PowerPak User's Guide
Contents
1. Warning Read User s Manual for Intrinsic Safety Precautions 34 RAE PowerPak User s Guide Operation Area and Conditions Hazardous Areas classified by Zones RAE PowerPak Is intended to be used In mines susceptible to firedamp or hazardous areas classified for zone 0 zone 1 or zone 2 within the temperature range of 40 C to 55 C where gases of explosion groups IIA IIB or IIC and T4 may be present Hazardous Areas classified by Divisions RAE PowerPak is intended to be used in hazardous areas classified for Class I Div 1 or 2 within the temperature range of 40 C to 55 C where gases of explosion groups A B C or D and temperature class T4 may be present Instruction For Safe Use Strictly follow the instructions for safe use Application of the RAE PowerPak requires full understanding and strict observation of the instructions The RAE PowerPak can be charged in hazardous areas by a charger complying with the intrinsically safe input entity parameters The RAEPowerPak can be charged outside hazardous areas by a charger complying with the Um parameter The internal encapsulated battery units can only be exchanged with the original RAE Systems battery Part Number F03 3002 000 in a safe area or with a hot zone permit The RAEPowerPak can be connected and disconnected inside the hazardous area 35 RAE PowerPak User s Guide Use In Hazardous Areas Equipment which is intended for use In exp2. 31 15 SPC CIIICA MOMS u s eU dum IR Pe SEP PIRE pu au a us 32 Appendix A Controlled Part Of RAE PowerPak FTB1000 IVAN eoosois chatons fesso a R 33 RAE PowerPak User s Guide 1 Safety Instructions WARNINGS Warning This instrument has not been tested In an explosive gas air atmosphere having an oxygen concentration greater than 21 Substitution of components may impair suitability for intrinsic safety Replace encapsulated internal batteries only in non hazardous locations Warning Charging of the FTB 1000 by means of mains charger can only be done in safe area and only with RAE Systems Charger P N F03 3012 000 Warning The internal encapsulated battery units can only be exchanged with the original RAE Systems battery RAE PowerPak User s Guide 1 1 RAE PowerPak Marking The RAE PowerPak is certified according to the IECEx scheme ATEX and CSA for US and Canada as protected by intrinsic safety The product is marked with the following information RAE PowerPak Type FTB1000 Serial No barcode FO32XXX XXX Cl I Dv 1 Group IECEx DNV C Eo0s75s amp m A B C D T4 09 0003X 1G Only as to intrinsic Ex ia VIIC T4 Ex ia VIC TA DNV Safety for use in 09 ATEX 55726X hazardous loc Intrinsically safe Securite Intrinseque Exia Li 0 1 uH Ci 0 1 uF Ui 10 V li 3 33 A Pi 8 8 W Um 11V Lo 3 4 uH Co 100 uF Uo 3 6 V Io 3 2A Po 3 1 W Lo Ro 20 6uH Q 40 C lt Tamb lt 55 C Wa
3. may need to be replaced Er05 to Er08 The battery 1s overcharging but does not send too much power to the MeshGuard since it has overvoltage protection Er09 to Er12 The battery 1s being charged in a location where the temperature is below 0 C 32 F and therefore is charging slowly The only problem this presents is that the battery cannot be fast charged 12 RAE PowerPak User s Guide The wrong type of battery has been placed in one of the four slots Replace it with the correct type The wrong type of charger is being used The correct RAE Systems charger part number F03 3014 000 identifies itself to the RAE PowerPak An internal fuse has been blown Fuses on the main circuit board cannot be replaced The main circuit board must be replaced Contact RAE Systems service The number of batteries 1s indicated by the number of segments showing in the left side of the display H O G D These segments correspond to the battery locations the enclosure is shown with its front cover removed Ll i au ml Note The percentage of battery charge is relative to the capacity of the entire number of batteries If there is one battery and the reading 1s 7596 that means 75 of the one battery s capacity If there are multiple batteries 75 means 75 of the total combined capacity Always refer to the number of segments indicating the total number of batteries 13
4. AE PowerPak to the MeshGuard 26 RAE PowerPak User s Guide 14 Troubleshooting amp Repair The RAE PowerPak is designed to be trouble free and require no maintenance However if you see the status LED glow orange and an error message in the display refer to the error message table on page 12 and take the suggested action 14 1 Encapsulated Internal Battery Replacement In the unlikely event that one of the encapsulated internal batteries needs replacement it 1s easy to replace them in the RAE PowerPak Follow these steps and only replace an encapsulated internal battery with a RAE Systems model with the same part number F03 3002 000 WARNING Only open the RAE PowerPak enclosure and change or charge encapsulated internal batteries in a non hazardous location or with a hot zone permit 27 RAE PowerPak User s Guide 1 Unscrew the four screws on the front of the enclosure 2 Disconnect the battery s power jumper from the main printed circuit board RAE PowerPak User s Guide 3 Remove the screws at both ends of the battery These attach the bracket that holds the battery in place 29 RAE PowerPak User s Guide 5 Insert a new battery and the bracket into the enclosure Before replacing the front cover check the display If it 1s not working then the ribbon cable between the display and the main circuit board might have become disconnected Make sure it 1s firmly connected t
