Alpha Technologies Novus 1800TP Setup guide

1800TP
Uninterruptible Power Supplies
From Alpha Technologies
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!Installation and Operator’s Manual

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!InstallationandOperator’sManual
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!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 TheNovus1800TP 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 theATS System .......................... 20
2.3 Starting and Testing theATS 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 Turningthe UPSOn or Off...................... 35
3.2 Testing the UPS ..................................... 37
3.3 Replacing the Batteries .......................... 38
3.4 UPS Operating Modes ........................... 39
3.5 TheLCD Panel and theMenu Tree ......... 41
3.6 Controlling the UPS................................ 43
3.7 Measuring Input and Output Values........ 45
3.8 TroubleshootingFaults ........................... 47
The emergency shutdown procedure is on the inside rear cover
3.9 TroubleshootingAlarms ..........................48
3.10 Battery Discharge States .....................49
4. Communication ......................50
4.1 Wiring the RS-232 Port ..........................51
4.2 HyperTerminalSet 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 InputVoltageParameters .......................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 RemovingSystem Components ............. 74
Specifications ..............................78
Index .............................................82
Warranty .......................................90
Introductiontothismanual:
TheNovus 1800TP systemprovides powerbackup totraffic lightsystems. Itconsists of theNovus 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.
• TheAutomaticTransferSwitch (ATS)(Section1.4).
• 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
installationandoperation.
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 shockandtoensure the safe operation of the Novus 1800TP
System,thesesymbolsareusedthroughout this manual.Wheretheyappearonlyqualified
personnelshouldcarryouttheinstructions.
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
AlphaTechnologies
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.
Donotworkaloneunderhazardousconditions.
Readthismanual.Ifyouhaveanyquestionsaboutthesafeinstallation,operationormainte-
nanceofthissystem,contactAlphaTechnologies’scustomerservicedepartment.
Carefullyunpacksystemcomponents.Reportanyshippingorotherdamageatonce.
Alwaysassumeelectricalconnectionsorconductorsarelive.Turnoffallcircuitbreakers
anddouble-checkwithavoltmeterbeforedoinganyinstallationormaintenance.
Beforeinstallation,verifytheinputvoltageandcurrentrequirementsoftheloadare
compatiblewiththesystem’soutput.Alsoverifythelinevoltageandcurrentarecompatible
withthesystem’sinputrequirements.
PlaceawarninglabelontheenclosuretotellemergencypersonnelanUninterruptible
PowerSupply(UPS)isinstalled.
Useproperliftingtechniqueswhenliftingormovingthesystemoritscomponents.
Thesystemhasmorethanonelivecircuit.ACpowermaybepresentattheoutputsevenif
thesystemisdisconnectedfromlineorbatterypower.

31 Introduction
AlphaTechnologies
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.
Neverletlivebatterywirestouchtheenclosureoranyothermetalobjects.Thiscancausea
fireorexplosion.
Lead-acid batteries can release Hydrogen gas. Never have open flames or sparks near
theenclosure.
Inspectthebatteriesonceayearforsignsofcracks,leaksorswells.Replaceasneeded.
Ifyouhavebatteriesinstorage,chargethematleastonceeverythreemonthsfor
optimumperformanceandtoextendtheirlifetime.
Always replacebatterieswith ones of identical type andrating.Never install old or un-
testedbatteries.
Alwaysuseinsulatedtools.
Removeallrings,watches,jewelryorothermetalitemsbeforeworkinginsidetheenclosure
ordoingmaintenanceonthesystem.
Followlocalregulationsforbatterydisposal.Recyclingisthebestmethod.
Never burn batteries to dispose of them. They may explode.
Never open the batteries. The contents are toxic.

1 Introduction 4
AlphaTechnologies
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.
Carefullyremovetheunitfromthe shipping container.Inspectthecontentsandmakesurethe
followingitemsareincluded:
1Novus1800TPUPS.
1,2 position terminal block for the 48 VDC output power.
1temperaturesensorcable.
2 cable tie wraps.
1Novus1800TPOperator’sManual.
Anyorderedoptions.
IforderedfromAlpha, the batteries,ATS,MBPorMBMareshippedseparately.
Save The Shipping Container
Toreturnthe1800TPforservicing,packitintheshippingcontainer.
AlphaTechnologiesis not responsible for damage causedbyim-
properpackagingofreturnedunits.
Read This Manual
Beforeinstallationbecomefamiliarwiththe1800TPbyreviewingthe
proceduresanddrawingsinthismanual.Ifyouhaveanyquestions
aboutthesafeinstallation,operationormaintenanceofthisunit,con-
tactAlpha’scustomerservicedepartment.

