UPS READY POWER DISTRIBUTION ASSEMBLY FOR TRAFFIC CABINETS with LED Signals INSTALLATION & OPERATOR S MANUAL VERSION 1.2 1
Note The instructions contained in this manual are not intended to cover all of the details or variations in equipment, or to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes, the matter should be referred directly to Always On UPS Systems Inc. Any electrical or mechanical modifications to this equipment, without prior written consent of Always On UPS Systems Inc, will void all warranties. Unauthorized modifications also can result in personal injury, death, or destruction or the equipment. Power Distribution Assembly Please complete the Warranty Card supplied with this PDA and return it by mail to Always On UPS Systems Inc. This activates the warranty. If additional information or technical assistance is required call: Always On UPS Systems Inc Sales and Technical Support Line Toll-free at 1-877-259-2976 Ext. 451 or (250) 491-9777 Ext. 451 or Fax (250) 491-9775 Or e-mail sales@alwayson.com or visit our web site at www.alwayson.com Or write to: Always On UPS Systems Inc. Bldg 1 150 Campion Road, Kelowna, BC, V1X 7S8, Canada Please complete the following information for your records. Model Number: Serial Number: Date of Installation: Inspected By: 2
IMPORTANT SAFETY INSTRUCTIONS THE PDA SYSTEM IS NOT INTENDED FOR EXTERNAL USE UNLESS SPECIFICALLY DESIGNED FOR IT. ALL SERVICING MUST BE DONE BY QUALIFIED PERSONNEL. DO NOT ATTEMPT TO SERVICE THIS EQUIPMENT YOURSELF. OPENING OR REMOVING COVERS WILL RISK EXPOSURE TO DANGEROUS VOLTAGES. DO NOT LOCATE PDA IN AN AREA WHERE UNAUTORIZED PERSONNEL HAVE ACCESS. THE POWER SUPPLY FOR THIS UNIT MUST BE SINGLE PHASE RATED IN ACCORDANCE WITH THE EQUIPMENT DATA PLATE. IT MUST BE SUITABLY GROUNDED. DO NOT STAND BEVERAGE CONTAINERS ON THE UNIT. THE POWER TERMINAL BLOCK ON THE PDA WILL BE LIVE WHEN THERE IS A UPS OR GENERATOR CONNECTED. QUALIFIED PERSONNEL SHOULD BE CONSULTED WHEN: LIQUID HAS BEEN SPILLED INTO THE UNIT THE UNIT DOES NOT OPERATE NORMALLY EVEN THOUGH THE OPERATING INSTRUCTIONS HAVE BEEN FOLLOWED DO NOT PLACE MAGNETIC STORAGE MEDIA ON TOP OF THE UNIT, AS THIS CAN RESULT IN DATA CORRUPTION. THIS PDA WAS DESIGNED FOR USE IN A TRAFFIC CABINET ONLY. ATTENTION: ALL REPAIRS SHOULD BE PERFORMED BY QUALIFIED SERVICE PERSONNEL. READ THIS MANUAL CAREFULLY BEFORE INSTALLING OR USING THE UNIT. FOLLOW ALL PROCEDURES, AS DESCRIBED, TO ENSURE SAFE, RELIABLE OPERATION OF THE PDA. SAVE THESE INSTRUCTIONS 3
MORE SAFETY INSTRUCTIONS DO NOT USE THIS EQUIPMENT FOR ANY PURPOSE OTHER THAN THE INTENDED USE. EXAMINE THE PACKAGING CONTAINER FOR DAMAGE. NOTIFY THE CARRIER IMMEDIATELY IF DAMAGE IS PRESENT. DO NOT DISASSEMBLE THE PDA. DO NOT OPERATE OR LOCATE NEAR WATER OR EXCESSIVE HUMIDITY. DO NOT USE OTHER MANUFACTURERS ACCESSORIES. MAY CAUSE DAMAGE OR UNSAFE CONDITIONS. KEEP LIQUID AND FOREIGN OBJECTS FROM GETTING INSIDE THE PDA. DO NOT PLACE OR OPERATE CLOSE TO GAS, HEATERS OR FIRE. DO NOT LET POWER CABLES CONTACT HOT SURFACES. THE POWER CONNECTIONS FOR THE PDA SHOULD BE WIRED IN ACCORDANCE WITH LOCAL AND NATIONAL ELECTRICAL CODE SPECIFICATIONS. ONCE THE PDA IS CONNECTED TO AN ENERGY SOURCE, SUCH AS THE BATTERIES, THE OUTPUT TERMINALS MAY BE LIVE EVEN WHEN THE PDA IS NOT CONNECTED TO AN AC SUPPLY, ESPECIALLY WHEN CONNECTED TO A UPS. SYMBOLS Protective grounding terminal; terminal must be connected to ground prior to making any other connection to the equipment. A terminal to or from which an alternating (sine wave) current or voltage may be applied or supplied. A terminal to or from which a direct current or voltage may be applied or supplied. This symbol indicates the word phase. May be used in lieu of the wording caution, risk of electric shock for any cautionary marking. 4
