User & Service Manual PD SERIES CONTINUOUS POWER SYSTEM MODELS COVERED: SP1250PD SP1250PD (PLUS) SP2000PD CLARY CORPORATION 150 E. Huntington Drive Monrovia, California 91016 Telephone 626-359-4486 800-44 CLARY Fax. 626-305-0254 World Wide Web HTTP: // WWW.CLARY.COM E-Mail SALES @ CLARY.
THE CONTINUOUS POWER COMPANY TABLE OF CONTENTS 1 GENERAL DESCRIPTION ......................................................................................... 5 1.1 1.2 1.3 1.4 2 GENERAL CHARACTERISTICS ............................................................................. 14 2.1 2.2 3 Introduction .................................................................................................................... 27 Normal Mode ...................................................................
THE CONTINUOUS POWER COMPANY LIST OF FIGURES Figure 1: FRONT PANEL VIEW (N).................................................................................... 9 Figure 2: BYPASS BOX ...................................................................................................... 12 Figure 3: BYPASS BOX with GFCI Option ...................................................................... 13 Figure 3: UPS TO CABINET INTERCONNECTIONS....................................................
THE CONTINUOUS POWER COMPANY “IMPORTANT SAFETY INSTRUCTIONS” “SAVE THESE INSTRUCTIONS” This manual contains important safety instructions that should be followed during installation and maintenance of the UPS and batteries. The instructions should be followed during installation and maintenance of the UPS and batteries.
THE CONTINUOUS POWER COMPANY 1 GENERAL DESCRIPTION 1.1 Introduction You have selected the highest quality power protection system available for your traffic control devices. You now own a PD Series Traffic UPS (Uninterruptible Power System) with a programmable LCD display. The PD Series is an all Digital Technology UPS product designed and manufactured by Clary Corporation, the first name in UPS reliability.
THE CONTINUOUS POWER COMPANY 1.2 Operating Modes Clary’s PD Series Uninterruptible Power Systems (UPS) are designed for powering low power (i.e., LED & NEON) traffic & pedestrian indications, plus critical traffic control devices (i.e., controllers, modems, CMU’s, etc.). The power system consists of three elements, which work together to provide critical loads with continuous, conditioned, regulated, sinusoidal waveform power that is free from disturbances such as spikes, surges, brownouts or blackouts.
THE CONTINUOUS POWER COMPANY When utility power returns, (or upon application of generator power) the PD Series UPS waits 30 seconds to be sure that the utility power has stabilized. After this built-in safety delay utility power is restored to the cabinet. The battery charger then recharges the batteries in typically 10 to 20 times (depending on the load) the duration of the outage or battery discharge time (whichever is shorter). The UPS can be set to force a break in power of 2.
THE CONTINUOUS POWER COMPANY 1.3 Physical Description This section will point out and illustrate the various indicators, functions and controls of the PD Series UPS. The important attributes of the PD Series unit are numbered to assist you in locating them on your machine and also to fully explain its function and how it relates to system operation. Numbers on the drawing will correspond to the operating component’s name at the bottom with a brief identification.
THE CONTINUOUS POWER COMPANY Table 1 describes items 1 – 22.
THE CONTINUOUS POWER COMPANY Table 1: FIGURE 1 DESCRIPTIONS PANEL VIEW DESCRIPTIONS 1 SYSTEM POWER SWITCH 12 DC INPUT – Protection circuit breaker for battery 2 INPUT AC LINE BREAKER 13 DC IN – Input receptacle for all DC power (to Batteries) 3 LCD DISPLAY 14 AC IN / OUT – Input terminal block for all AC power to Bypass Box 4 SELECT/MENU MODE 15 RELAYS – NO/NC Contacts for Flash 5 ENTER/SHOW TIME 16 BATTERY TEST POINTS 6 UP ARROW + 17 AUX. TEMP. SENSOR – Input for Optional Aux.
THE CONTINUOUS POWER COMPANY SUMMARY OF INDICATORS AND CONTROLS SYSTEM POWER SWITCH - The main control switch that engages utility power to the entire unit. By activating this switch it initializes normal operation. DC INPUT - A two pole, 20A (25A for SP1250PD (PLUS) & SP2000PD) circuit breaker used to connect the battery to the internal UPS electronics. It also protects against over-current situations in the battery circuit.
