Alpha Technologies Novus 1800TP Installation And Operator's Manual

Brand: Alpha Technologies

Model: Novus 1800TP

Category: Uninterruptible power supplies (UPSs)

Type: Installation And Operator's Manual

1800TP

Uninterruptible Power Supplies

From Alpha Technologies

!Installation and Operator’s Manual

www.alpha.com

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Returning a Unit to Alpha for Repair

Alpha Technologies does not assume responsibility for damage caused by

improper packaging of returned units.

Before returning a unit for repair, obtain a Return Material Authorization (RMA) number from Alpha’s customer service

department. Clearly write it on the original shipping container. If you do not have the container, pack the replacement

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prepaid and insured (COD and freight collect cannot be accepted).

+44-1279-501110

!Installation and Operator’s Manual

!Novus 1800TP

Traffic Light Power Backup

Alpha Technologies

Table of Contents

1. Introduction.............................. 1

1.1 Safety Checklists..................................... 2

1.2 Unpacking and Inspection Checklist......... 4

1.3 The Novus 1800TP UPS Front Panel ........ 5

1.4 Automatic Transfer Switch (ATS) System 11

1.5 Manual Bypass Switch (MBP) System .. 13

1.6 Manual Bypass Module (MBM) System . 15

2. Installation and Start Up ....... 17

2.1 Site Preparation Checklist......................18

2.2 Wiring the ATS System .......................... 20

2.3 Starting and Testing the ATS System ..... 23

2.4 Wiring the MBP System ........................ 25

2.5 Starting and Testing the MBP System .... 27

2.6 Wiring the MBM System........................30

2.7 Starting and Testing the MBM System ...32

3. UPS Operation ....................... 34

3.1 Turning the UPS On or Off...................... 35

3.2 Testing the UPS .....................................37

3.3 Replacing the Batteries .......................... 38

3.4 UPS Operating Modes ........................... 39

3.5 The LCD Panel and the Menu Tree ......... 41

3.6 Controlling the UPS................................ 43

3.7 Measuring Input and Output Values........ 45

3.8 Troubleshooting Faults ...........................47

The emergency shutdown procedure is on the inside rear cover

3.9 Troubleshooting Alarms ..........................48

3.10 Battery Discharge States .....................49

4. Communication ......................50

4.1 Wiring the RS-232 Port ..........................51

4.2 HyperTerminal Set Up ............................ 52

4.3 Programming the UPS ........................... 56

4.4 Using the Event Log ............................... 58

4.5 Using the Main Menu .............................59

4.6 Measuring UPS Inputs, Outputs and Specifi-

cations.......................................................... 63

4.7 Controlling the UPS................................ 64

4.8 Input Voltage Parameters .......................66

4.9 Using the Menu Screens........................ 68

5. Maintenance ...........................70

5.1 Measuring the Battery Backup Time ...... 71

5.2 Troubleshooting ......................................72

5.3 Removing System Components ............. 74

Specifications ..............................78

Index .............................................82

Warranty .......................................90

Introduction to this manual:

The Novus 1800TP system provides power backup to traffic light systems. It consists of the Novus 1800TP

Uninterruptible Power Supply (UPS) and it’s batteries. A detailed description of the front panel is given in

Section 1.3 while instructions on how to operate it are given in Sections 3 and 4.

For connection to line power and the loads, one of three transfer switches is used.

• The Automatic Transfer Switch (ATS) (Section 1.4).

• The Manual Bypass Switch (MBP), (Section 1.5).

• The Manual Bypass Module (MBM), (Section 1.6).

You should read Section 1.3 on the UPS module and the section on your transfer switch before starting

installation and operation.

Novus 1800TP

Save This Manual

It contains important installation and operating instructions.

Keep it in a safe place.

NOTICE:

The Novus 1800TP generates, uses and can radiate radio frequencies if not installed and tested in

accordance with the instructions contained in this manual. It has been tested and found to comply

with the limits established for a Class A computing device pursuant to part 15 of FCC rules when it is

operated alone. It also complies with the radio interference regulations of DOC which are designed to

provide reasonable protection against such interference when this type of equipment is used in a

commercial environment. If there is interference to radio or TV reception, which is determined by

switching it on and off, relocate the equipment or use an electrical circuit other than the one used by

the Novus 1800TP.

To reduce the risk of electrical shock and to ensure the safe operation of the Novus 1800TP

System, these symbols are used throughout this manual. Where they appear only qualified

personnel should carry out the instructions.

A dangerous voltage exists in this area. Use extreme caution.

