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1800TP
Uninterruptible Power Supplies
From Alpha Technologies
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!Installation and Operator’s Manual
www.alpha.com
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!Installation and Operator’s Manual
!!
!!
!Novus 1800TP
Traffic Light Power Backup
Alpha Technologies
i
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
ii
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
1
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
1
48V Battery Connector
It connects the battery to the unit. The battery string voltage is 48 VDC.
2
Battery Circuit Breaker
It acts as an ON/OFF switch for battery power. It must be turned on for normal UPS
operation.
3
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.
4
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
1
2
34
Figure 1.3.2
Battery Connections and LCD Panel
1 Introduction 6
Alpha Technologies
1.3 The Novus 1800TP UPS Front Panel (Continued)
5
6
7
Figure 1.3.3
Input/Output Power Connections and Power Switch
1.3.2: Input/Output Power Connections and Power On/Off Switch
5
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”).
6
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.
7
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
8
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.
8
Isolated
Ground
1
6
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
9
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
9
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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
+
34
SELF
TEST
12 ATS 5
NO 6
C7
NC
ON BATTERY LOW BATTERY
8
NO 9
C10
NC 11
NO 12
C13
NC
TIMER
14
NO 15
C16
NC 17
NO 18
C19
NC
ALARM
20
NO 21
C22
NC
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
g
h
a 3 Amp PCB mounted fuse.
1
C2
NC 3
NO
1 to 3
ON BATT
4
C5
NC 6
NO 7
C8
NC 9
NO
4 to 9
LOW BATTERY 10 to 15
TIMER
10
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
10
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.
11
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.
12
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.
13
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.
10
11
12
13
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
1
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).
2
The line power is connected to this end of the terminal block.
3
The load is connected to this end of the terminal block.
4
The optional Alpha Technologies LA–P surge suppressor is plugged into this connector.
5
The optional battery heater mat is plugged into this connector.
6
This cord is wired into the Novus 1800TP’s AC Output terminal blocks.
7
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).
8
This cord is wired into the Novus 1800TP’s AC Input terminal block.
9
This circuit breaker provides input power protection for the Novus 1800TP.
10
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
IN
L
L
NEUT
GND
OUT
OFF ON
I
0
9810
TIP: Mount the
ATS as shown with
the top side up.
1
2
3
4
5
6
7
8
9
10
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
1
This break-before-make rotary switch toggles the MBP between Bypass, Transfer and
UPS.
2
Line power is connected to this end of the terminal block.
3
The UPS’s input is connected to this end of the terminal block.
4
The loads are connected to this end of the terminal block.
5
The UPS’s output is connected to this end of the terminal block.
6
This thermal circuit breaker provides input power protection for the Novus 1800TP.
7
This thermal circuit breaker provides protection for the secondary outputs (8 and 9).
8
The optional battery heater mat is plugged into this connector.
9
The optional Alpha Technologies LA–P surge suppressor is plugged into this connector.
Figure 1.5.2
Manual Bypass Switch Front Panel
1
2
3
4
5
67
8
9
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
/
