PCM TC Series User manual

TC SERIES

Wide Temperature Range UPS

TC-650,1100,2000,2500,3000 System

Installation, Operation and Maintenance Manual

TABLE OF CONTENT

UNPACKING AND INSPECTION CHECKLIST -----------------------------------------------

SAVE THE ORIGINAL SHIPPING BOX --------------------------------------------------------

READ THE OPERATOR’S MANUAL -----------------------------------------------------------

■ Section 1: Installation & Start-Up Manual --------------------------------------------------------------

1.1

DESCRIPTION -----------------------------------------------------------------------------------------

1.1.1

System Description ---------------------------------------------------------------------

1.1.2

TC-650,1100,2000,2500,3000 UPS -----------------------------------------------------

1.1.3

Auto Transfer Switch -------------------------------------------------------------------

1.1.4

Batteries ------------------------------------------------------------------------------------

1.2

MOUNTING ---------------------------------------------------------------------------------------------

1.3

WIRING --------------------------------------------------------------------------------------------------

1.4

START-UP AND TEST -------------------------------------------------------------------------------

1.5

SHUTDOWN --------------------------------------------------------------------------------------------

1.5.1

TC UPS ------------------------------------------------------------------------------------------

1.5.2

ATS -----------------------------------------------------------------------------------------------

1.6

TROUBLESHOOTING

-----------------------------------------------------------------------------------

1.7

SPECIFICATIONS

-----------------------------------------------------------------------------------------

1.8

EMERGENCY SHUTDOWN PROCEDURE

------------------------------------------------------

■ Section 2: Operator’s Manual ---------------------------------------------------------------------------------

2.1.1

THE ADVANTAGES

-------------------------------------------------------------------------------------

2.1.2

A TOUR OF THE TC SERIES

------------------------------------------------------------------------

2.2.1

LCD PANEL

------------------------------------------------------------------------------------------------

2.2.2

TC UPS OPERATING MODES

-----------------------------------------------------------------------

2.2.3

SELF TEST

-------------------------------------------------------------------------------------------------

2.2.4

START UP

---------------------------------------------------------------------------------------------------

2.2.5

SHUTDOWN

------------------------------------------------------------------------------------------------

2.2.6

BATTERY REPLACEMENT.

--------------------------------------------------------------------------

2.2.7

LCD MENU TREE

-----------------------------------------------------------------------------------------

2.2.8

STATUS SUBMENU

-------------------------------------------------------------------------------------

2.2.9

CONFIG SUBMENU

--------------------------------------------------------------------------------------

2.2.10

MAINTENANCE MENU

---------------------------------------------------------------------------------

2.2.11

ALARM MENU

---------------------------------------------------------------------------------------------

2.2.12

FAULT MENU

----------------------------------------------------------------------------------------------

2.2.13

LOW BATTERY MODE STATUS

--------------------------------------------------------------------

2.3.1

RS232/USB SET-UP

-------------------------------------------------------------------------------------

2.3.1.1

Wiring Set-up Procedure

-----------------------------------------------------------------

2.3.2

HYPER TERMINAL SET UP

---------------------------------------------------------------------------

2.3.3

MAIN MENU

------------------------------------------------------------------------------------------------

2.3.4

MENU TREE & RS232/USB SUB MENUS

--------------------------------------------------------

2.3.4.1

RS232/USB Menu Tree

--------------------------------------------------------------------

The complete MENU Tree

----------------------------------------------------------------

2.3.4.2

Unit Specifications, Input/Output Values

-------------------------------------------

2.3.4.3

Input / Output Values

----------------------------------------------------------------------

2.3.4.4

Maintenance

----------------------------------------------------------------------------------

2.3.4.5

Line Slow Detection Parameters

------------------------------------------------------

2.3.5

MENU TUTORIAL

----------------------------------------------------------------------------------------

2.4.1

BATTERY BACK-UP TIME TEST

-------------------------------------------------------------------

2.4.2

TC SERIES

RETURN INSTRUCTIONS

------------------------------------------------------------

2.4.3

TROUBLESHOOTING

-----------------------------------------------------------------------------------

