Operation of Legacy Battery Systems

Operation of Legacy Battery Systems
………
Operation and Maintenance of Legacy
Maxa Beam Searchlight Battery Systems
© 2016 Peak Beam Systems, Inc.
Handheld Maxa Beam Searchlights are powered by rechargeable battery packs that
attach to the underside of the searchlight.
The standard Operation Manual covers the use of Peak Beam’s current MBP-1308
Lithium Iron Phosphate (LiFePO4) batteries. The Operation Manual is available for
download at http://www.peakbeam.com/downloads/.
This document covers operation and maintenance of older battery chemistries
including MBP-1207 NiCad Battery Systems, MBP-1307 Lithium Ion Battery
Systems and MBP-1310 Lithium Iron Phosphate Battery Systems.
If you have a technical question not covered in this document, please contact
Peak Beam’s Technical Support Department and we will be happy to assist you:
1-610-353-8505 / techsupport@peakbeam.com.
Table of Contents
General Safety Warnings ............................................................................................ 2
MBP-1207 NiCad Battery Systems ............................................................................ 3
MBP-1307 Lithium-Ion Battery Systems ................................................................... 6
MBP-1310 Lithium Iron Phosphate Battery Systems ................................................. 8
Troubleshooting ........................................................................................................ 10
Warranty and Repairs ............................................................................................... 12
1
General Safety Warnings
ANSI Risk Group 3. Warning.
Visible and infrared radiation emitted from this searchlight.
Permanent eye damage can result. Avoid direct exposure to the beam.
• Do not look directly into the searchlight beam. Exposure of the eye to either
the direct searchlight beam or a beam reflected from a flat mirror-like surface
can cause permanent eye injury to the unprotected eye. Follow the same
precaution even when an Infrared Filter is installed on the searchlight.
o Nominal Ocular Hazard Distance (NOHD), Visible Light: 10 meters
o NOHD, Infrared Light: 30 meters for exposures greater than 10 seconds
• Do not operate searchlight if the front lens is damaged or removed.
Ultraviolet injury to skin and cornea can occur if the searchlight is operated with
a damaged front lens or if the lens is removed.
• Do not allow the concentrated beam of light to be focused on flammable
materials at close distances for prolonged periods of time.
• Do not operate light in an explosive environment.
• Do not touch lamp connections during operation as high voltage is present.
• Do not touch the quartz envelope of the lamp. If the lamp is accidentally
touched, clean with alcohol or the solution supplied in the replacement lamp kit.
• Always wear protective eyewear, long sleeves, and gloves if removing the
front lens cover. The lamp is under positive pressure and should be handled
with care.
• Always disconnect searchlight from power cord when not in use, when
placed in storage or when being transported to prevent accidental activation.
• Maxa Beam Batteries are for use with Maxa Beam Searchlights only. They
should never be used with any other device.
2
MBP-1207 Nickel Cadmium (NiCad) Batteries
The MBP-1207 NiCad Battery is rated at 1000 cycles and can be conditioned for
optimum performance on the MBP-5200 or MBP-5600 Series charger. As with all
Nickel-based batteries, this battery should not be stored in a discharged condition
and may be permanently damaged if excessively discharged.
Maxa Beam searchlights have protective circuitry incorporated in their design to
prevent excessive discharging of batteries. This protective circuitry can be
overridden if the situation warrants risking damage to the batteries by pressing and
holding down the red power button. This emergency override procedure may yield
several minutes of remaining battery power.
Run Time
Charge Time
Compatible
Chargers
Life Cycles
Dimensions
Weight
MBP-1207 7Ah NiCad Battery
55 minutes (high)
90 minutes (default)
135 minutes (low)
18 hours
2.5 hours
MBP-3100 Series Trickle
MBP-4000 Series Chargers
Chargers
MBP-5200 Series Smart Charters
MBP-5600 Series Smart Chargers
1,000
5 x 7.25 x 3.5 inches
5.5 lbs.
Battery Safety Warnings:
• • • • • Do not expose to fire or open flame.
Do not puncture, deform, incinerate or heat above 85°C (185°F).
Do not open or disassemble. Batteries are sealed in a waterproof case with no
user-serviceable components. Do not attempt to use a battery that has a
damaged case; please contact the factory about our re-casing service.