5. Appendix A Controlled Part Of RAE PowerPak FTB1000 Manual The scope of this document ts to control the safety related parts of the manual which cannot be changed without permission from the competent body WARNINGS Warning This instrument has not been tested In an explosive gas air atmosphere having an oxygen concentration greater than 21 substitution of components may impair suitability for intrinsic safety Replace encapsulated internal batteries only In non hazardous locations Warning Charging of the FTB 1000 by means of mains charger can only be done in safe area and only with RAE Systems Charger P N F03 3012 000 Warning The internal encapsulated battery units can only be exchanged with the original RAE Systems battery 33 RAE PowerPak User s Guide RAE PowerPak Marking The RAE PowerPak is certified according to the IECEx scheme ATEX and CSA for US and Canada as protected by intrinsic safety The product is marked with the following information RAE PowerPak Type FTB1000 Serial No barcode FO32XXX XXX Cl I Dv 1 Group IECEx DNV C Eos7s amp m A B C D TA 09 0003 X 1G Only as to intrinsic Ex 1a I IIC T4 Ex ia VIC TA DNV safety for use in 09 ATEX 55726X hazardous loc Intrinsically safe Securite Intrinseque Exia Li 0 1 uH Ci 0 1 uF Ui 10V li 3 33 A Pi 8 8 W Um 11V Lo 3 4 uH Co 100 uF Uo 3 6 V Io 3 2A Po 3 1 W Lo Ro 20 6WH Q 40 C lt Tamb lt 55 C
6. RAE PowerPak User s Guide FTB1000 SYSTEMS Rev A July 2009 P N F03 4001 000 b T E by Honeywell S Y m Copyright 2009 RAE Systems Inc Ordering Replacement Parts If you need replacement parts a list is available online http www raesystems com RAE PowerPak User s Guide Contents Safety Ins Uc HOS uuu u Z u S PRI q aha eras 4 1 1 RAE PowerPak Marking 5 12 Operation Area and Conditions 6 1 3 Instruction For Safe Use 6 1 4 Use In Hazardous AT64a8 uu a L natn 7 PMEDS IT LP I EL Em 3 GeneralHilormatiou u e u OD A u aN teeth 4 Koy Ton aun m u Saa sq tuus 9 5 Physical DOeserpuiohbhu u uuu ona a apas ip deae ds eade 10 v LEDS LFD ecc oeste I n de kid e 11 T LED Stats Indica uyu uuu apa h kimia EEG 11 8 LCD Status Information amp Error Messages 12 9c s l LIL O ie deste C n maio ee 14 10 Operation Instructions 17 11 CODE CHOR acustico elites ect ete i batatus kikaqps2s 18 12 Changing The RAE PowerPak 21 13 Charging The RAE PowerPAak 24 14 Troubleshooting amp Repalt 5 yk ay ka aaa 27 14 1 Encapsulated Internal Battery Replacement 27 14 2 Batteries And Proper Battery Disposal
7. RAE PowerPak User s Guide 9 Installation The RAE PowerPak is designed to be located close to a detector such as a MeshGuard MeshGuard LEL or MeshGuard Router To accommodate this and to ensure security both are mounted on a steel plate which can be attached to a wall or other flat vertical surface Before attaching the steel plate to a surface you should attach the metal enclosure for the MeshGuard to the plate L 2 3 Place the MeshGuard in the steel enclosure Turn the plate and MeshGuard over Line up the hole on the back of the MeshGuard with the hole on the plate Insert an M4x10 screw through a flat washer and locking washer and tighten the MeshGuard s steel enclosure to the plate Front view Rear view egi we Align the holes Insert screw through flat and locking washers and secure 14 RAE PowerPak User s Guide Secure the plate to a wall or other solid flat surface by using M8 size screws with flat washers and locking washers following this diagram At a minimum use four screws at the corners The MeshGuard has been removed from the drawing for simplicity 430 mm 16 93 380 mm 15 35 70 mm 2 75 470 mm 2 75 G2 Z unu Q4 t L ww ore 340 mm 13 39 70 mm 2 75 390 mm 15 35 IMPORTANT Allow sufficient clearance around the mounting plate to accommodate replacing sensor and lifting and removing BatteryPak 15 RAE PowerPak User s Guide Next