Attention: Important operating instructions. Follow them exactly.

Danger

Risk Of Electrical Shock

Novus 1800TP

Section 1

Introduction

This section introduces the various parts

of the Novus 1800TP system:

• Safety checklists (Section 1.1).

• An unpacking checklist (Section 1.2).

• The 1800TP UPS front panel’s connectors and

controls (Section 1.3).

• The Automatic Transfer Switch (ATS) system

(Section 1.4).

• The Manual Bypass Switch (MBP) system

(Section 1.5).

• The Manual Bypass Module (MBM) system

(Section 1.6).

1 Introduction 2

Alpha Technologies

1.1 Safety Checklists

1.1.1 Safety Checklist

This system is to be installed by people trained in the safe use of high-en-

ergy power supplies and their batteries. Also assumed is knowledge of the

local electrical code(s) and their safe application.

DANGER: NEVER let rain, a sprinkler’s output, road splash or other

sources of water enter the enclosure when it is open to prevent accidental

shorts, shocks or electrocutions.

Do not work alone under hazardous conditions.

Read this manual. If you have any questions about the safe installation, operation or mainte-

nance of this system, contact Alpha Technologies’s customer service department.

Carefully unpack system components. Report any shipping or other damage at once.

Always assume electrical connections or conductors are live. Turn off all circuit breakers

and double-check with a voltmeter before doing any installation or maintenance.

Before installation, verify the input voltage and current requirements of the load are

compatible with the system’s output. Also verify the line voltage and current are compatible

with the system’s input requirements.

Place a warning label on the enclosure to tell emergency personnel an Uninterruptible

Power Supply (UPS) is installed.

Use proper lifting techniques when lifting or moving the system or its components.

The system has more than one live circuit. AC power may be present at the outputs even if

the system is disconnected from line or battery power.

31 Introduction

Alpha Technologies

1.1 Safety Checklists (Continued)

1.1.2 Battery Safety Checklist

Battery Emergency Procedures

If electrolyte splashes on your skin, immediately wash the affected area

with water. If electrolyte gets into your eyes, wash them for at least 10

minutes with clean running water or a special neutralizing eye wash

solution. Seek medical attention at once.

Neutralize spilled electrolyte with special neutralizing solutions in a “spill

kit” or a solution of 1 lb. (0.45 kg) of baking soda (bicarbonate of soda) in 1

gallon (3.9 L) of water.

Never let live battery wires touch the enclosure or any other metal objects. This can cause a

fire or explosion.

Lead-acid batteries can release Hydrogen gas. Never have open flames or sparks near

the enclosure.

Inspect the batteries once a year for signs of cracks, leaks or swells. Replace as needed.

If you have batteries in storage, charge them at least once every three months for

optimum performance and to extend their lifetime.

Always replace batteries with ones of identical type and rating. Never install old or un-

tested batteries.

Always use insulated tools.

Remove all rings, watches, jewelry or other metal items before working inside the enclosure

or doing maintenance on the system.

Follow local regulations for battery disposal. Recycling is the best method.

Never burn batteries to dispose of them. They may explode.

Never open the batteries. The contents are toxic.

1 Introduction 4

Alpha Technologies

1.2 Unpacking and Inspection Checklist

TIP: If items are missing or damaged, contact Alpha Technologies and the

shipping company at once. Most shippers have a short claim period.

Carefully remove the unit from the shipping container. Inspect the contents and make sure the

following items are included:

1 Novus 1800TP UPS.

1, 2 position terminal block for the 48 VDC output power.

1 temperature sensor cable.

2 cable tie wraps.

1 Novus 1800TP Operator’s Manual.

Any ordered options.

If ordered from Alpha, the batteries, ATS, MBP or MBM are shipped separately.

Save The Shipping Container

To return the 1800TP for servicing, pack it in the shipping container.

Alpha Technologies is not responsible for damage caused by im-

proper packaging of returned units.

Read This Manual

Before installation become familiar with the 1800TP by reviewing the

procedures and drawings in this manual. If you have any questions

about the safe installation, operation or maintenance of this unit, con-

tact Alpha’s customer service department.

51 Introduction

Alpha Technologies

1.3 The Novus 1800TP UPS Front Panel

1.3.1: Battery Connections and LCD Panel

48V Battery Connector

It connects the battery to the unit. The battery string voltage is 48 VDC.

Battery Circuit Breaker

It acts as an ON/OFF switch for battery power. It must be turned on for normal UPS

operation.

Battery Voltage Test Points

These measure the battery’s voltage. To use them, the battery circuit breaker must be

turned on .