51 Introduction
AlphaTechnologies
1.3 The Novus 1800TP UPS Front Panel
1.3.1: Battery Connections and LCD Panel
1
48V Battery Connector
Itconnectsthebatterytotheunit.Thebatterystringvoltageis48VDC.
2
Battery Circuit Breaker
Itactsasan ON/OFF switch for battery power. It must be turned on for normal UPS
operation.
3
Battery Voltage Test Points
Thesemeasurethebattery’svoltage.Tousethem,thebatterycircuitbreakermustbe
turnedon.
TIP: It is not a power outlet.
4
Liquid Crystal Display (LCD) Control Panel
Itcontrolstheunit.InformationonitsuseisgiveninSection 3.5,“TheLCDPanelandthe
MenuTree.”
Figure 1.3.1
Novus1800TPFrontPanel
1
2
34
Figure 1.3.2
BatteryConnectionsandLCDPanel

1 Introduction 6
AlphaTechnologies
1.3 The Novus 1800TP UPS Front Panel (Continued)
5
6
7
Figure 1.3.3
Input/OutputPowerConnectionsand PowerSwitch
1.3.2: Input/Output Power Connections and Power On/Off Switch
5
AC Input & Output Circuit Breaker
Itactsasaninputandoutputpoweron/offswitchtofacilitatetheunit’smaintenanceor
replacement.Itmustbeintheonpositionfornormaloperation.
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
Thisterminalblockand5–15Rreceptaclearetheunit’soutputpowerconnectors.The5–
15Ristheauxiliaryoutput and is circuit breaker protected.
7
AC Input
Thisterminalblockistheunit’sinput power connector.

71 Introduction
AlphaTechnologies
1.3 The Novus 1800TP UPS Front Panel (Continued)
Figure 1.3.4
RS–232Connector
1.3.3: RS–232 Communications
8
Serial Interface
ThisDB–9femaleconnectoris used to connect the unit to ahostcomputerforremote
control,monitoringandcalibrationviaRS–232commands.Itslayoutandoperationis
showninFigure 1.3.5.Aserialcable to connect it toacomputer is available fromAlpha.
Moreinformationonitsconnectionanduse 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
SerialInterfaceOperationandLayout
NOTE: 100 mA (Max)
TIPS:
1) Therelaysmaximum
rating are 0.5 Amps at
125VAC or 110 VDC.
2) Forthe computer port
pin diagram, see Section
4.1,“Wiring the RS–232
Port,”Figure 4.1.1.

1 Introduction 8
AlphaTechnologies
1.3 The Novus 1800TP UPS Front Panel (Continued)
1.3.4: Status/Self Test Terminal Block
9
Status/Self Test Terminal Block
Thisterminalblockprovidescommunicationwiththe intersection controller,controlsthe
AutomaticTransferSwitch(ATS)andstartstheselftest.
Therearetwo types of terminal blocks offeredasfactory installed options: a 19 position
terminalblock(Figure1.3.8)wheretherelay’sfunctionscannotbeprogrammed and a 22
postionterminalblock(Figure1.3.9)wheretherelay’sfunctionscanbeprogrammedwith
RS–232commands(Section4.3.1,“ProgrammableStatus/SelfTest Terminal Block”).The
functionsofeach contact is described inFigure1.3.7.
This terminal block is opto–isolated and shares a common ground with the
serial interface
Figure 1.3.6
Status/SelfTestTerminalBlock
9
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.hctiwsehtsedivorpresuehT.tsetfless'tinuehttratsotstcatnocesehttrohS
STA
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ttaBnO
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desuseirettabehthctamottasesolctcatnocehtegatlovdemmargorperpehtegnahcnacuoY:PIT egatloVyrettaB",53#"SPUehtgnillortnoC",7.4noitceSeeS.snoitidnocgnitarepolautcaehtdna ".yticapaCfo%04@leveL
remiT
.sruoh2rofedomyrettaBnineebsahtinuehtretfaezigrenesyaleresehT
mralA
oN;mralAegatloVtuptuOwoL:gniwollofehtfoenosretnuocnetinuehtnehwsezigreneyalersihT erutarepmeTwoLroycneuqeFeniL;detcennoCtoNyrettaB;mralAdaolrevO;eborPerutarepmeT .)smralAgnitoohselbuorT",9.3noitceSdna"stluaFgnitoohselbuorT",8.3noitceS(
Figure 1.3.7
Status/SelfTestTerminal BlockContacts

91 Introduction
AlphaTechnologies
1.3 The Novus 1800TP UPS Front Panel (Continued)
Figure 1.3.9
22-PositionTerminal 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-PositionTerminal 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 3Amp 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
AlphaTechnologies
1.3 The Novus 1800TP UPS Front Panel (Continued)
1.3.5: Temperature Control Connections
10
Internal Fan
Thismicroprocessor-controlledfanregulatestheunit’s internal temperature.Itmustnotbe
blocked.Thefilterinfrontofthefanisremovable.
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, 4Amp (Max)) that can be used to power an optional 48 Vdc
enclosurefanwhichregulatestheenclosure’s interior temperature.
12
Battery Temp Sensor
Itattachesthebatterytemperatureprobe to the unitforbatterytemperaturemonitoring.The
chargingvoltageistemperaturedependentandtheunit’smicroprocessoradjuststhevolt-
ageforoptimumcharging.
Theprobemustbeattachedfornormaloperation.Thesensorendshouldbefirmlyattached
tothecaseofthecenterbatterywithhighstrengthflameprooftape.
13 Battery Temperature Sensor Strain Relief
ThissecurestheBatteryTemperatureSensor Cord to the front panel and preventsconnec-
tordisconnectionduringanEarthquakeorotherseverevibrations.
Firstattachthesensorcabletotheconnector.Then use one of the tiesprovidedinthe
mountingkittoattachthesensor cord to the strain relief loop. Ensure that thetieis
tightened.
10
11
12 13
Figure 1.3.10
TemperatureControlConnections