THE CONTINUOUS POWER COMPANY 1.
THE CONTINUOUS POWER COMPANY Figure 3: BYPASS BOX with GFCI Option 11 10 1 2 1 – To Utility - H 2 – To Utility - N 3 – To UPS IN - H 4 – To UPS IN - N 5 – To UPS OUT - H 6 – To UPS OUT - N 3 4 5 6 7 8 7 – To CABINET - H 8 – To UPS OUT - N 9 - Generator Input (Optional) 10 - GFCI Outlet (Optional) 11 - Circuit Breaker for GFCI Table 3: BYPASS BOX DESCRIPTIONS 13 9
THE CONTINUOUS POWER COMPANY 2 GENERAL CHARACTERISTICS 2.1 Characteristics Overview The Clary PD Series Traffic UPS is a turnkey, true on-line, power conditioner and battery backup or uninterruptible power system (UPS) designed for the extreme environments found in traffic cabinets (-40 to + 74 deg C). The Clary PD Series, with its standard 41Ahr battery pack, is capable of operating, a full LED intersection for over 2 hours at 700W (watts) output.
THE CONTINUOUS POWER COMPANY Utility Voltage Windows and Battery Operation The UPS operates from utility if the utility voltage is between 85 and 135 VAC. When the utility falls below 85 VAC or climbs above 135 VAC the UPS operates from the batteries. In the Standby modes of operation, the UPS relay is activated when the utility is below 100 +/- 2 VAC or above 130 +/-2 VAC. There is a programmable noise rejection window, which specifies how the UPS system treats small time-duration power glitches.
THE CONTINUOUS POWER COMPANY The batteries are provided with appropriate interconnect wiring harness. Optional battery mounting trays and brackets are available. The interconnect cable connects to the base module via a quick-release circular connector. The UPS module includes a charger that replenishes the Battery Pack whenever possible and required. This charger operates with a maximum charging current of 0.6A.
THE CONTINUOUS POWER COMPANY 2.2 Specifications The various specifications of the UPS system are provided in the following tables. Table 4: ELECTRICAL SPECIFICATIONS Electrical Specifications Input Specification Nominal Input Voltage 120 VAC, Single Phase Input Voltage Range 85 VAC to 135 VAC Input Frequency 45 to 65 Hz (+/- 5%) Input Configuration 3 Wire (Hot, Neutral & Ground) Input Current (Max. draw) 8.
THE CONTINUOUS POWER COMPANY Table 5: Physical Specifications, UPS Electronics Module Physical Specifications, UPS Electronics Module Dimensions: Width = 19”, Depth = 10”, Height = 6” Weight: UPS: 20 lbs., Shipping weight: 25 lbs. Table 6: PHYSICAL SPECIFICATIONS Physical Specifications, Bypass Box Dimensions: Width = 7”, Depth =2.5”, Height =4.5” Weight: BYPASS BOX: 5 lbs., Shipping weight: 5 lbs. Table 7: ENVIRONMENTAL SPECIFICATIONS Environmental Specifications Temperature: - 40°C to +74°C.
THE CONTINUOUS POWER COMPANY Table 9: CLARY OutPostTM BATTERIES* Estimated Runtime (Per set @ 77°F / 25°C) (New Batteries, fully charged) Clary Volts/ Part. No.* A-hrs. OP72C (Set of Six Batteries) 12 VDC/ 300 Watts 6.5 500 700 875 Watts Watts Watts 4.0 2.5 1.8 Hrs.** Hrs.** Hrs.** Hrs.** Unit Weight Overall Dimensions Per Battery Inches (cm.) Lbs. Length Width Height (Kg.) L W H 29 7.68 5.15 7.9 (13.2) (19.6) (13.1) (20.
