Bowens Marine Battery BWL 0440 User Manual

TURBOPAK  
USER GUIDE BWL-0440 (04/07)  
BOWENS INTERNATIONAL LIMITED  
355 Old Road  
Clacton On Sea  
Essex CO15 3RH  
Tel: +44 (0)1255 422807  
Fax: +44 (0)1255 436342  
ʻBowensʼ ® and ʻthe power behind the pictureʼ ® are registered trademarks of Bowens International Ltd.  
 
Battery Cassette & Charging  
!!! WARNING HIGH VOLTAGE !!!  
Control Panel Guide  
Gemini  
Connections  
ONLY USE A CHARGER APPROVED BY BOWENS FOR USE WITH THIS  
EQUIPMENT  
TAKE CARE NOT TO DROP THE BATTERY CASSETTE - THE BATTERY IS  
HEAVIER THAN THE SIZE OF THE CASSETTE MIGHT SUGGEST.  
DO NOT USE A DAMAGED BATTERY CASSETTE.  
KEEP THE BATTERY CASSETTE CLEAN AND DRY TO PREVENT CONTAMINATION  
OF THE CONTACTS AND FUSES.  
THE BATTERY WITHIN THE CASSETTE SHOULD ONLY BE REPLACED BY  
AUTHORISED SERVICE PERSONNEL  
Notes on Battery Cassette Usage  
The pack cannot be used without a Battery Cassette or the Extender Battery Fitted.  
Battery  
Level  
Carry Handle  
Indicator  
The pack can still be used while charging the Battery Cassette or Extender Battery  
providing there is sufficient charge remaining.  
Charge  
Socket  
Use only Bowens approved charger's or permanent damage may result.  
The Battery Cassette can be charged either within or outside the pack from the mains using  
the supplied charger or alternatively from a vehicle using the optional Automobile (car)  
charger.  
On / Off  
Switch  
The battery has no memory effect so it can be charged and discharged from any state.  
However, for best results and service life never fully discharged the battery, charge it as  
soon as possible after use and keep it fully charged.  
Extra Battery Cassettes and charger's are available as accessories allowing quick  
replacement of an exhausted Cassette with a fully charged Cassette to allow continuous  
shooting.  
Fast / Slow  
Charge  
Switch  
 
Charging the Battery Cassette  
Fitting the Battery Cassette  
Lay the pack on is longest side with the on/off switch uppermost.  
Connect the charger to the mains supply and switch on.  
Lay the Battery Cassette with the fuses uppermost and the slotted handle to the right.  
A red indicator on the charger shows that the Cassette is charging normally.  
Rotate the toggle button on the base of the Cassette to release the two handles and open  
them fully out.  
In the unlikely event that the indicator shows yellow then there is a fault and the Cassette  
and charger should be disconnected.  
Slide the Battery Cassette into the pack with the slotted handle towards the right. The  
Cassette will not fit in the pack the wrong way round.  
The green indicator briefly flickering shows the transition between charging and trickle  
charge.  
Gently push the Cassette all the way in and fold the handles down so that they lock the  
Cassette inside the pack.  
When the indicator shows a steady green colour the Cassette is approximately 90-95%  
charged and is being trickle charged.  
Lock the handles in place by rotating the toggle button. Rotate the toggle button to adjust  
the lock.  
If possible leave the Battery Cassette to charge for a further 30-60 minutes to ensure that it  
is fully charged. The Battery Cassette cannot be overcharged if the charger is left  
connected.  
Stand the pack upright.  
A full charge from a discharged state may take anytime up to 6 hours depending on the  
charger used.  
Removing the Battery Cassette  
Please read the Battery Cassette safety and maintenance instructions at the end of these  
instructions.  
Removal of the Cassette is the reverse of fitting.  
Controlling the TurboPak  
Lay the pack on its longest side.  
Rotate the toggle button on the base of the Cassette to release the two handles.  
General  
Fold out the handles and pull on them whilst using the thumbs against the pack to eject the  
Cassette out of the pack.  
The TurboPak is very simple to operate and control as follows:  
NOTE: For safety the TurboPak cannot charge any fitted monolight unless all other sockets are  
fitted with either a dummy plug or a Travel-Pak cable (BW7632) terminated with a monolight.  
Only monolights switched to position II will be charged.  
Charging the Battery Cassette  
Turning The Pack On & Off  
One universal voltage charger is supplied with the pack and is provided with a set of mains  
adaptors suitable for the majority of mains outlets around the world.  
Turn the TurboPak on and off using the On/Off switch. The TurboPak will immediately display the charge  
state of the Battery Cassette regardless of the number or type of monolights fitted. If one or more  
monolights are fitted and switched on then after about 2 seconds the charge indicators will light to  
indicate a monolight is charging.  
Choose the adaptor suitable for your mains supply, slide it into place until it is fully home. If  
an unusual mains outlet is encountered an appropriate travel adaptor (not supplied) may  
need to be used together with one fitted to the charger.  
Charge Socket  
If the Battery Cassette is to be charged inside the pack, plug the charger output connector  
into the CHARGE jack socket on top of the pack.  
Use only Bowens approved charger's or permanent damage to your unit may result.  
The top panel charge socket allows the supplied 2A charger to charge the Battery Cassette when fitted  
in the unit.  
If the Battery Cassette is to be charged outside the pack, plug the charger output connector  
into the CHARGE jack socket on the side of the Cassette. Avoid knocking or placing strain  
on the connector.  
 