TIP: It is not a power outlet.

Liquid Crystal Display (LCD) Control Panel

It controls the unit. Information on its use is given in Section 3.5, “The LCD Panel and the

Menu Tree.”

Figure 1.3.1

Novus 1800TP Front Panel

Figure 1.3.2

Battery Connections and LCD Panel

1 Introduction 6

Alpha Technologies

1.3 The Novus 1800TP UPS Front Panel (Continued)

Figure 1.3.3

Input/Output Power Connections and Power Switch

1.3.2: Input/Output Power Connections and Power On/Off Switch

AC Input & Output Circuit Breaker

It acts as an input and output power on/off switch to facilitate the unit’s maintenance or

replacement. It must be in the on position for normal operation.

TIP: When this breaker is turned off, an auxiliary switch opens, disabling the On Batt relay in the terminal block

(see Section 1.3.4, “On Batt”).

AC Output

This terminal block and 5–15R receptacle are the unit’s output power connectors. The 5–

15R is the auxiliary output and is circuit breaker protected.

AC Input

This terminal block is the unit’s input power connector.

71 Introduction

Alpha Technologies

1.3 The Novus 1800TP UPS Front Panel (Continued)

Figure 1.3.4

RS–232 Connector

1.3.3: RS–232 Communications

Serial Interface

This DB–9 female connector is used to connect the unit to a host computer for remote

control, monitoring and calibration via RS–232 commands. Its layout and operation is

shown in Figure 1.3.5. A serial cable to connect it to a computer is available from Alpha.

More information on its connection and use is given in Section 4, “Communication.”

The interface is opto–isolated and shares a common ground with the

Status/Self Test Terminal Block.

Isolated

Ground

2345

789

Relays Close On Alarm

Microprocessor

Low Battery

Alarm Service

Alarm

Gnd Rx Tx

Isolated

RS-232 Isolated

+5 Vdc

Opto-

Isolator

Remote Inverter Off or Reset of Novus 1800TP

[Activated by +5 V applied for at least 0.3 sec]

Figure 1.3.5

Serial Interface Operation and Layout

NOTE: 100 mA (Max)

TIPS:

1) The relays maximum

rating are 0.5 Amps at

125 VAC or 110 VDC.

2) For the computer port

pin diagram, see Section

4.1, “Wiring the RS–232

Port,” Figure 4.1.1.

1 Introduction 8

Alpha Technologies

1.3 The Novus 1800TP UPS Front Panel (Continued)

1.3.4: Status/Self Test Terminal Block

Status/Self Test Terminal Block

This terminal block provides communication with the intersection controller, controls the

Automatic Transfer Switch (ATS) and starts the self test.

There are two types of terminal blocks offered as factory installed options: a 19 position

terminal block (Figure 1.3.8) where the relay’s functions cannot be programmed and a 22

postion terminal block (Figure 1.3.9) where the relay’s functions can be programmed with

RS–232 commands (Section 4.3.1, “Programmable Status/Self Test Terminal Block”). The

functions of each contact is described in Figure 1.3.7.

This terminal block is opto–isolated and shares a common ground with the

serial interface

Figure 1.3.6

Status/Self Test Terminal Block

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Figure 1.3.7

Status/Self Test Terminal Block Contacts

91 Introduction

Alpha Technologies

1.3 The Novus 1800TP UPS Front Panel (Continued)

Figure 1.3.9

22-Position Terminal Block Layout and Operation

The unit’s self test

(Section 3.2, “Testing the

UPS”) is started by

shorting these contacts.

You provide the switch.

Microprocessor

SELF

TEST

12 ATS 5

NO 6

ON BATTERY LOW BATTERY

NO 9

C10

NC 11

NO 12

C13

TIMER

NO 15

C16

NC 17

NO 18

C19

ALARM

NO 21

C22

1212

C=Common

NO=Normally Open

NC=Normally Closed

Contacts are rated at

120 V at 1 Amp.

The ATS contract provides a direct

connection to the batteries through

a 3 Amp PCB mounted fuse.

Novus 1800 TP Interior

DEFAULT SETTING SHOWN. CONTACTS C1 TO C6 ARE PROGRAMMABLE VIA RS-232 INTERFACE.

C1 C2 C3 C4 C5 C6

Figure 1.3.8

19-Position Terminal Block Layout and Operation

The unit’s self test

(Section 3.2, “Testing

the UPS”) is started by

shorting these contacts.

You provide the switch.

Microprocessor

Novus 1800 TP Interior

C=Common

NC=Normally Closed

NO=Normally Open

Contacts are rated at

120V at 1 Amp.