THE CONTINUOUS POWER COMPANY 3 INSTALLATION AND OPERATIONS 3.1 Installation The UPS system is typically rack or shelf mounted in standard traffic cabinets. When determining how to position the UPS system inside your cabinet, the following requirements MUST be met. • The installation site MUST maintain an ambient air temperature of less than 165oF (74oC). • The air inlets, vents and fan MUST NOT be obstructed or blocked in any way. There MUST BE clearance around each air-inlet and vent.
THE CONTINUOUS POWER COMPANY • • • • • Unpack and ensure that all UPS System components are on-hand and operative: o UPS System Module o (Bypass Box) o Battery Module (6 batteries w/cabling) Collect appropriate mounting hardware for the particular installation. o For 170/332 cabinets only, one or two battery trays (per shipping documents, depends on version purchased) Assemble your tools and inventory your equipment. Table 10 is a checklist of items that have proved useful during previous installations.
THE CONTINUOUS POWER COMPANY 3.3 Procedure The recommended installation procedure is presented in Table 11 . The Table refers to, which presents a schematic wiring diagram. Read through the entire procedure before beginning. If any steps are unclear, do not begin the installation process – please contact Clary Corporation for assistance. Finish each step completely before continuing to the next. See Figure 4 for diagram. Table 11: TYPICAL INSTALLATION PROCEDURE FOR TRAFFIC UPS 1.
THE CONTINUOUS POWER COMPANY 3.4 Operating Configuration and Setup: Figure 3 shows how the UPS System is connected to the traffic cabinet. This schematic diagram illustrates the interconnections.
THE CONTINUOUS POWER COMPANY 3.5 Start-up Once the system has been properly installed, it is ready to operate. The following procedures will explain how to start-up the system while wired into rated electrical power and also how to start-up with no AC power available. Normal Operation on AC Start-Up: • Verify that the unit is wired into properly rated electrical power through the Bypass Box. • The AC IN and DC IN cables must be fully connected to the unit. Position the DC breaker to the ON position.
THE CONTINUOUS POWER COMPANY The unit will start up similarly to normal AC start-up except the Alarm LED will continue to blink. It will now operate as described above in battery operation. 3.6 Optional Communication Procedure The UPS system includes additional interfaces for communications to host computers or other similar devices. Their use is optional, but allows for remote monitoring and control of the power system.
THE CONTINUOUS POWER COMPANY SIGNAL PORT 2- AC INPUT FAIL/FLASH TIMER 3- UPS ON RS232 PORT 1- LOW BATTERY 2- TX 4568- 34568- COMMON SIGNAL RETURN LOW BATTERY +9VDC +9VDC SIGNAL: DB-9 CONNECTOR RX RS232 SHUTDOWN GROUND +9V AC FAIL RS232: DB-9 CONNECTOR Figure 5: SIGNAL/RS232 PIN ASSIGNMENTS 26
THE CONTINUOUS POWER COMPANY 4 PROGRAMMABLE LCD DISPLAY 4.1 Introduction The LCD display on the UPS front panel is used to show various operational parameters of the UPS (in real time) as well as other important system information. It is also used to program options and set points for many UPS functions. The LCD display operates in two main modes: 1. Normal Mode - The default mode of operation for displaying real time UPS parameters.
THE CONTINUOUS POWER COMPANY 4.2 Normal Mode The Normal mode’s main screen shows the Load and Battery percentage, AC input status and Inverter status. The Normal mode display will look something like the following. LOAD 50% BATT 90% AC LINE BAD, INV ON To see the time and date, press the ENTER/SHOW TIME button. LOAD 50% BATT 90% mm/dd/yy hh:mm:ss 4.3 Battery System Status STATUS: BATTERY Syst Once at this screen, press the ENTER/SHOW TIME button.
THE CONTINUOUS POWER COMPANY St23: Estim Bat Time 10 minutes Shows estimated time remaining when UPS is running on Battery Power. St24: Bat Condition Battery is GOOD! Shows condition of the Batteries. St25: Bat Install mm/dd/yyyy Shows Battery installation date. Can only be set to the current date. To reset, press and hold both the UP and Down Arrow buttons simultaneously until it resets to the current date. St26: Battery Type 72 Volts ??Ahr Shows the nominal battery voltage and the battery Amp hours.