Battery Level Indicator  
Controlling the TurboPak  
The Battery Cassette can also be charged at the same time as the unit is being used and this will  
effectively extend the number of flashes available. A discharged battery will take approximately 5-6  
hours to fully charge.  
The TurboPak should not be allowed to fully discharge the Battery Cassette as this may significantly  
reduce the future capacity and operating life of the Battery Cassette.  
It is not recommended to keep using the TurboPak when the red battery low indicator is showing  
although it will keep going until the flat battery condition is reached, when it will automatically switch off.  
For best results and maximum life from a Battery Cassette always keep it fully charged and avoid fully  
discharging it. Always charge the Battery Cassette as soon as possible after use and never leave it flat.  
Always recharge the Battery Cassette as soon as possible after discharge. If FAST mode is selected  
then this will be overridden once the battery indicator drops to the amber level to prevent excessive drain  
from the near flat battery.  
For maximum duty and flexibility spare Battery Cassettes and charger's are available to allow swapping  
out and charging outside of the TurboPak.  
Head Socket  
Spare Battery Cassettes and charger's are available so that discharged Modules can be quickly  
replaced with a fully charged one to allow shooting to continue.  
Each socket can power one Esprit Gemini / Travelite III monolight. When a head socket is not used it  
should be fitted with a dummy plug. The unit will not operate unless ALL sockets are fitted with either a  
dummy plug or a Gemini cable with a unit attached, whether switched on or not.  
Charge Indicators  
A charge indicator is fitted adjacent to each socket. In normal use these light to indicate that charge is  
being supplied to the associated socket. Under fault conditions the indicators are also used in  
combination to indicate the pack status or faults. See the section on Status & Fault Indication.  
Battery Level Indicator  
This shows the charge level of the battery from fully charged to flat. It also indicates when the unit is  
disabled due to the battery voltage being too low for correct operation.  
During normal use the TurboPak checks each socket to see if a monolight is fitted and switched on. If  
one is fitted, it then checks to see if it requires a top-charge (i.e. the unit is READY) or requires a full  
charge (i.e. the monolight has just been switched on or has been flashed). A brief flash of the  
appropriate indicator shows a top-charge while an indicator remaining lit indicates full charge. The  
monolights are fully charged one at a time while other units are topped up to keep them at READY.  
Battery Level Indication Approx Battery Voltage  
Battery Condition  
Action  
Green, Yellow, Amber  
Yellow, Amber  
Amber  
> 12.4V  
> 12.2V  
> 12.0V  
Good  
Fair  
Okay for use  
Okay for use  
Thermal Management  
The internal temperature of the TurboPak is continually monitored to protect the unit against  
overheating.  
Low  
Okay for use but  
getting low  
The charge rate is progressively decreased as the temperature increases to try and prevent the unit  
from reaching the overheat condition after which it will be disabled. This allows continued shooting  
albeit at a slower rate.  
Red  
< 12.0V  
< 11.6V  
> 11.6V  
Very Low  
Flat  
Restricted use - charge  
or replace ASAP  
If the temperature rises above a preset level the internal fan is turned on to cool the TurboPak. Once  
the TurboPak has cooled sufficiently the fan is turned off. This reduces the drain on the battery when  
the TurboPak is used infrequently. If the ambient temperature is very high then the fan may be on for  
longer or not turn off at all.  
Flashing Red Only  
Other colors flashing  
Disabled - charge or  
replace ASAP  
If the temperature is too high for correct operation then ALL charge will be disabled and an overheat  
condition will be indicated. This will occur if the temperature sensor has a fault, the fan fails, or if the  
ambient temperature is too low for correct operation.  
On Charge  
Disabled - wait or  
replace ASAP  
 