The ATS contact provides a direct

connection to the batteries throu

a 3 Amp PCB mounted fuse.

NC 3

1 to 3

ON BATT

NC 6

NO 7

NC 9

4 to 9

LOW BATTERY 10 to 15

TIMER

C11

NC 12

NO 13

C14

NC 15

NO 16 17

SELF

TEST

18 & 19

ATS

18 19

1 Introduction 10

Alpha Technologies

1.3 The Novus 1800TP UPS Front Panel (Continued)

1.3.5: Temperature Control Connections

Internal Fan

This microprocessor-controlled fan regulates the unit’s internal temperature. It must not be

blocked. The filter in front of the fan is removable.

TIP: Inspect the filter every 6 months, or as often as required. Clean by removing it, running water through the

filter and air-drying before reinstallation.

DC Out

It provides DC power (48 Vdc, 4 Amp (Max)) that can be used to power an optional 48 Vdc

enclosure fan which regulates the enclosure’s interior temperature.

Battery Temp Sensor

It attaches the battery temperature probe to the unit for battery temperature monitoring. The

charging voltage is temperature dependent and the unit’s microprocessor adjusts the volt-

age for optimum charging.

The probe must be attached for normal operation. The sensor end should be firmly attached

to the case of the center battery with high strength flameproof tape.

Battery Temperature Sensor Strain Relief

This secures the Battery Temperature Sensor Cord to the front panel and prevents connec-

tor disconnection during an Earthquake or other severe vibrations.

First attach the sensor cable to the connector. Then use one of the ties provided in the

mounting kit to attach the sensor cord to the strain relief loop. Ensure that the tie is

tightened.

Figure 1.3.10

Temperature Control Connections

11 1 Introduction

Alpha Technologies

1.4 Automatic Transfer Switch (ATS) System

1.4.1: Automatic Transfer Switch System Description

The ATS system automatically provides backup power to the loads. See Figure 1.4.1 for a

system block diagram. The ATS also allows for loads rated higher than the UPS can supply. The

ATS is the outlet for the UPS’s output power if line power is unqualified.

The ATS’s maximum input current is 40 Amps. Line power is connected to the ATS’s input

(Figure 1.4.2). When the line is qualified, it is sent to the loads.

When the line is unqualified, the UPS controller detects this and sends a signal via the control

line to the ATS, causing an internal contactor to transfer the load from the line to the UPS’s

output. Backup battery power is provided to the loads until the line is qualified or the batteries

are discharged.

For installation and start up instructions, see Sections 2.2 and 2.3.

Figure 1.4.1

Simplified Block Diagram for the Novus 1800TP System With Automatic Transfer Switch

Automatic Transfer Switch

(ATS)

Utility Line

(Line is Qualified)

Power

Upstream Circuit Breaker Downstream Circuit Breaker

(If used)

Power From UPS

(Line is Unqualified)

UPS Line

Monitoring Circuit

Output

Power Control

Line Status/Self Test

Terminal Block

To Intersection Controller

Flash Control Point

Line Power Input

(40 Amps Maximum)

Output Power to Loads

Batteries

Novus 1800TP

(Backup power)

1 Introduction 12

Alpha Technologies

1.4.2: Automatic Transfer Switch

The line power and the loads are connected to this terminal block. The Ground and Neutral

are used for the ATS receptacle only. The terminal block neutral is rated at 15 Amps (Max).

The line power is connected to this end of the terminal block.

The load is connected to this end of the terminal block.

The optional Alpha Technologies LA–P surge suppressor is plugged into this connector.

The optional battery heater mat is plugged into this connector.

This cord is wired into the Novus 1800TP’s AC Output terminal blocks.

These two control wires are attached to the “ATS” portion of the Novus 1800TP’s Status/

Self Test terminal block (TIP: They are color coded. See Section 2.2, Step 2).

This cord is wired into the Novus 1800TP’s AC Input terminal block.

This circuit breaker provides input power protection for the Novus 1800TP.

This circuit breaker provides protection for the secondary outputs (4 and 5).

Figure 1.4.2

Automatic Transfer Switch Front Panel

OPTIONAL

BATTERY

HEATER

MAT

UPS OUT

BYPASS

CONTROL

(48 VDC)

UPS IN

UPS

INPUT

OUTPUT

RECEPT.

OPTIONAL

LA-P

NEUT

GND

OUT

OFF ON

9810

TIP: Mount the

ATS as shown with

the top side up.