Battery must be recycled or disposed of properly. Do no dispose in fire or
landfill.
A Safety Data Sheet (SDS) for this battery is available upon request.
Battery Transport:
Sealed Nickel Cadmium batteries are considered to be "dry cell" batteries and are not
subjected to dangerous goods regulation for the purpose of transportation by the U.S.
Department of Transportation (DOT), the International Civil Aviation
Administration (ICAO), the International Air Transport Association (IATA) or the
International Maritime Dangerous Good regulations (IMDG).
International air transport is not restricted provided that, as stated in IATA special
provision A123, batteries and battery powered devices/equipment being transported
by air are protected from short-circuiting.
3
Battery Charging:
To maintain peak battery run time, always discharge the NiCad Battery fully before
recharging with a MBP-3110 Trickle Charger or conducting a fast charge on a MBP5200 or MBP-5600 Charger. Battery may be recharged at any state of charge if
conducting a conditioning charge on a MBP-5200 or MBP-5600 Series Charger.
Charging with MBP-3110 Trickle Chargers:
The MBP-3110 Plug-In Trickle Charger is designed to charge the MBP-1207 NiCad
Battery only. Do not use this charger to charge a Lithium-based Maxa Beam battery
or any other device. This charger may be used with either a 110V or 220V AC
power input supply.
1. Set input supply voltage switch to the appropriate voltage (110V or 220V).
2. Plug wall adapter into an outlet and connect its output connector to the NiCad
battery.
1. The battery will recharge in approximately 18 hours. Do not leave battery
connected to Trickle Charger for more than 48 hours as this may cause
permanent battery damage.
Charging with MBP-4000 Series Chargers:
MBP-4000 Series Smart Chargers such as the MBP-4200 AC Charger/Power Supply
were discontinued in 2001. Please consult the Operation Manual that shipped with
your charger for operation and troubleshooting information. Please contact Peak
Beam Systems, Inc. if you need any additional support.
Charging with MBP-5200 and MBP-5600 Series Chargers:
MBP-5200 and MBP-5600 Series Multi-Voltage Chargers are designed to charge
MBP-1207 NiCad Batteries only. For mobile and vertically mounted applications,
always use the safety strap to secure the battery or battery and searchlight to the
charger. These chargers can accept input voltages of 11-36VDC or 100-240VAC
50/60Hz depending on which Maxa Beam adapters are used with them.
NiCad Batteries can be charged with either a slow 18 hour trickle charge or a fast 2.5
hour charge. An optional conditioning cycle discharges the battery fully before
charging it. The NiCad Battery may be left connected to the MBP-5200 or MBP5600 charger for prolonged periods of time without damaging battery and the
charge level will be maintained.
The MBP-5600 Charger also acts as a power supply and can directly power the light
from an 11-36VDC or 100-240VAC 50/60Hz source. The MBP-5600 will
automatically stop charging the battery if an attached searchlight is turned on. When
light is turned off charging will resume.
4
CAUTION: Do not attempt to charge two batteries at the same time with one
charger. Make sure that you do not have one battery resting on top of the charger
while a second battery is connected to the pigtail as this may damage the charger.
1. Plug the charger into external
power, ensuring that proper
adapter is being used to match
local voltage. The RED indicator
light will turn on.
2. For a slow 18 hour trickle charge,
lower the battery, with or without
searchlight, onto the charger. Do
not slide battery in horizontally.
Indicator
light
FLASHES
AMBER during trickle charge
then turns solid GREEN when charged.
3. For a fast 2.5 hour charge, lower battery onto charger tray and connect the
charger’s pigtail to the battery. Indicator light will turn solid AMBER during
fast charge then turn solid GREEN when battery is charged.
4. For a conditioning charge cycle, lower battery onto charger tray, connect pigtail
and press the green recessed button on the charger. Indicator light will FLASH
GREEN as battery is discharged, turn solid AMBER during charging, then turn
solid GREEN when charged. The charger will become very warm during this
cycle, which may take up to 24 hours.
5. If the indicator light turns RED when a battery is connected to or on top of the
charger, the searchlight power cord or the internal battery circuit is open. A
FLASHING RED indicator light signifies a fault. Consult the Troubleshooting
section of this guide.