Status & Fault Indication  
Fast / Slow Switch  
All batteries have a finite capacity and life. Both of these are affected by the way the battery is charged  
and discharged. A high discharge rate will reduce both the capacity (number of flashes available from a  
full charge) and the time to end of life (the point at which the battery is deemed to be unusable).  
The following will be indicated if the pack status changes or a fault occurs:-  
1)  
Monolight Not Charging - ALL charge is disabled if a fitted monolight is not charging correctly.  
This is indicated by the associated charge LED slowly flashing. This automatically resets after  
approximately 1 minute or can be reset manually by switching the Fast/Slow switch or  
changing the status of any of the fitted monolights i.e. switch on or off, fit or remove the cable.  
The fault indication will re-occur if there is a genuine problem.  
The Fast/Slow switch provides the user with a means of controlling how fast the attached monolights  
are charged and consequently how quickly the Battery Cassette is discharged. Unless a particular set-  
up and application requires Fast charge then it is recommended that Slow mode is always selected to  
achieve the maximum capacity and life of the Battery Cassette. Only use Fast when the job requires a  
continual fast recycle time.  
2)  
3)  
4)  
Overheat - ALL charge is disabled if the TurboPak internal temperature exceeds a preset  
threshold. This is indicated by the charge indicator LEDs flashing briefly in pairs in the order  
A and B, C and D, A and B etc. This automatically resets when the TurboPak cools sufficiently  
for normal operation. Check the vents for obstruction and confirm that the fan is operational.  
It is not possible to give recycle times for all combinations of monolights, flash settings, battery state  
temperature etc. The following equation will give a very approximate recycle time for a fully charged  
battery at normal ambient temperature:-  
Powerdown/Standby - ALL charge is disabled if none of the fitted monolights is flashed within  
a ten minute period. This is indicated by all four charge LEDs flashing briefly together at 2  
second intervals. This can be reset manually by switching the Fast/Slow switch or changing  
the status of any of the fitted monolights i.e. switch on or off, fit or remove the cable.  
Where ʻPower A, Power Bʼ etc is the power rating or setting of each monolight fitted in Ws or Joules,  
ʻCharge Rateʼ is 200 for Slow and 500 for Fast and ʻMonosʼ is the number of monolights fitted.  
Flat Battery - ALL charge is disabled if the Battery Module charge state is deemed to be too  
low for correct operation. This is indicated by the Battery condition LEDs flashing slowly. This  
will normally start with the Red LED flashing first but, if the charger is left connected and  
switched on, progressively more LEDs will flash as the Battery Module charges. This  
automatically resets after approximately 4 minutes but will re-occur unless the Battery Module  
has received sufficient charge to continue.  
As a guide typical charge times for 750Ws monolight set to maximum and flashed simultaneously from  
a fully charged Battery Cassette are as follows:  
Number of 750Ws  
Monolights Fitted.  
Typical Time to ALL Monolights  
Ready in Slow Mode (seconds)  
Typical Time to ALL Monolights  
Ready in Fast Mode (seconds)  
Typical Flash Capacity  
1
2
3
4
4.2  
8.2  
2.0  
3.7  
5.5  
7.4  
Number Of Monolights Fitted  
12.1  
16.4  
Power Rating  
125Ws  
X 1  
1600  
800  
540  
400  
260  
200  
X 2  
800  
400  
270  
200  
130  
100  
X 3  
530  
266  
180  
166  
86  
X 4  
400  
200  
135  
100  
65  
250Ws  
If the unit is worked heavily then it will automatically ramp down the charge rate to control the internal  
temperature and hence it will take longer to recycle the attached Gemini. To overcome this either slow  
the rate of flashing or wait for the unit to cool.  
375Ws  
500Ws  
Note: Even if Fast is selected the TurboPak will override it as the battery becomes discharged or the  
internal temperature increases. The temperature and battery monitors work together to slow the charge  
progressively. As a rough guide when the amber battery indicator starts to show, the attached  
monolights will start to charge at a slower rate. This can be overcome by changing the battery module  
for a fully charged one or by using a Battery Extender. In addition, a mains or car charger is available;  
the pack may be used with a charger connected so that the battery is always being topped up.  
750Ws  
1000Ws  
66  
50  
 