1.4 Automatic Transfer Switch (ATS) System (Continued)

13 1 Introduction

Alpha Technologies

1.5 Manual Bypass Switch (MBP) System

1.5.1: Manual Bypass Switch System Description

The UPS must be set to Bypass mode before the switch is turned to bypass

or the UPS’s internal fuse may blow. See Section 3.6, “Bypass.”

The MBP (Figure 1.5.2) allows the UPS to be removed for replacement or maintenance without

turning off power to the loads. See Figure 1.5.1 for a block diagram of the system. Line power is

connected to the MBP’s input. Its output is connected to the load. The MBP’s maximum input

current is 20 Amps.

When the break-before-make rotary switch is turned to:

•Bypass, line power is connected to the loads and disconnected from the UPS (NOTE:

neutral is still connected). This setting is used to remove the UPS for maintenance or

replacement.

•Transfer, line power is provided both to the load and the UPS. This setting is used to

start and test the UPS without having to interrupt power to the load.

•UPS, the UPS is connected to line power and its output is connected to the load.

For installation and start up instructions, see Sections 2.4 and 2.5.

Figure 1.5.1

Simplified Block Diagram for the Novus 1800TP System With Manual Bypass Switch

Manual Bypass Switch (MBP)

Load

Line Power Input

(20 Amps Maximum)

UPSTREAM

CIRCUIT

BREAKER

Novus 1800TP Controller

(Backup Power)

BYPASS

TO INTERSECTION CONTROLLER

FLASH CONTROL POINT

Batteries

STATUS/SELF TEST

TERMINAL BLOCK

UPS

TRANSFER

System Power Ouput

BYPASS

UPS

TRANSFER

DOWNSTREAM

CIRCUIT

BREAKER

(If Used)

1 Introduction 14

Alpha Technologies

1.5 Manual Bypass Switch (MBP) System (Continued)

1.5.2: Manual Bypass Switch

This break-before-make rotary switch toggles the MBP between Bypass, Transfer and

UPS.

Line power is connected to this end of the terminal block.

The UPS’s input is connected to this end of the terminal block.

The loads are connected to this end of the terminal block.

The UPS’s output is connected to this end of the terminal block.

This thermal circuit breaker provides input power protection for the Novus 1800TP.

This thermal circuit breaker provides protection for the secondary outputs (8 and 9).

The optional battery heater mat is plugged into this connector.

The optional Alpha Technologies LA–P surge suppressor is plugged into this connector.

Figure 1.5.2

Manual Bypass Switch Front Panel

TRANSFER UPS

BYPASS

15 1 Introduction

Alpha Technologies

1.6 Manual Bypass Module (MBM) System

1.6.1: Manual Bypass Module System Description

The UPS must be set to Bypass mode before the switch is turned to Line/

Transfer or the UPS’s internal fuse may blow. See Section 3.6, “Bypass.”

The MBM (Figure 1.6.2) allows the UPS to be removed for replacement or maintenance without

turning off power to the loads. See Figure 1.6.1 for a block diagram of the system. Line power is

connected to the MBM’s input and its output is connected to the load. The MBM’s maximum

input current is 20 Amps.

When the break-before-make rotary switch is turned to:

•Line/Transfer:

If CB1 is off; line power is connected to the loads and disconnected from the UPS (NOTE: neutral is

still connected). This setting is used to remove the UPS for maintenance or replacement.

If CB1 is on; line power is provided both to the load and the UPS. This setting is used to start and

test the UPS without having to interrupt power to the load.

•UPS, the UPS is connected to line power and its output is connected to the load.

For installation and start up instructions, see Sections 2.6 and 2.7.

Figure 1.6.1

Simplified Block Diagram for the Novus 1800TP System With Manual Bypass Module

Manual Bypass Module (MBM)

Load

Line Power Input

(20 Amps Maximum)

UPSTREAM

CIRCUIT

BREAKER

Novus 1800TP Controller

(Backup Power)

TO INTERSECTION CONTROLLER

FLASH CONTROL POINT

Batteries

STATUS/SELF TEST

TERMINAL BLOCK

UPS

LINE/TRANSFER

System Power Ouput

DOWNSTREAM

CIRCUIT

BREAKER

(If Used)

CB1

LINE/

TRANSFER

UPS

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Alpha Technologies Novus 1800TP Installation And Operator's Manual

Brand: Alpha Technologies

Model: Novus 1800TP

Category: Uninterruptible power supplies (UPSs)

Type: Installation And Operator's Manual

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Alpha Technologies Novus 1800TP Installation And Operator's Manual

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