6. To directly power the light (MBP-5600 Chargers Only), connect the female end
of the light’s power cord to the male connector on the light. Connect male end
of the power cord to the female receptacle on the body of the MBP-5600 unit.
Note: If using an MBP-5200 or MBP-5600 series charger in an environment where
salt water can splash onto the charger, wipe charger thoroughly to remove any
pooled water and wipe the battery’s charging contacts dry before attempting to
charge the battery.
5
MBP-1307 Lithium-Ion Batteries
The MBP-1307 Li-Ion Battery is rated at 500 cycles and features a five-level LED
fuel gauge. The Li-Ion Battery is compatible with all Maxa Beam Searchlights.
Run Time
Charge Time
Life Cycles
Dimensions
Weight
Compatible
Charging Adapters
MBP-1307 6.6Ah Li-Ion Battery
60 minutes (high) 110 minutes (default)
3 hours
500
5 x 7.25 x 2.75 inches
2.5 lbs.
MBP-5003:
MBP-5230:
MBP-5010:
MBA-7406:
MBP-5630:
MBP-4000S:
MBP-7110:
135 minutes (low)
3A 100-240VAC Adapter
10-29VDC Vehicle Adapter
10A 100-240VAC Adapter
NATO Slave Adapter
10-29VDC Vehicle Adapter
100-240VAC Power Supply
12VDC Vehicle Adapter
Battery Safety Warnings:
• • • • • Do not expose to fire or open flame.
Do not puncture, deform, incinerate or heat above 85°C (185°F).
Do not open or disassemble. Batteries are sealed in a waterproof case with no
user-serviceable components. Do not attempt to use a battery that has a
damaged case; please contact the factory about our re-casing service.
Do not dispose in fire. Disposal must be conducted in accordance with
applicable local, state, or national regulations. Batteries contain recyclable
materials; recycling is encouraged over disposal.
A Safety Data Sheet (SDS) for this battery is available upon request.
Battery Storage and Transport:
Always disconnect battery from the searchlight before storing or transporting. If
storing battery for long periods of time, recharge once every three months. Store in a
cool, dry location not subject to frequent temperature fluctuations. Elevated
temperatures can result in reduced battery service life.
All Lithium Ion batteries are classified as Class 9 Dangerous Goods for air, sea and
surface transport and must be packaged and transported according to applicable
regulations. However, small batteries such as the MBP-1307 Li-Ion Battery are not
subject to certain provisions of the regulations (e.g. Class 9 labeling and UN
specification packaging).
Batteries must be identified as “UN 3480, Lithium Ion batteries” or “UN 3481,
Lithium Ion batteries, packed with equipment.” For air shipments, batteries must be
packed and marked according to IATA/ICAO PI 965 Sec II (batteries only) or PI 966
Sec II (with equipment).
Defective, damaged, or recalled Lithium Ion Batteries are forbidden for air transport.
6
Battery Charging:
Use only approved Peak Beam chargers. Improperly charging a battery may reduce
service life and, in extreme cases, may cause the product to flame or leak.
1. Locate Li-Ion battery and compatible charging adapter. (See table on page 6.)
2. Plug the female end of the power adapter into the male connector on the battery.
All connections are keyed; never force connections.
3. Connect the power adapter to the appropriate power source. The battery’s
bottom LED indicator will light, signifying that power is connected.
4. The battery will begin to charge automatically and the charge will complete in
approximately 3 hours. When charge is complete the fuel gauge lights will turn
off.
7
MBP-1310 Lithium Iron Phosphate (LiFePO4) Batteries
The MBP-1310 10Ah Lithium Iron Phosphate (LiFePO4) Battery is compatible with
all Maxa Beam Searchlights, however, the LiFePO4 battery’s connected differs from
the connectors on older Maxa Beam batteries. Therefore, a LiFePO4-specific power
cord (signified with “-L” suffix) must be used to connect this battery to a searchlight.
Run Time
Charge Time
Compatible
Chargers
Life Cycles
Capacity
Dimensions
Weight
MBP-1310 10Ah Lithium Iron Phosphate Battery
90 minutes (high) 135 minutes (default)
170 minutes (low)
120 minutes
180 minutes
MBP-3205: 100-240VAC Charger
MBP-3200: 1st Gen.