8. ak screws into the MeshGuard s battery compartment Bottom views of the MeshGuard in its steel enclosure are shown in the procedure below 1 Remove battery cover with the 3 pin end of the sensor and battery removal tool by turning counterclockwise Power end of cable y Z 2 Lift off the cover 3 Insert the power end of the cable connected to the Power Pack 18 RAE PowerPak User s Guide Cord to RAE Power Pack 4 Use the open hex end of the wrench and with both pins mated with the two holes on the power end tighten by turning clockwise until it is snug Do not overtighten On the bottom of the RAE PowerPak are two dust caps that are screwed onto the connectors Unscrew the one on the left by turning it counterclockwise When it is removed you see the four pins of the connector RAE PowerPak User s Guide Screw the end of the connecting cable to the port on the bottom of the RAE PowerPak Do not use tools or overtighten FTB1000 20 RAE PowerPak User s Guide 12 Changing The RAE PowerPak 1 Unscrew the battery connector from the RAE PowerPak MeshGuard LEL 2 Loosen the safety screw holding the battery latch 21 RAE PowerPak User s Guide 3 Raise the latch na ILI un 4 Lift up the battery and slide it off the steel plate 22 RAE PowerPak User s Guide 5 Mount a fully charged RAE PowerPak on the mounting brack
9. ce or monitoring e Large easy to read continuous display of power percentage and charging error messages e Bright 3 color status LED e Simple operation without switches or controls e P 65 rated for outdoor use In harsh environments e Unit can be replaced in hazardous location RAE PowerPak User s Guide 5 Physical Description Front View T F F M d Bottom View Carrying handle Stainless steel enclosure 3 Status LED 6 Power output port to MeshGuard 8 Power input from charger Z o 9 Powerinputdusteap 0 0 o RAE PowerPak User s Guide 6 LCD amp LED The RAE PowerPak has a single LED and an LCD that indicates charge and in the case of errors any messages C 3 colorLED c FULL 7 LED Status Indicator The LED glows red orange or green depending on different status alerts it is conveying Green Battery or LCD says FULL batteries fully charged Battery or LCD says CHRG charging batteries charging Indicates an LCD shows error code error Check the beginning with the letters Er LCD for more followed by two digits information indicating the type of error 11 RAE PowerPak User s Guide 8 LCD Status Information amp Error Messages Error codes may appear in the LCD indicating battery or fuse conditions as well as temperatures outside the normal operating range Wrong charger Explanation amp Solution
10. et na 7 Tighten the safety screw 23 RAE PowerPak User s Guide 8 Connect the Meshguard LEL to the battery ENN x LEL Rar 9 Turn on the MeshGuard LEL 13 Charging The RAE PowerPak Before using the RAE PowerPak and whenever the RAE PowerPak shows a low power reading 10 or less you should charge it in a safe location 1 Ifthe RAE PowerPak is currently in service and is attached to a MeshGuard follow the instructions for removing it on page 2i 2 Remove the cap over the charging port on the bottom of the RAE PowerPak by unscrewing it RAE PowerPak User s Guide 3 Ina safe location connect the charging cable between the RAE PowerPak and the Charger and connect the AC mains cord from the Charger to an AC power plug cC FTB1000 4 The LED above the display should glow red and the display should say CHRG If not check your connections and the AC outlet L HAG 5 When the RAE PowerPak is fully charged the LED glows green and the display says Full 6 Disconnect the AC mains cord from the AC power outlet 25 RAE PowerPak User s Guide 7 Disconnect the Charger from the RAE PowerPak 8 Screw the cap back on over the charging port on the bottom of the RAE PowerPak 9 Place the RAE PowerPak on the steel mounting plate detailed instructions are shown on page 14 10 Follow the insructions on page 17 to reconnect the R
11. heres and which has been assessed and certified according to international regulations may be used only under specified conditions The components may not be modified in any way The appropriate regulations for service and repair must be properly observed during such activities FCC Part 15 statement and CE This device complies with Part15 class B of the FCC rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation RAE PowerPak User s Guide 2 Standard Kit RAE PowerPak FTB1000 as specified with two or four encapsulated internal batteries Cable for connecting MeshGuard to RAE PowerPak D01 3003 000 3 General Information The RAE PowerPak FTB 1000 is an intrinsically safe rechargeable battery power source for use with a MeshGuard EC or MeshGuard LEL monitor or MeshGuard Router or any other equipment with matching entity parameters FTB1000 QRA MeshGuard LEL and RAE PowerPak RAE PowerPak User s Guide 4 Key Features e Up to 4 months continuous operation before recharging when it contains four encapsulated internal batteries and is used with a MeshGuard 4 months MeshGuard LEL 25 days or MeshGuard Router 1 5 months e Rugged stainless steel enclosure e Very low cost installation no hardwiring involved e Very little maintenan