THE CONTINUOUS POWER COMPANY 4.4 Power System Status STATUS: POWER System Once at this screen, press the ENTER/SHOW TIME button. Then press the SELECT/MENU MODE button to go through the Battery System Status menu. St30: Input Line Pwr 115Vrms 60Hz 1.5A Shows the Input line power Voltage, Frequency and Current going into the UPS. St31: Output Pwr Src UTILITY Shows the power source which the UPS is currently running off of (UTILITY or BATTERY).
THE CONTINUOUS POWER COMPANY 4.5 UPS System Status STATUS: UPS SYSTEM Once at this screen, press the ENTER/SHOW TIME button. Then press the SELECT/MENU MODE button to go through the Battery System Status menu. St40: Operating Mode NORMAL Shows the operating status of the UPS (NORMAL, BACKUP,……..etc). St41: Alarm Status 1 ALARM Shows the Alarm status and number of alarms which are currently active (OVERTEMP, OVERLOAD, OUTPUT BAD, GENFAIL, INPUT IS BAD,………...etc).
THE CONTINUOUS POWER COMPANY 4.6 UPS Information Status: UPS Info Once at this screen, press the ENTER/SHOW TIME button. Then press the SELECT/MENU MODE button to go through the UPS Information menu. St50: UPS Model # SP1250I Shows UPS Model# St51: UPS Pwr Rating 1250VA Shows UPS power rating in VA. St52: UPS Firmware 86501-35.301 Shows the type and revision of the UPS firmware(EPROM) installed in the unit.
THE CONTINUOUS POWER COMPANY 4.7 Event Log Status: EVENT LOG’s Displays a history of the most recent 100 logged events. Once at this screen, press the ENTER/SHOW TIME button. Then press the SELECT/MENU MODE button to go to the logs. LOG# 100 AC FAIL mm/dd/yy hh/mm/ss Use the Arrow Keys to scroll through the logs. Press and hold both the up and down arrow keys simultaneously to clear all the event logs. 4.
THE CONTINUOUS POWER COMPANY FLASH TRIGGER (VOLT) current value = 69 This is the battery voltage that specifies the trip point that activates the Low Battery NO/NC contacts on the UPS. Used for delayed flash. To Change the value, press the arrow buttons. Once at the desired value, press the Enter/Show Time button to save. The screen will now show the new value. Default is 69. BATTERY TEST (HOURS) current value = 160 This will set the Battery Test Interval.
THE CONTINUOUS POWER COMPANY LONG RETURN ALWAYS current value = OFF This option is used in the “Standby Mode”. When “ON”, the UPS will force a break in power to the cabinet for 2.5 seconds after utility power has returned. This is used when you need a hard restart to the controller when coming out of flash. To Change the value, press the arrow buttons. Once at the desired value, press the Enter/Show Time button to save.
THE CONTINUOUS POWER COMPANY BROWNOUT PROTECTION current value = ON This feature is used only in the standby mode. The brownout protection feature allows the UPS to switch to inverter power from utility power to the cabinet without running off of batteries when utility power is experiencing certain brownout conditions. When the input voltage falls below 100VAC ±2V or rises above 130VAC ±2V, the UPS switches over to inverter power but is still running off of the utility power.
THE CONTINUOUS POWER COMPANY 4.10 Relays Status: RELAY’s Once at this screen, press the ENTER/SHOW TIME button. Then press the SELECT/MENU MODE button to go through the three main Relay menus. 4.10.1 ASSIGN RULE TO RELAY SEE TABLES 12 & 13 FOR DETAILED RULE DESCRIPTIONS AND ALARMS/FAULTS. ASSIGN RULE to RELAY This menu allows you to select a “Rule” for each of the eight relays. Once at this screen, press the ENTER/SHOW TIME button. To scroll thru the eight relays, press the SELECT/MENU MODE button.
THE CONTINUOUS POWER COMPANY 4.10.2 MODIFY RULE PARAMETERS MODIFY RULE PARAM’s This menu allows you to change the parameters of each rule. Once at this screen, press the ENTER/SHOW TIME button. To scroll thru the sixteen “Rules”, press the SELECT/MENU MODE button. RULE 02: LOW_BAT_1 New TRIP PT = 40% Once at the desired “Rule”, press the arrow buttons to set new value for the “Rule”. When finished, press the ENTER/SHOW TIME button.