Table of Contents 1. PRODUCT DESCRIPTION...6 1.1. SCHEMATIC...7 1.2. DESCRIPTION OF OPERATION...8 2. HANDLING...10 2.1. DELIVERY...10 2.2. INITIAL INSPECTION...10 3. INSTALLATION...11 3.1. INSTALLING INTO THE CABINET...11 3.2. CONNECTING THE AC SUPPLY TO THE MAIN SERVICE ENTRANCE...12 3.3. WIRING TO THE TERMINAL BLOCK...13 4. OPERATION...15 4.1. MAIN SERVICE ENTRANCE LOCATION & OPERATION...15 4.2. FRONT PANEL LAYOUT...15 4.3. TO TURN PDA OFF...ERROR! BOOKMARK NOT DEFINED. 4.4. TO TURN PDA ON...ERROR! BOOKMARK NOT DEFINED. 4.5. TO TURN OFF AN INDIVIDUAL CIRCUIT...18 4.6. GENERATOR MODE / CONNECTING A GENERATOR (GENERATOR OPTION ONLY)...18 4.7. PLACE PDA IN BYPASS, DISABLE OR AUTO MODE ( UPS READY OPTION ONLY)...19 5. MAINTENANCE...21 5.1. RESET A BREAKER...21 5.2. FUSE REPLACEMENT...21 5.3. SURGE SUPPRESSOR INSPECTIONS & REPLACEMENT...22 6. OPTIONAL EXTRAS...23 6.1. UPS (FOR UPS READY PDA)...23 7. TECHNICAL DATA...24 8. CONTACT INFORMATION...25 8.1. ADDITIONAL PURCHASES OR UPGRADES...25 8.2. QA / WARRANTY QUESTIONS...25 8.3. SOFTWARE QUESTIONS...25 5
1. Product Description This Power Distribution Assembly (PDA) was designed as a UPS ready power supply for traffic cabinets. This power supply allows for easy connection of a UPS to the power supply and allows the UPS to be a detachable unit that may be added or removed from the panel at any time, without interruption of service to the traffic cabinet (when optional ATS installed). The panel is intended to be a power distribution panel with an optional main service entrance, along with more refined secondary protection for sensitive control circuits. Furthermore, the unit may be equipped with special features, such as a generator transfer switch, UPS power backup and conditioning, TVSS power conditioning and filtering or a wrap-around bypass for servicing the UPS or allowing the PDA to be UPS ready. These features are further described below. The main features of the panel are the optional main service entrance, the serviceable TVSS module and the conveniently accessed branch protection, all in a slim minimum footprint PDA. The TVSS module offers high protection that surpasses other similar products. Furthermore, the TVSS module offers power line conditioning to the traffic cabinet s sensitive equipment, regardless if a UPS is installed. As extra features, an automatic UPS sensing Bypass Module may be added to the PDA to allow for easy installation of a UPS or servicing of a UPS at any time without service interruption to the traffic cabinet. Also, there is a generator transfer switch option that allows the user to easily and safely connect a 20A, 120VAC generator to power the PDA and traffic cabinet at the flip of a switch. No need to perform unsafe jumpers. Optional service entrance breaker. 6
1.1. Schematic PDA Schematic 7
1.2. Description of Operation Optional Main Service Entrance: Allows connection of an AC Service to the traffic cabinet. Neutral is bonded to ground with a non-ferrous bonding screw. A 30A, 10kAIR breaker is installed as an optional feature. A 22kAIR breaker is available upon request. Generator Connection: Allows easy connection of a generator to the PDA with a 120VAC, 20A twist-lock dongle. Optional Generator Transfer Switch: Allows easy transfer from AC service to generator back up without back feeding the AC service. This break-before-make transfer switch also switches the neutral from the AC service to generator service. A 20A, 10kAIR magnetic circuit breaker is installed. Sub-distribution Auxiliary Circuits: The auxiliary circuits are unprotected by TVSS or UPS modules. These circuits are fed raw unfiltered AC from the AC service. All neutral connections of loads fed from auxiliary circuits are fed from the neutral bus N1. A 20A, 10kAIR magnetic circuit breaker is installed and each branch is equipped with supplementary fusing that is all accessible from the front panel. WARNING: ALL NEUTRAL CONNECTIONS OF LOADS FED FROM THE PROTECTED CIRCUITS ARE FED FROM THE NEUTRAL BUS N2 OR LOADS MAY NOT OPERATE