Accessories  
Recommended Maintenance  
The Battery Cassette needs very little routine maintenance but for longest service life the following  
should be noted:  
Heavy-Duty Battery  
Keep the Battery Cassette clean and dry. Do not use any organic solvents or detergents.  
Wipe it with a clean dr cloth.  
Designed to quickly and easily double the capacity  
of either the Explorer1500 or the TurboPak the  
Heavy-Duty Battery from Bowens offers  
Only use a Bowens recommended charger.  
Charge or swap out the Battery Cassette before it is fully discharged.  
Never store the Battery Cassette in a partial or fully discharged condition.  
photographers the assurance they need on  
extended location shoots to know theyʼve always  
got enough power to capture that vital shot. Able  
to offer up to 1000 shots at 1500Ws the  
The Battery Cassette has no so-called memory effect but recharge it as soon as possible  
after use and keep it fully charged for longest life.  
Heavy-Duty Battery from Bowens allows  
photographers total freedom from mains power.  
Fully charge every 6-9 weeks to maintain battery condition.  
If possible leave the Battery Cassette on charge indefinitely.  
BW7643  
Safety Information  
The Battery Cassette contains a Sealed Lead Acid Battery containing hazardous chemicals and it is  
therefore subject to special waste disposal and/or recycling depending on your local legislation. The  
battery is recyclable.  
Heavy-Duty Battery Telescopic  
Trolley  
In the USA only, you may call 1-800-SAV-LEAD (1-800-728-5323) for complete recycling information.  
Designed to make moving the Heavy-Duty  
Battery easier, this accessory simply  
attaches onto the back of the unit with the  
use of a simple clamp to securely connect  
them together.  
The best way of disposal is to return the Battery Cassette to your authorised dealer or service centre  
where it will be responsibly disposed of or recycled.  
Do flush the skin with water at once if contact is made with electrolyte (acid).  
Do not replace the fuses with any other type or rating.  
BW7649  
Do not open the Battery Cassette or try to modify it for any reason. There are no user-  
serviceable parts inside.  
Do not charge in a gas tight container.  
Do not short out or bridge the Cassette connections.  
Do not drop or subject to heavy knocks.  
DID YOU KNOW? that Bowens have over 40 light shaping tools  
and accessories available for all their monolights that use the  
current ʻSʼ type accessory fitting. Included among the range of  
accessories are a wide variety of reflectors and softboxes. For  
more information visit the website on www.bowens.co.uk  
Do not dispose of the battery in normal household waste.  
Do not dispose f the battery in a fire.  
 
Battery Cassette Specifications  
TurboPak Specifications  
Weight  
Size  
9.8Kg (inc battery)  
Battery Type  
Maintenance free, non-spillable,  
Sealed Lead Acid Battery  
(L x W x H)  
270mm x 180mm x 242mm  
(H = 281mm inc. handle)  
Number of Cells  
6
Nominal Battery Voltage  
Nominal Battery Capacity  
Maximum Charge Currents  
12V  
12AH  
Power Source  
Interchangeable Battery Cassette  
(BW7642)  
Managed Charge Only - 3A Bulk Charge  
0.1A Float  
Typical Recycle Time  
Items Supplied in Carton  
500 Ws  
Charger  
Only use a Bowens recommended charger  
1 x BW7655 TurboPak  
Typical Battery Charge  
Times  
With Supplied 2A Charger (BW1227) -  
approximately 5-6 hours.  
With Optional Car Charger (BW1245) -  
approximately 5-6 hours.  
1 x BW7642 Battery Cassette  
1 x BW1227 Universal Mains 2A  
Battery Charger  
1 x BWL0440 Operating Instructions  
1 x Registration Card  
Size  
172mm x 108mm x 120mm  
(L x W x H)  
1 x Safety Leaflet  
Weight  
Fuses  
4.7Kg  
Additional items may be supplied for use in specific  
countries.  
3 x 30A, User Replaceable,  
Automobile Type (ATO Fast Acting)  
Accessories Available  
BW1227 Universal Mains 2A Battery  
Charger  
BW1245 Automobile Battery Charger  
BW7642 Spare Battery Cassette  
BW7632 Cable for connection to Gemini  
heads  
Due to our policy of constant product improvement, Bowens International reserves the right to change equipment  
specifications at any time and without notice.  
 

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