Download M1601_Intersection_Traffic_Light_PDA_Manual

“UPS READY”
POWER DISTRIBUTION ASSEMBLY
FOR TRAFFIC CABINETS
with LED Signals
INSTALLATION & OPERATOR’S MANUAL
M1601 - VERSION 1.2
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 [email protected] 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:
______________________________________________________________
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IMPORTANT SAFETY INSTRUCTIONS
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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
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MORE SAFETY INSTRUCTIONS
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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.
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Table of Contents
1.
PRODUCT DESCRIPTION ............................................................................................................ 6
1.1.
1.2.
2.
HANDLING .................................................................................................................................. 10
2.1.
2.2.
3.
OPTIONAL MAIN SERVICE ENTRANCE LOCATION & OPERATION ................................................................... 15
FRONT PANEL LAYOUT.............................................................................................................................. 15
TO TURN OFF AN INDIVIDUAL CIRCUIT ....................................................................................................... 18
GENERATOR MODE / CONNECTING A GENERATOR (GENERATOR OPTION ONLY) .......................................... 18
PLACE PDA IN BYPASS, DISABLE OR AUTO MODE (“UPS READY” OPTION ONLY)......................................... 19
MAINTENANCE .......................................................................................................................... 21
5.1.
5.2.
5.3.
6.
INSTALLING INTO THE CABINET .................................................................................................................. 11
W IRING CONNECTIONS ............................................................................................................................. 12
W IRING TO THE TERMINAL BLOCK.............................................................................................................. 12
OPERATION................................................................................................................................ 15
4.1.
4.2.
4.3.
4.4.
4.5.
5.
DELIVERY ................................................................................................................................................. 10
INITIAL INSPECTION ................................................................................................................................... 10
INSTALLATION ........................................................................................................................... 11
3.1.
3.2.
3.2
4.
SCHEMATIC .................................................................................................................................................7
DESCRIPTION OF OPERATION .......................................................................................................................8
RESET A BREAKER ................................................................................................................................... 21
FUSE REPLACEMENT ................................................................................................................................ 21
AIR GAP LIGHTNING ARRESTOR INSPECTIONS & REPLACEMENT ................................................................. 22
OPTIONAL EXTRAS ................................................................................................................... 23
6.1.
UPS (FOR “UPS READY” PDA) ................................................................................................... 23
7.
TECHNICAL DATA ..................................................................................................................... 24
8.
CONTACT INFORMATION ......................................................................................................... 25
8.1.
8.2.
8.3.
ADDITIONAL PURCHASES OR UPGRADES.................................................................................................... 25
QA / W ARRANTY QUESTIONS .................................................................................................................... 25
SOFTWARE QUESTIONS ............................................................................................................................ 25
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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.
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Schematic
PDA Schematic
1.1.
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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.
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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.
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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.
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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
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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
3.2 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
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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.
WARNING:
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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.
3.2.3. Terminal Block Layout & Termination Diagram
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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.
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Front Panel Location
Sub-Distribution Location; also Generator Transfer Switch, Generator
Breaker & Maintenance Bypass Control Location (if equipped)
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UPS & Bypass Breakers
(“UPS Ready” option, if equipped)
Supplementary Fusing
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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.
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(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.
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Bypass Circuit Details (Optional)
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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.

5.2.


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.
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.
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Replacing a Fuse
5.3.
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
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.
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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 8pole snap-on cable and can be obtained
from your PDA dealer.
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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
UPS AC Connection
120VAC
1 Phase
15A
-
72VDC MAX
-
-
1500 Watts Max
UPS DC & Battery Connection
Temperature Rating
10kA Interrupt
(22kA optional)
10kA Interrupt
(22kA optional)
10kA Interrupt
(22kA optional)
10kA Interrupt
(22kA optional)
-40C to +74C, Non-Condensing, Sea Level
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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: [email protected]
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: [email protected]
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: [email protected]
Website: www.alwayson.com
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