THE CONTINUOUS POWER COMPANY 4.10.3 TOGGLE RELAY ON/OFF TOGGLE RELAY ON/OFF This menu allows you to manually control the Relays. Once at this screen, press the ENTER/SHOW TIME button. To scroll thru the eight relays, press the SELECT/MENU MODE button. STATE of MANUAL MODE Current state = OFF When the Relay’s Manual mode is off, the current state of each relay can only be read but may not be changed. To manually change the state of a relay, Manual mode must be first activated.
THE CONTINUOUS POWER COMPANY Table 12: LIST OF RULES # Rule 00 Relay Off 01 On_Bat 02 Low_Bat_1 03 Bat_Timer_1 04 Alarms_1 05 Faults_1 06 Low_Bat_2 07 Bat_Timer_2 08 Alarms_2 09 Faults_2 10 Low_Bat_3 11 Bat_Timer_3 12 Alarms_3 13 Faults_3 14 Fan_Ctrl_1 Description Parameters Turns Relay OFF. Activates when UPS is on Battery Mode. Activates when batteries reach user settable capacity level. Activates after user settable time when UPS is in Battery mode. Activates when Alarm conditions occur.
THE CONTINUOUS POWER COMPANY Table 13: ALARMS AND FAULTS Alarms/Faults Heat Sink is Hot Input is bad Output Strange System Overload Bypass Failure Charger Failure Fan Fail Fuse Failure Sleep Alarm General Fault All Outputs Off Shut Off Pending Shut Off Imminent System Shutdown Description Heat Sink on main Board temperature too high. AC input to UPS is not within limits. Bad UPS output. Load is higher than UPS rated load. Bypass Line failed. Charger not functioning properly. Fan not functioning properly.
THE CONTINUOUS POWER COMPANY 5 CARE AND MAINTENANCE 5.1 Safety There are hazardous high voltages and materials present in the UPS system which present safety risks. You MUST follow basic safety procedures when maintaining the UPS. In addition please note the following: ELECTRICAL SAFETY • • • • • Hazardous high voltages are present in this product, which can cause electrical shock. Do not work alone under hazardous conditions. Always wear eye-protection when servicing energized power electronics.
THE CONTINUOUS POWER COMPANY 5.2 Preventive Maintenance CLEANING This device is designed to be maintenance-free. It can be cleaned with a damp cloth or nonabrasive cleanser. WARNING: Do not use ACETONE-BASE cleaning solutions. Keep cleaning solutions out of the electrical receptacles on this device. Be sure filters, vents and fans are kept free from accumulation of dust, dirt or lint.
THE CONTINUOUS POWER COMPANY • • • The batteries used in this equipment are recyclable. Proper disposal is required and mandated by law. The batteries contain lead and pose a hazard to the environment and human health if not dispose of properly. Refer to local codes for proper disposal requirements or return the batteries to the factory. ALWAYS contact the factory for information concerning shipment, disposal, or replacement of batteries.
THE CONTINUOUS POWER COMPANY 5.4 Service and Repair Your PD Series UPS is backed by one of the finest customer service teams available. Write or call them at any time to obtain more information about your unit. Clary Corporation 150 E. Huntington Drive Monrovia, CA 91016 1-800-551-6111 If a problem should occur, it is important that you obtain a Return Material Authorization (RMA) number from the Service Department to process any unit returned to the factory.
THE CONTINUOUS POWER COMPANY 6 SCHEMATICS 46
THE CONTINUOUS POWER COMPANY WARRANTY 1. 2. 3. TIME AND SCOPE OF WARRANTY: 1.1. Clary Corporation hereby warrants parts shipped under this Agreement to be free from defective workmanship for a period of 2 years following date of shipment. Accidental damage, misuse or normal wear and tear shall not be construed as a defect. 1.2. The date of shipment as used herein will be the date on the Bill of Lading. If no Bill of Lading is issued the date of shipment shall be shown on seller's shipping document.