MBP-3230: 12VDC Charger
AC/DC LiFePO4 Charger
MBP-4312: 12VDC Power Inverter
2,500
10 Amp-hours / 120 Watt-hours
5 x 7.25 x 3.5 inches
3.5 lbs.
Battery Safety Warnings:
• • • • • Do not expose to fire or open flame.
Do not puncture, deform, incinerate or heat above 85°C (185°F).
Do not open or disassemble. Batteries are sealed in a waterproof case with no
user-serviceable components. Do not attempt to use a battery that has a
damaged case; please contact the factory about our re-casing service.
Do not dispose in fire. Disposal must be conducted in accordance with
applicable local, state, or national regulations. Batteries contain recyclable
materials; recycling is encouraged over disposal.
A Safety Data Sheet (SDS) for this battery is available upon request.
Battery Storage and Transport:
Always disconnect battery from the searchlight before storing or transporting. If
storing battery for long periods of time, recharge once every six months. Do not
store batteries above 60°C (140°F) or below -20°C (-4°F). Store in a cool, dry
location not subject to frequent temperature fluctuations. Elevated temperatures can
result in reduced battery service life.
The MBP-1310 10Ah LiFePO4 Battery is classified as Class 9 Dangerous Goods for
air, sea and surface transport and must be packaged and transported according to
applicable regulations. Batteries must be identified as “UN 3480, Lithium Ion
batteries” or “UN 3481, Lithium Ion batteries, packed with equipment.” For air
shipments, batteries must be packed and marked according to IATA/ICAO PI965
Section 1A (batteries only) or PI966 Sec I (with equipment).
Defective, damaged, or recalled Lithium Ion Batteries are forbidden for air transport.
8
Battery Charging:
Use only approved Peak Beam chargers. Improperly charging a battery may reduce
service life and, in extreme cases, may cause the product to flame or leak.
Charging with MBP-3200 1st Generation AC/DC LiFePO4 Chargers:
1. Locate Battery and MBP-3200 AC/DC Charger. Connect charger’s 110240VAC Power Adapter or 12VDC Vehicle Adapter. Connect adapter to
appropriate input power source.
2. Connect the charger’s pigtail to battery. Battery will automatically begin to
charge. Charger LED will turn FLASH GREEN during charge and turn
SOLID GREEN when charge is complete.
3. Do not leave battery connected to charger for longer than 24 hours.
Charging with MBP-3205 or MBP-3230 Chargers:
1. To charge battery from a 100-240VAC Power Source, locate the MBP-3205
AC Charger. Connect charger’s power cord to a 100-240VAC power source.
Connect charger to battery.
2. To charge battery from a 12VDC Vehicle, locate the MBP-3230 DC Charger.
Connect charger’s 12V cigarette lighter plug to vehicle’s 12V receptacle.
Connect charger to battery.
3. Battery will automatically begin to charge. Charger’s LED will turn RED
during charging and will turn GREEN when charge is complete. The MBP3205 AC Charger’s LED may pulse green during final charge stage.
4. Do not leave battery connected to charger for longer than 24 hours.
Charging with MBP-4312 12VDC Inverter:
1. Locate the MBP-3205 AC Charger. Connect charger’s power cord to a 100240VAC power source. Connect charger to battery.
2. Locate the MBP-4312 Inverter. Connect inverter’s 12V cigarette lighter plug to
a vehicle’s 12V receptacle. Plug charger into inverter’s 110V outlet.
3. Turn Inverter’s toggle power switch to the on positon. Battery will
automatically begin to charge. Charger’s Charger’s LED will turn RED during
charging and will turn GREEN when charge is complete. The MBP-3205 AC
Charger’s LED may pulse green during final charge stage.