PROPERLY OR DAMAGE MAY OCCUR. Sub-distribution Protected Circuits: The protected circuits are protected from surges and EMI by the TVSS/EMI module as standard and the UPS as an option. All neutral connections of loads fed from the protected circuits are fed from the neutral bus N2. A 15A, 10kAIR magnetic circuit breaker is installed and each branch is equipped with supplementary fusing that is all accessible from the front panel. WARNING: ALL NEUTRAL CONNECTIONS OF LOADS FED FROM AUXILIARY CIRCUITS ARE FED FROM THE NEUTRAL BUS N1 OR LOADS MAY NOT OPERATE PROPERLY OR DAMAGE MAY OCCUR. TVSS/EMI Module: The TVSS/EMI module filters transients from the raw AC service to add robust protection to the protected loads. 8
Surge Suppressor Modules: The surge suppressor modules complement the TVSS/EMI module by keeping high voltage transients such as lightning from ruining the protected loads. There are two stages of surge suppressor modules on either side of the TVSS/EMI module and are both serviceable and can be replaced if sacrificed during a transient event. The first stage is a gas tube arrestor that takes the brunt of a high voltage transient and is placed in front of the TVSS/EMI module. The second stage is a Varistor based surge suppressor that further protects the load while the gas tube arrestor works to reduce the voltage spike to a safe level. Automatic Maintenance Bypass (if equipped with UPS Ready option): The built in automatic bypass senses for a UPS and will switch automatically from maintenance bypass to UPS power without disruption to the load. The control switch also disables the bypass function or forces a bypass of the UPS. UPS Ready Connection (if equipped with UPS Ready option): A UPS connection can be made with an optional cable that provides AC and DC power to the UPS and also delivers AC power back to the PDA. This cable allows one to take full advantage of the UPS Ready PDA features. Mercury Contactor: A traffic rated mercury contactor is also installed as standard for operation with the signal bus. Supplementary Fusing: Provides secondary circuit protection for sensitive control circuitry. All fuses can be serviced conveniently from the front panel. 9
2. Handling 2.1. Delivery Upon receiving the PDA system, inspect the packaging integrity and the physical condition of the unit carefully. In the event that physical damage is visible, the carrier must be informed immediately and a claim filed with them. Inform Always On as soon as the claim has been filed and a copy of claim should be faxed to Always On at (250) 491-9775. A detailed report of the damage is necessary for carrier insurance claim. 2.2. Initial Inspection Unpack the system carefully, notice the packing method, and retain the box and packing material. If you must return the PDA at any time, you must repack it the way it was originally shipped. Visually inspect the PDA for damage that may have occurred during shipment. If there is damage, or anything is missing, contact the dealer from whom you purchased the unit, and save the packaging for future shipment. When the unit has passed the initial inspection, record the installation date in the space provided towards the front of this manual. 10
3. Installation The PDA is intended for installation in a temperature and humidity controlled environments, free of conductive contaminants with unrestricted airflow. Absolute maximum ambient temperature at sea level must not exceed 74ºC (165ºF). The PDA should be wired in accordance with local and national electrical code specifications by qualified personnel. Maintenance and Servicing of the PDA requires access to the front and side of the PDA. Provide the necessary free space to access the side panel of the PDA. 3.1. Installing into the Cabinet Mount the PDA to the Cabinet C-Channel through the holes provided at the top and the bottom of the PDA. Mounting Hole Locations 11