12. losive atmospheres and which has been assessed and certified according to international regulations may be used only under specified conditions The components may not be modified in any way The appropriate regulations for service and repair must be properly observed during such activities 36 E u L M i eywell cou Y y H RAE Systems by Honeywell World Headquarters 3775 N First St San Jose CA 95134 1708 USA Phone 408 952 8200 Toll Free 888 723 4800 Fax 408 952 8480 E mail sales support raesales raesystems com E mail technical support tech raesystems com Web Site www raesystems com RAE Systems Europe Kristinehej 23A DK 2770 Kastrup Denmark Tel 45 8652 5155 Fax 45 8652 5177 RAE Systems Hong Kong Ltd Units 1516 18 15 F Delta House 3 On Yiu Street Shatin N T Hong Kong Web www raesystems cn Email asiasales raesystems com Phone 852 2669 0828 RAE Systems Middle East LOB 7 Ground Floor Office 19 Jebel Ali Free Zone Dubai United Arab Emirates Email mesales raesystems com Phone 971 4 887 5562 Rev A July 2009 P N F03 4001 000
13. mount the RAE PowerPak onto the steel plate Note Make sure the RAE PowerPak has been fully charged before installation R m j i Align the RAE Slide the RAE PowerPak PowerPak with the rails down until it stops on the metal plate Use the latch to lock the RAE PowerPak in place Flip the latch down to Turn the screw until it is the horizontal finger tight do not position overtighten or use tools 16 RAE PowerPak User s Guide 100peration Instructions The FTB 1000 Power Pack is only to be used with RAE Systems products whose entity parameters match the entity parameters of the RAE PowerPak Fig 1 Connections FTE IHE QRar ID Fig 2 RAE PowerPak connected to the MeshGuard The RAE PowerPak can be connected and disconnected inside the hazardous area 17 RAE PowerPak User s Guide 11 Connection Note The following steps must be performed outside the hazardous area or with a hot zone permit Now connect the cable between the RAE PowerPak and the MeshGuard With the MeshGuard or MeshGuard LEL securely in its housing you can remove the cover over the battery compartment so that you can replace the internal battery in the MeshGuard Use the sensor and battery removal tool as shown Sensor and battery mesnGuard LEL removal tool BE al P N 019 2044 000 le g a W L L TI ae _ oo The connector from the RAE PowerP
14. o the printed circuit board and to the display module 30 RAE PowerPak User s Guide The display should indicate the correct number of batteries If not check that the connector between the battery and the circuit board is firmly connected 7 Once everything checks out replace the front cover and tighten the screws 14 2 Batteries And Proper Battery Disposal This product may contain one or more sealed lead acid nickel cadmium NiCd nickel metal hydride NiMH lithium L1 or lithium ion batteries Specific battery information is given in this user guide Batteries must be recycled or disposed of properly This symbol crossed out wheeled bin indicates separate collection of waste electrical and electronic equipment in the EU countries Please do not throw the equipment into the domestic refuse Please use the return and collection systems available in your country for the disposal of this product 31 RAE PowerPak User s Guide 15 Specifications Display Dimensions Weight Package Output Voltage Maximum Output Current Capacity Mounting Options Customized LCD and red orange green LED 36 2 cm x 26 cm x 14 6 cm 14 25 H x 10 25 W x 5 75 D 15 kg 33 Ibs with four internal batteries IP 65 3 3V 0 1 V 0 33A Two internal battery units 26Ah Four internal battery units 52Ah Stainless steel wall mount plate Stainless steel or zinced steel version 32 RAE PowerPak User s Guide
15. rning Read User s Manual for Intrinsic Safety Precautions RAE PowerPak User s Guide 1 2 Operation Area and Conditions Hazardous Areas classified by Zones RAE PowerPak Is intended to be used In mines susceptible to firedamp or hazardous areas classified for zone 0 zone or zone 2 within the temperature range of 40 C to 55 C where gases of explosion groups IIA IIB or IIC and T4 may be present Hazardous Areas classified by Divisions RAE PowerPak is intended to be used in hazardous areas classified for Class I Div 1 or 2 within the temperature range of 40 C to 55 C where gases of explosion groups A B C or D and temperature class T4 may be present 13 Instruction For Safe Use Strictly follow the instructions for safe use Application of the RAE PowerPak requires full understanding and strict observation of the instructions The RAE PowerPak can be charged in hazardous areas by a charger complying with the intrinsically safe input entity parameters The RAEPowerPak can be charged outside hazardous areas by a charger complying with the Um parameter The internal encapsulated battery units can only be exchanged with the original RAE Systems battery Part Number F03 3002 000 in a safe area or with a hot zone permit The RAEPowerPak can be connected and disconnected inside the hazardous area RAE PowerPak User s Guide 1 4 Useln Hazardous Areas Equipment which is intended for use in explosive atmosp
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