4. Do not leave battery connected to charger for longer than 24 hours.
9
Troubleshooting
Symptom
Searchlights, All
Probable Cause
Remedy
Searchlight ignites but then
flashes repeatedly or turns
off after 1-2 seconds
Low/Dead Battery OR
Low Input Voltage
Charge Battery OR
Check Power Source
If Battery/Input Voltage are OK,
Bad Lamp
For Gen. 2* Searchlights only,
Failed Ignition Circuit
Low Battery OR
Low Input Voltage
Replace Lamp
No Power
Check Power Source and Cable
Spot/Flood Limits not set
correctly
Adjust Spot/Flood Limits (p. 7) or
Restore Factory Settings (p. 8)
If Restore Settings does not
resolve issue, Defective Servo or
Switch/Controller
Defective Switch/Controller
Call Factory for an RMA #
Flood Limit not set correctly OR
Lamp is not fully seated in socket
Reprogram Flood Limit (p. 7) OR
Reseat Lamp (p. 14-15)
Supply Voltage is too high
Ensure Supply Voltage is within
correct range (p. 18)
Searchlight ignites but turns
off when switched to high
beam
Nothing happens when
power button is pressed
Searchlight turns on but
motorized focus will not
work
Searchlight turns on but
high/strobe and focus will
not work
Searchlight beam will not
focus to the full flood
position
Searchlight turns on but
will not change power level
Call Factory for an RMA #
Charge Battery OR
Check Power Source
Call Factory for an RMA #
MBP-1207 NiCad Batteries
Battery hot and will not run
searchlight
Internal thermal circuit breaker in
battery is tripped
Battery runs light for
shorter and shorter duration
Battery has developed memory
Disconnect battery from searchlight;
Allow to cool until breaker auto
resets
Discharge battery until light turns off
& then recharge; Repeat cycle until
no improvement in run time is
observed OR Run a conditioning
cycle on 5200 or 5600 Series
Charger OR Return battery to
Factory for evaluation
MBP-5200 & MBP-5600 Series Chargers
Check power source OR Check fuse
in vehicle power adapter
Check power source OR Check fuse
in vehicle power adapter
Indicator does not light
No power OR Reversed polarity
Indicator flashes red with
no battery connected
Incorrect Voltage
Indicator flashes red when a
battery is connected
Battery is shorted OR Battery has
bad cells OR Battery is too hot or
cold
Try another Battery OR Bad Charger
Indicator alternates between
red and amber when battery
is connected
Insufficient Power
Check Line Voltage if using AC
adapter; Try different AC adapter
OR Make sure socket is clean on DC
Vehicle Adapter
Indicator stays red when a
battery is connected or set
on top
Battery is bad OR has overheated
If battery is warm, allow to cool and
try again
*Gen. 2 searchlights were sold prior to 2005. The searchlight’s generation is indicated by a “G2” (for Gen. 2)
or “G3” (for the current Gen. 3) in the serial number.
10
Indicator stays red when
battery set on top & turns
amber when pigtail
connected
Indicator turns solid amber
instead of flashing amber
when battery is set on top
without its tail connected
The fast charge cycle ends
before battery is fully
charged
Dirty trickle charge contacts OR
battery is turned in the wrong
direction
Clean contacts OR Turn Battery
around
Defective Charger
Call Factory for an RMA #
Battery is out of balance OR
Over-discharged
Allow Battery to slow charge for one
cycle (place battery on top & do not
connect pigtail) and wait for flashing
amber indicator to turn solid green
(takes about 14 hours)
MBP-5600 Series Chargers Only
The indicator flashes red
when powered up with
something connected to the
searchlight power jack
Searchlight occasionally
strobes or blinks once when
starting if it is cold
Searchlight jack is outputting 20 volts
Searchlight continuously
strobes and the indicator
light does not go out when
attempting to turn on
searchlight
Something other than a
searchlight is connected OR Red
button is pressed on light OR
Shorted light or coil cord
Normal
Normal
Defective MBP-5600
Only power Maxa Beam searchlights
with MBP-5600 OR Allow MBP5600 to power up before pressing
power button OR Try another light
and/or cord
Contact Factory if this happens
consistently or if this is a problem for
your application
Output will instantly drop to 13V
when light is turned on
Call Factory for an RMA #; Do not
attempt to use with a searchlight until
MBP-5600 is repaired
MBP-1307 Lithium Ion Battery Systems
Battery hot and will not run
searchlight
Light turns off during high
beam use when battery’s
charge is <40%
Light will not turn on when
battery is connected to
charging adapter
Internal thermal circuit breaker in
battery is tripped
Allow to cool until breaker auto
resets
Internal thermal circuit breaker in
battery is tripped
Wait for internal breaker to auto reset
Battery cannot power light when
