Option Selection Delay: delay after transfer (15 minutes, 10 minutes ) ACC. LP. : Lamp test cycle changed from 24 hrs to one min. 30 Days Self-Test: or test sequence selection. RESET ACC. DELAY Single Output Circuit Wiring Diagram BATTERY FAILURE / 1 MINUTE BATTERY DISCNECT / 5 MINUTES CHARGER FAILURE / 30 MINUTES () 10 MINUTES () LAMP FAILURE / 60 MINUTES () 20 MINUTES () SERVICE ALARM A.C. CHARGER / SILENCE Option Selection Location Double Output Circuit Board To select one option: 1. Remove all power sources to the board (AC and battery). 2. With long-nose plier, pull on the shunt until it is free from the pins. 3. Put the shunt back in place according to the option selection. 4. Reconnect the AC and battery. Option Selection Delay: delay after transfer (15 minutes, 10 minutes ) ACC. LP. : Lamp test cycle changed from 24 hrs to one min. 30 Days Self-Test: or test sequence selection. RESET ACC. DELAY

7 Smart Charger Microcontroller Board Suggested Specification The Ready-Lite Smart Charger Microcontroller unit shall supply the rated load for a minimum of a 1/2 hour to 87.5% of the rated battery/voltage. The unit shall be rated 120 or 347 V, 60 Hz and be CSA listed. The charger shall be fully computer tested and its charge voltage factory set to ± 1 % tolerance. Chargers with field adjusted potentiometers are not acceptable. A Pulse type charger shall be employed to promote long battery life and reduce the potential for grid corrosion. The charger shall provide a continuous high charge to recharge the battery. When the battery is at full capacity, the charger will shut off. Periodically the charger shall provide a Pulse of energy to keep the battery topped off. The Pulse charge shall be current limited and precisely regulated by a micro-processing circuit which samples the battery in relation to its temperature, state of charge and input voltage fluctuations. The charger shall be current limited, temperature compensated, short-circuit proof and reverse polarity protected. The unit shall be furnished with an electronic lockout circuit which will connect the battery when the AC circuit is activated, and an electronic brownout circuit which will activate the unit when utility power dips below 75% of nominal voltage. A low voltage battery protection circuit shall be provided and will disconnect the load and circuitry from the fused output circuit when the battery reaches 87.5% discharge. The unit shall self test for 1 minute every 30 days, 10 minutes on the 6th month and full discharge every 12 months. The unit shall be capable of full recharge in compliance with CSA specifications. The unit shall be furnished with sealed dust tight relay, a test switch and seven diagnostic LED indicator lights to continuously monitor the status of the unit: Battery Failed, Battery Disconnected, Charger Failure, Lamp Failure, Service alarm, AC, Charger High Rate. Printed in Canada. 03/02 RE/Smart-E

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