CONTRAST ADJUSTMENT LCD DISPLAY

------------------------------------------------------

2.4.4

BATTERY MAINTENANCE

----------------------------------------------------------------------------

2.4.5

SPECIFICATIONS

----------------------------------------------------------------------------------------

2.4.6

WARRANTY

------------------------------------------------------------------------------------------------

2.4.7

EMERGENCY SHUTDOWN PROCEDURE

-------------------------------------------------------

IMPORTANT SAFETY INSTRUCTIONS ARE

CONTAINED IN THIS MANUAL

CAUTION

RISK OF ELECTRICAL SHOCK

To reduce the risk of electrical shock and to ensure the safe operation of the TC UPS, the important safety

instructions are marked with the symbols as shown below. These symbols are used throughout this manual

and wherever they appear, it indicates that the instructions should only be carried out by qualified personnel.

Indicates presence of DANGEROUS VOLTAGE in the area.

Extreme caution should be used.

Indicates ATTENTION to Important operating instructions.

Follow them as indicated.

DANGER: Do not expose the TC UPS to rain or moisture.

DANGER: Total Earth ground leakage current of loads connected to the

TC UPS should not exceed 2.4 mA.

The TC UPS 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 a 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 TC UPS.

IMPORTANT SAFETY PRECAUTIONS

Only qualified personnel should service or supervise the service of the TC UPS.

Danger: Sealed lead-acid batteries with high energy and chemical hazards are used. This manual

contains important operation and safety instructions.

TC UPS Safety System Checklist

• Carefully unpack the TC UPS. Report any shipping damage at once.

• Read this manual. If you have any questions about safe installation, operations or maintenance of the system,

contact Manufacturer service department.

• Before installation, confirm that the voltage and current requirements of the load(s) are compatible with the

system’s output. Confirm that the line voltage and current is compatible with the system’s input requirements.

• The system should be installed on a dedicated power circuit.

• Place a warning label on the enclosure indicating that an Uninterruptible Power Supply (UPS) is located inside,

in case of an emergency.

• Use proper lifting techniques when moving system.

• The TC UPS has more than one live circuit. It is fed from AC as well as battery power. Power may be present

at the output(s) even if the system is disconnected from line power.

• When installing a system in other than a Manufacturer cabinet, ensure that the environment meets the

system specifications shown in Section 1.7, “Specifications” of this manual.

SAVE THIS MANUAL

It contains important installation and operating instructions.

Keep it in a safe place

Battery Safety Checklist

• High & dangerous voltages are present inside the system. Only qualified personnel should perform installation

and maintenance.

• Live battery wires must not touch the TC UPS chassis or any other metal objects. This can cause a fire or

explosion.

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

• When batteries are in storage, charge them at least once every three months for optimum performance and to

extend their lifetime.

• Always replace batteries with the ones of identical type and rating. Never install old or untested batteries. Never

mix old with new batteries. Never mix the different amp hour rated batteries within one system.

• Use insulated tools during servicing.

•Remove all rings, watches, jewelry, or other conductive items before working inside the enclosure.

•Follow local regulations for the disposal of batteries. Recycling is the best method.

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

• Do not open the batteries. The contents are toxic.

Stand-By Generator

Note: If the TC UPS constantly switches between Battery and Line modes because of line

fluctuations, the input parameters should be broadened from Normal to Generator (see Section

2.2.2 “Sense Type”)

In Generator mode, the acceptable range of input frequency and voltage is expanded to accommodate the

voltage and frequency fluctuations created by a generator or a power source of such kind.

Use a generator with electronic speed and voltage controls which typically produces the Total Harmonic

Distortion in % (THD) to be less than 10%. Generators with mechanical governors can force the system to run

continuously in Battery mode.

Before installation, compare the generator’s output voltage to the TC UPS’s input voltage requirements as listed

on both nameplates. To insure the system’s smooth operation, use a generator capable of supplying 2X or twice

as much power as required by the total load.

Unpacking and Inspection Checklist

Purpose: Describes the unpacking and inspection procedures.

