User & Service Manual SP170-PDA SERIES POWER DISTRIBUTION ASSEMBLY/ CONTINUOUS POWER SYSTEM MODELS COVERED: SP170-PDA/1250 SP170-PDA/1250(PLUS) SP170-PDA/2000 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 Introduction ...................................................................................................................... 5 Operating Modes ............................................................................................................. 6 1.2.1 1.2.2 1.3 2 Characteristics .........................................
THE CONTINUOUS POWER COMPANY LIST OF FIGURES Figure 1: FRONT PANEL VIEW .................................................................................. 10 Figure 2: REAR PANEL VIEW ..................................................................................... 11 Figure 3: SIGNAL/RS232 PIN ASSIGNMENTS........................................................ 25 LIST OF TABLES Table 1: FIGURE 1 (FRONT PANEL) DESCRIPTIONS.........................................
“IMPORTANT SAFETY INSTRUCTIONS” “SAVE THESE INSTRUCTIONS” This manual contains important safety instructions that should be followed during installation and maintenance of the unit and batteries. The instructions should be followed during installation and maintenance of the unit and batteries. Be aware of the following symbols and their meaning as they appear throughout the manual: This symbol indicates that dangerous voltage constituting a risk of electrical shock is present within the unit.
1 GENERAL DESCRIPTION 1.1 Introduction You have selected the highest quality power protection & distribution system available for your traffic control devices. You now own a SP170-PDA Series unit. The SP170-PDA Series is a Power Distribution Assembly (PDA) with a built in all Digital Technology UPS product designed and manufactured by Clary Corporation, the first name in UPS reliability.
1.2 Operating Modes The SP170-PDA is basically made up of two parts, the Power Distribution Assembly and the UPS module. 1.2.1 Power Distribution Assembly (PDA) The Power Distribution Assembly (PDA) is responsible for the input power and provides a 30 Amp Main Circuit Breaker (MCB). The MCB supplies power to the UPS/Cabinet and controller receptacles, the Flasher Bus Circuit Breakers and the Mercury Contactor (MC). The MC is a normally closed mercury contactor rated at 50 Amps.
A Clary Model PDA24 DC power supply is installed into the unit. This module slides in from the front of the unit. It is secured by one 6-32 x 3/8 sems screw. The PDA24 supplies 24VDC to the Rear Panel of the unit. The Front of the PDA24 has two fuses, F1 (3A, 125V) which protects the input of the DC power supply, and F2 (7A, 125V) which protects the output of the PDA24 from accidental overloading.
drawing its power from the battery pack. This operation continues until good utility power is restored, after which, the relays switch back to route the utility power to the PDA module which powers the cabinet. With Standby operation, 0.5 seconds (user programmable from 30ms to 2.5sec) after an outage is detected, standby power is connected to the system and if desired, the Flash Command is initiated, forcing the cabinet into Flash Mode operation.
1.3 Physical Description This section will point out and illustrate the various indicators, functions and controls of the SP170-PDA Series Unit. The important attributes of the SP170-PDA 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.
R 24V D/C TEST + POINT - 24V POWER SUPPLY MODEL PDA24 F2 5A F1 7A Figure 1: FRONT PANEL VIEW 10
T5 T1 N O C C1 N C N O C C2 N C N O C C3 N C N O C C4 N C T6 1 1 2 T2 GND TEMP. SENSOR SNMP SIGNAL T3 RS232 CR +24 +24 GND GND 24V DC BATTERY CONN.
Table 1: FIGURE 1 (FRONT PANEL) DESCRIPTIONS FRONT PANEL VIEW DESCRIPTIONS 1 COLD START – DC start switch 16 SB4 – Signal Circuit Breaker 4, 5A 2 COLD START INDICATOR 17 SB5 – Signal Circuit Breaker 5, 5A 3 ALARM SILENT/TEST – Dual function switch 18 SB6 – Signal Circuit Breaker 6, 5A 4 ALARM SILENT/TEST ACKNOWLEDGE INDICATOR 19 EQUIP – Equipment Circuit Breaker, 15A 5 SYSTEM ON/OFF SWITCH 20 MCB – Main Circuit Breaker, 30A 6 LCD DISPLAY 21 BATTERY TEST POINTS 7 SELECT/MENU MODE 2
Table 2: FIGURE 2 (REAR PANEL) DESCRIPTIONS REAR PANEL VIEW DESCRIPTIONS 1 T4 - AC INPUT 7 CR – CONTROLLER RECEPTACLE 2 BATTERY CONNECTOR 8 T5 – RELAY CONTACTS 3 BATTERY CIRCUIT BREAKER 9 T6 – OPTIONAL EXT TEMP SENSE 4 T1 - TERMINAL BLOCK 10 RS232 PORT 5 T2 - TERMINAL BLOCK 11 SIGNAL PORT 6 T3 - +24V DC 12 OPTIONAL SNMP CARD T1 AND T2 PINOUTS T1-1 GND T1-2 NEUTRAL T1-3 NEUTRAL T1-4 SB5 LINE T1-5 120V LINE T1-6 120V LINE T1-7 FTR T1-8 SB6 LINE T1-9 120V LINE T1-10 GFI LINE T2-1 GFI
SUMMARY OF INDICATORS AND CONTROLS UPS MODULE SYSTEM POWER SWITCH - The main control switch that engages utility power to the UPS module. By activating this switch it initializes normal operation. COLD START - A momentary push-button switch to activate the system in the event no utility power is available. The system will be allowed to start up by using power from the battery. Depress this switch, the indicator above it will light, and hold it in until the audible alarm beeps once.