connected to charging adapter
Disconnect charging adapter
MBP-4312 12VDC Power Inverter (MBP-1307 Li-Ion Battery)
Error LED turns solid red
Low Input Voltage
Check Power Source; toggle power
switch to clear error and reset
Error LED turns solid red
and buzzer sounds for 1
minute
Input Voltage below 10VDC
threshold
Check Power Source; toggle power
switch to clear error and reset
Error LED flashes red
High Input Voltage or Overload
Error LED flashes red and
buzzer sounds for 1 minute
Overheating
Check Power Source; toggle power
switch to clear error and reset
Allow to cool; toggle power switch
to clear error and reset
MBP-1310 Lithium Iron Phosphate (LiFePO4) Battery Systems
Battery will not run
Searchlight
Power cord will not connect
to battery
Battery discharged OR short
circuited
Older-style cord is being used
Charger’s LED does not
light (all charger models)
Charger’s LED Flashes Red
No Power OR
Defective Charger
No Power OR Blown Fuse in
Adapter
(MBP-3200 Only)
Connect battery to charger
Utilize a LiFePO4-specific power
cord to connect to the battery; older
cords are not compatible
Check Power Source OR
Call Factory for an RMA #
Check Power Source OR Replace
fuse in plug with new 3AG 15A fuse.
11
Warranty and Repairs
Warranty
Peak Beam Systems, Inc. warrants that for a period of 12 months from the date of purchase that its
products (except as listed below) shall be free of defects in materials and workmanship under
normal use and that Peak Beam Systems, Inc. shall, at its option, repair or replace any defective
product upon the prepaid return of the product to its factory. In the case of any lamp, light bulb or
other form of light source and the battery, the warranty period shall be 90 days.
The warranty only applies to defects in materials and workmanship and not to damage incurred in
shipping or handling, damage due to abuse, misuse, alteration or improper application of the
equipment. Damage incurred in return shipping and handling due to improper packaging is not
covered.
In order to be eligible for coverage under the warranty, the equipment must have the original Peak
Beam Systems, Inc. label with a legible serial number attached. Removal of any portion of the
factory-affixed labels on any product will result in the voiding of any written or implied warranty.
The foregoing warranty is in lieu of any and all other warranties whether expressed or implied. This
warranty contains the entire warranty. Peak Beam Systems, Inc. authorizes no other person or
organization to modify this warranty or to assume for it any other warranty or liability concerning
its products. The remedies of the buyer set forth hereon are exclusive and the liability of Peak Beam
Systems, Inc. whether arising out of contract, negligence, strict tort, any warranty or otherwise shall
not, except as expressly provided, exceed the price of the goods upon which such liability is based.
In no event shall Peak Beam Systems, Inc. be liable for direct, indirect or consequential damages,
loss of anticipated profits, loss of time or any other losses incurred by the buyer in connection with
the purchase, installation, operation or failure of operation of the product.
Returns to the Factory
All factory returns must have a Return Material Authorization (RMA) number. Peak Beam Systems
is not responsible for items returned without an authorization number. All warranty returns without
an RMA number will be returned at the customer’s expense. RMA numbers can be obtained by
calling 1-610-353-8505 or e-mailing techsupport@peakbeam.com. Please provide the following
information:
• Serial number(s) of unit(s) to be returned
• Date and location of purchase (if known)
• For service returns, a description of the problem
• Method of payment for non-warranty service
Products returned by the customer to Peak Beam Systems must be sent freight prepaid.
Out-of-warranty repairs must be prepaid unless other arrangements have been made. Non-U.S.
warranty repairs and out-of-warranty repairs will be returned to the customer by the customer’s
choice of freight carrier with the freight charges paid by the customer.
Domestic warranty repairs will be returned freight prepaid by Peak Beam Systems, Inc.’s choice of
freight carrier with the freight charges paid by Peak Beam Systems. The customer will pay any
additional freight costs for special handling or expedited freight.
Returns of non-defective goods will only be accepted from the original buyer within 90 days of sale
and must be in “like new” condition. These returns are subject to a minimum restocking charge of
20% plus freight out and must be returned freight prepaid. Custom equipment is not returnable.
Rev. -, 4/16
12
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