3.2. Wiring Connections 3.2.1 Connecting the AC Supply to the PDA Connect the AC line to the protected and auxiliary breaker terminals. Connect the AC neutral to input neutral bus. Connect the ground wire to the ground bus. 3.2.2 Connecting the AC Supply to the Main Service Entrance (Optional) If the unit features an optional Main Service Entrance, to terminate the AC supply to the PDA, the Main Service Entrance (MSE) cover must be removed. Once the cover is removed, the terminal lugs for the neutral bus, main breaker and service ground can be accessed. Also, the neutral bus contains the bonding screw that bonds it to ground. Optional Main Service Entrance & Termination Locations 12
3.3 Wiring to the Terminal Block Load power terminations are to be made to terminal blocks TB1 & TB2. Remove the terminal block cover. The load neutral connects are to be made on N1 & N2. All loads that are designated Auxiliary and not Protected are to be connected to N1. This includes the GFI receptacle (TB1-1), the Heater (TB1-2), Lamp (TB1-3), Fan (TB1-4), and Aux (TB1-7) circuits. All other loads are to be connected to the N2 neutral bus bar. Improper termination of neutral wires to the wrong neutral bus may cause adverse effects to the output voltage if a UPS is connected. Refer to the PDA schematic. Replace the terminal block cover when done with the terminations. Load Terminal Block Location WARNING: ALL NEUTRAL CONNECTIONS OF LOADS FED FROM AUXILIARY CIRCUITS ARE FED FROM THE NEUTRAL BUS N1 OR LOADS MAY NOT OPERATE PROPERLY OR DAMAGE MAY OCCUR. 13
WARNING: ALL NEUTRAL CONNECTIONS OF LOADS FED FROM THE PROTECTED CIRCUITS ARE FED FROM THE NEUTRAL BUS N2 OR LOADS MAY NOT OPERATE PROPERLY OR DAMAGE MAY OCCUR. 3.2.1. Terminal Block Layout & Termination Diagram 14
4. Operation 4.1. Optional Main Service Entrance Location & Operation 4.2. Front Panel Layout The secondary protection and distribution of circuits can be controlled from the front panel. Also, if equipped with the generator transfer switch and UPS Automatic Maintenance Bypass, these features may be operated from the front panel as well. Review the following figures for locations of these features. 15
Front Panel Location Sub-Distribution Location; also Generator Transfer Switch, Generator Breaker & Maintenance Bypass Control Location (if equipped) 16
UPS & Bypass Breakers ( UPS Ready option, if equipped) Supplementary Fusing 17
4.3. To Turn Off an Individual Circuit Determine the correct fuse or circuit breaker that is in the circuit. Remove the fuse from the circuit s fuse holder or switch the circuit breaker to the off position. 4.4. Generator Mode / Connecting a Generator (Generator option only) Breaker Feeds Put PDA into Generator Mode: A generator may be connected to the PDA by plugging in a generator to the 120VAC, 20A male twist-lock plug at the end of the generator connection dongle. Throw the generator transfer switch to Gen once the generator is connected and operating properly. The PDA is now being fed from the generator and the AC service or Util is not connected. Return PDA to AC Service: Throw the generator transfer switch from Gen to Util. The PDA is now being fed from the AC Service. 18
(OPTIONAL) TO LOADS (OPTIONAL) (OPTIONAL) Generator Transfer Switch Details 4.5. Place PDA in Bypass, Disable or Auto Mode ( UPS Ready option only) Force Manual Bypass: Move the Bypass Control Switch from Auto or Disable to Bypass to force the bypass to manually bypass the UPS circuit and continue to power the load if AC service is present. The UPS can be removed for maintenance. The red indicator on the front panel will light representing that the circuit is in bypass mode. Select Auto Sensing of a UPS: Move the Bypass Control Switch from Bypass to Auto to allow the bypass to switch to UPS power if it senses a UPS present. If a UPS is not present and operating, the bypass will operate in bypass mode automatically and a red indicator will be lit. Forcing the Bypass to operate in UPS Mode: Move the Bypass Control Switch from Auto or Bypass to Disable to force the bypass to operate off of the UPS. In this mode, the bypass system will not automatically bypass the UPS if the UPS is not present or is turned off. 19