AUTO/FLASH SWITCH – Switches between the Auto and Flash positions. Will illuminate when in the Flash position. Will also illuminate when any of the SB1-SB6 breakers are turned off or tripped. PDA24 MODULE 24VDC TEST POINTS – Test points to measure the actual voltage of the 24VDC power supply. 24VDC INDICATOR LED – LED that illuminates when PDA24 is operating. F1 – A 7A fuse that protects the 24VDC output. F2 – A 3A fuse that protects the Input power to the PDA24.
2 GENERAL CHARACTERISTICS 2.1 Characteristics Overview The Clary SP170-PDA 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 SP170-PDA, with its standard 41Ahr battery pack, is capable of operating, a full LED intersection for over 2 hours at 700W (watts) output. A typical intersection consuming 450W can be powered for approximately 4 hours.
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.
2.2 Specifications SP170-PDA W/UPS MODULE ELECTRICAL DESIGN Input Voltage Standard Features Power Factor Corrected Input; Fully Regenerative; True On-Line Continuous Power; Low Distortion Sinewave Ouput; Designed for Non-linear Loads; Extended Brownout Protection; EIA/RS232 Data Interface; Specifications Meets FCC Class A, IEEE 120VAC +12%(135VAC), 25%(90VAC) (before battery use) Frequency 48 to 62Hz Current (1250, 1250(PLUS), 2000) 8.8A, 8.8A, 14.3A Power Factor Corrected 587/ANSI C62.
Table 3: 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) (20.1) 41 AH *OP72X battery sets include six (6) batteries per set.
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.
• • • • • Unpack and ensure that all UPS System components are on-hand and operative: o SP170-PDA o UPS MODULE o Battery Module (6 batteries or 8 batteries(2000VA) 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 4 is a checklist of items that have proved useful during previous installations.
3.3 Procedure The recommended installation procedure is presented in Table 5 . 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. Table 5: TYPICAL INSTALLATION PROCEDURE FOR SP170-PDA 1. 2. 3. 4. 5. Mount SP170-PDA in cabinet.
3.4 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. • The DC IN cable must be fully connected to the unit. Position the DC breaker to the ON position.
3.5 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. Effective utilization of these capabilities will enhance the reliability of the traffic power system. There are two DB-9, subminiature, female connectors. These are provided for communications links to a computer or sophisticated monitoring device.
SIGNAL PORT 23- AC INPUT FAIL/FLASH TIMER 4568- COMMON SIGNAL RETURN UPS ON LOW BATTERY +9VDC +9VDC RS232 PORT 1- LOW BATTERY 2- TX 34568- SIGNAL: DB-9 CONNECTOR RX RS232 SHUTDOWN GROUND +9V AC FAIL RS232: DB-9 CONNECTOR Figure 3: SIGNAL/RS232 PIN ASSIGNMENTS 25
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. When left unattended, the display will always revert back to normal mode. 2.
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. Then press the SELECT/MENU MODE button to go through the Battery System Status menu.
St23: BACKUP Events 2 Events Shows number of times UPS went to Battery Power. To clear events, press and hold both the UP and Down Arrow buttons simultaneously until the event count clears. St24: Battery Type 72 Volts 41 Ahr Shows the nominal battery voltage and the battery Amp hours. St25: Battery Ahr ALTER> Ahr = 41 This screen allows the user to enter the Battery Capacity within the range of 10Ahr to 150Ahr. To change Ahr rating, Press Enter. Press the Arrow buttons until the desired rating is displayed.
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).
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, INPUT IS BAD………...etc).
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 Base Model # SP1250I Shows UPS Base Model# St51: UPS User Model My Model # Shows the model of the UPS. To change the model #, Press the enter key. Hold down the Enter, Up Arrow and Down Arrow until display clears. Use the arrow keys to increment to the character you want. Press Enter to go to the next position.
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. 4.8 Options Status: OPTION’s Displays the current system option values and allows selected options to be modified.
FLASH TRIGGER (VOLT) current value = 69 This is the battery voltage that specifies the trip point that activates the Low Battery open collector signal on the Signal port. 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 unit will perform a battery self test to determine the condition of the battery.
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.
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.
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 6 & 7 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.
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.
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.
Table 6: 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 15 Fan_Ctrl_2 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.
Table 7: ALARMS AND FAULTS Alarms/Faults Heat Sink is Hot Input is bad Output is Bad System Overload Bypass Failure Charger Failure Fan Fail Fuse Failure General Failure VAC is Missing 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. Open Fuse in system.
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.
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.
BATTERY RECYCLING • • • 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. Table 9: PREVENTIVE MAINTENANCE SCHEDULE Item Schedule Actions Cleaning 6 Mos.
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.
6 SCHEMATICS 45
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. 1.3.