Carefully remove the TC UPS from its box. Inspect the contents and make sure the following items are included:

• One TC UPS System.

• One plastic bag containing the following:

• Temperature sensor probe cable with 3-pin connector and extension cord.

• Installation, Operations and Maintenance manual.

Tip: If any items are missing or damaged, contact Manufacturer and the shipping company at once.

Most shippers have a short claim period.

SAVE THE ORIGINAL SHIPPING BOX

When returning the TC UPS for servicing, use the original shipping box with the supplied Styrofoam protectors.

Manufacturer is not responsible for damage caused by improper packaging of returned systems.

READ THE OPERATOR’S MANUAL

Before installation, become familiar with the TC UPS by reviewing the procedures and drawings in this manual. If

you have any questions about safe installation, operation, or maintenance, contact Manufacturer customer

service department.

Complete the following for records & future servicing

Model No.: TC-__________________________________________________

Serial No.:

(Above items can be found on the nameplate label attached to the side of the unit)

Products Sales Order No.____________________________

TC- P/N: _

Your Purchase Order No.:__________________________

Purchased from: _

(Following details are for installation location)

Installation date: _

Installed by: _

City: _

State/Province: _

Zip/Postal Code: _

Country: _

Telephone #: _

Fax #: __

E-Mail:__________________________________________

Street names of location: ____________________________

Cabinet / controller type: ___________________________

TC UPS

Uninterruptible Power Supply

■ Section 1: Installation & Start-Up Manual

1.1 Description

Purpose: Describes the operation of the TC UPS System (Figure 1, 2 & 3).

1.1.1 System Description

The TC UPS System provides backup power to traffic control signal equipment. It consists of the TC

Uninterruptible Power Supply (UPS) System, the Auto Transfer Switch (ATS), and batteries that provide back up

power when the line is unqualified. These three components can be mounted inside an enclosure to provide

protection from most weather conditions.

Figure 1

Simplified TC UPS 120V System Block Diagram

TC-2000 UPS

*ACTIVATE WHEN BUCK / BOOST IS ENABLED

CONTINOUS

RS232 & USB

CONNECTION

UPS OUTPUT

Fault

The traffic signal cabinet is powered continuously when a TC UPS system is installed. The system allows

connection for the normal utility power ( using standard terminal blocks or Anderson PP45 Quick connector or

IEC Socket) or an optional generator power. The optional bypass switch redirects utility power to the load and allows the

TC UPS to be removed for service on a temporary or permanent basis without disrupting the operation of the traffic signal.

With a fully functioning UPS system, the ATS allows utility power to flow out to the traffic cabinet, when the utility

line is qualified (within the acceptable range as programmed). If the UPS is not functioning, the ATS will bypass

the UPS allowing the utility to flow out to the traffic cabinet. The UPS input is protected with one circuit breaker

located on the ATS as well as another one located on the UPS module. When the UPS internal BOOST and

BUCK is enabled, the ATS is activated allowing UPS to continuously boost the output when input is lower, buck or

lower the output when input is higher or run from batteries when input power is outside the specified acceptable

range.

The smart, temperature compensated internal charger continuously monitors and maintains the batteries in a fully

charged state. For the protection of the battery, the charging process is automatically discontinued when the

battery temperature exceeds 50 degrees C. When input power is not qualified or is outside the acceptable range,

the UPS derives the DC power from the storage tank of batteries connected and maintains output power until the

batteries are depleted down to a specified level or the utility power returns within its specified levels. The traffic

intersection will continue to operate in full operation AND / OR in flash mode as programmed by the user.

Programmable contacts allows the user to place the intersection in flash mode as soon as the input power is lost

or after the batteries are depleted down to a certain capacity that is determined and programmed by the user. The

amount of back-up time battery power can provide depends on the Amp-hour capacity of the batteries as well as

the intersection watt load that requires support.

1.1.2 TC-650,1100,2000,2500,3000 UPS

The TC UPS System shown below provides control functions and backup power as described above. For more

information, please see Section 2 of this manual.

TC-650,1100 UPS Front Panel

Figure 2

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