Bypass Circuit Details (Optional) 20
5. Maintenance The PDA is intended for installation in a temperature and humidity controlled environment, free of conductive contaminants with unrestricted airflow. Absolute maximum ambient temperature at sea level must not exceed 74ºC (165ºF). Maintenance and servicing of the PDA requires access to the front and side of the PDA. Provide the necessary free space to access the side panel of the PDA. 5.1. Reset a Breaker If a circuit has tripped, first find the cause of the problem. After the problem is fixed, find the breaker that looks out of the on position or is in the off position. Place that breaker back into the on position to reset. Please note that the main service breaker needs to be pushed to the off position and then into the on position to be reset. 5.2. Fuse Replacement If a circuit is not working and has caused a fuse to clear or blow, first find the cause of the problem. After the problem is fixed, find the fuse that blew. Remove that fuse from its holder by pushing in and twisting counterclockwise. The fuse can now be removed and will not be disconnected from the live circuit. Replace fuse with same rating and type and replace by conducting the reverse of the above process. WARNING: REPLACE FUSE WITH SAME TYPE AND RATING. 21
Replacing a Fuse 5.3. Air Gap Lightning Arrestor Inspections & Replacement Inspect for burns, open wire leads, cracks or any other damage. For replacement, remove damaged arrestor and terminate new air gap arrestor to terminals 1, 2 and 5 as shown in the figure. WARNING: ONLY REPLACE SURGE SUPPRESSOR MODULE WITH FACTORY APPROVED MODULES. WARNING: ONLY QUALIFIED PERSONNEL SHOULD CONDUCT MAINTENANCE ON THE PDA. 22
6. Optional Extras 6.1. UPS (For UPS Ready PDA) A UPS may be connected to the PDA with the supplied connections. A cable is available from your PDA dealer and will be ordered depending on the types of terminations the UPS has. Please consult the manufacturer for ordering the cable with the required types of terminations. 6.1.1. Battery Connection The battery connection is made at the bottom of the PDA using a simple 6-pole snap-on battery connector. The corresponding cable and batteries can be obtained from your PDA dealer. 6.1.2. UPS Connection The UPS connection is made at the top rear of the PDA. This connection is an 8- pole snap-on cable and can be obtained from your PDA dealer. 23
7. Technical Data VOLTAGE PHASES/POLES CURRENT RATING OTHER Utility (AC) Service 120VAC 1 Phase 30A - Main Breaker 120VAC 1 Pole 30A Generator Connection 120VAC 1 Phase 20A Generator Transfer Switch 120VAC DPDT 30A Automatic Maintenance Bypass 120VAC - 15A 10kA Interrupt (22kA optional) 10kA Interrupt (22kA optional) 10kA Interrupt (22kA optional) 10kA Interrupt (22kA optional) UPS AC Connection 120VAC 1 Phase 15A - UPS DC & Battery Connection 72VDC MAX - - 1500 Watts Max Temperature Rating -40 C to +74 C, Non-Condensing, Sea Level 24
8. Contact Information 8.1. Additional Purchases or Upgrades Always On UPS Systems Inc. Bldg 1 150 Campion Road, Kelowna, BC, Canada, V1X 7S8 Phone: (250) 491-9777 Ext 451 Fax: (250) 491-9775 Email: sales@alwayson.com Website: www.alwayson.com 8.2. QA / Warranty Questions Always On UPS Systems Inc. Bldg 1 150 Campion Road, Kelowna, BC, Canada, V1X 7S8 Phone: (250) 491-9777 Ext 209 Fax: (250) 491-9775 Email: qa@alwayson.com Website: www.alwayson.com 8.3. Software Questions Always On UPS Systems Inc. Bldg 1 150 Campion Road, Kelowna, BC, Canada, V1X 7S8 Phone: (250) 491-9777 Ext 204 Fax: (250) 491-9775 Email: webmaster@alwayson.com Website: www.alwayson.com 25