11 1 Introduction
AlphaTechnologies
1.4 Automatic Transfer Switch (ATS) System
1.4.1: Automatic Transfer Switch System Description
TheATS systemautomaticallyprovides backup power to theloads.See Figure 1.4.1 for a
systemblockdiagram.TheATSalsoallowsforloadsratedhigherthantheUPScansupply.The
ATSis the outlet for the UPS’soutputpoweriflinepower is unqualified.
TheATS’smaximuminput current is 40Amps.Linepower is connected to theATS’sinput
(Figure1.4.2).When the line is qualified, itissent to the loads.
Whenthelineisunqualified,theUPScontrollerdetectsthisandsendsasignalviathecontrol
linetotheATS, causing an internal contactor to transfer the load from the line to the UPS’s
output.Backupbatterypower is provided to the loads untilthelineis qualified or the batteries
aredischarged.
Forinstallationandstartupinstructions, see Sections 2.2 and 2.3.
Figure 1.4.1
SimplifiedBlockDiagramfor the Novus 1800TPSystemWithAutomaticTransferSwitch
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
AlphaTechnologies
1.4.2: Automatic Transfer Switch
1
Thelinepowerandtheloadsareconnectedtothisterminalblock.TheGroundandNeutral
areusedfortheATSreceptacleonly.The terminal block neutralisratedat15Amps(Max).
2
Thelinepowerisconnectedtothis end of the terminal block.
3
Theloadisconnectedto this end of the terminal block.
4
TheoptionalAlphaTechnologiesLA–Psurgesuppressorispluggedintothisconnector.
5
Theoptionalbatteryheatermatispluggedintothisconnector.
6
Thiscordiswired into the Novus 1800TP’sAC Output terminal blocks.
7
Thesetwocontrolwiresare attachedtothe“ATS”portionoftheNovus 1800TP’sStatus/
Self Test terminal block (TIP: They are color coded. See Section 2.2, Step 2).
8
Thiscordiswiredinto the Novus 1800TP’sAC Input terminal block.
9
Thiscircuitbreakerprovidesinputpowerprotection for the Novus 1800TP.
10
Thiscircuitbreakerprovidesprotectionforthesecondary outputs (4 and 5).
Figure 1.4.2
AutomaticTransferSwitchFront 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 asshown 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
AlphaTechnologies
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.”
TheMBP(Figure1.5.2)allowstheUPStoberemoved for replacement or maintenance without
turningoff power to the loads. See Figure 1.5.1 for a block diagram of thesystem. Line poweris
connectedtotheMBP’sinput.Itsoutputisconnectedtotheload.TheMBP’smaximuminput
currentis20Amps.
Whenthebreak-before-makerotaryswitchisturnedto:
•Bypass,line power is connected tothe loads and disconnected from theUPS (NOTE:
neutralisstillconnected).ThissettingisusedtoremovetheUPSformaintenanceor
replacement.
•Transfer, line power is providedboth to the load and the UPS.This setting is used to
startandtesttheUPSwithouthavingtointerruptpowertotheload.
•UPS, the UPS is connected to line power and its output isconnected to theload.
Forinstallationandstartupinstructions, see Sections 2.4 and 2.5.
Figure 1.5.1
SimplifiedBlockDiagram for the Novus 1800TP SystemWithManualBypass 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
AlphaTechnologies
1.5 Manual Bypass Switch (MBP) System (Continued)
1.5.2: Manual Bypass Switch
1
Thisbreak-before-makerotaryswitchtogglestheMBPbetween Bypass,Transferand
UPS.
2
Linepoweris connected to this end of theterminalblock.
3
TheUPS’sinputisconnected to this end of the terminal block.
4
Theloadsareconnectedtothisend of the terminal block.
5
TheUPS’soutputisconnectedtothisendof the terminal block.
6
ThisthermalcircuitbreakerprovidesinputpowerprotectionfortheNovus1800TP.
7
Thisthermalcircuitbreakerprovidesprotectionforthesecondaryoutputs(8and9).
8
Theoptionalbatteryheatermatispluggedintothisconnector.
9
TheoptionalAlphaTechnologiesLA–Psurgesuppressorispluggedintothisconnector.
Figure 1.5.2
ManualBypassSwitchFrontPanel
1
2
3
4
5
67
8
9
TRANSFER UPS
BYPASS

15 1 Introduction
AlphaTechnologies
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.”
TheMBM(Figure1.6.2)allowstheUPStoberemovedforreplacementormaintenancewithout
turningoff power to the loads. See Figure 1.6.1 for a block diagram of thesystem. Line poweris
connectedtotheMBM’sinputanditsoutputisconnectedtotheload. The MBM’s maximum
inputcurrentis20Amps.
Whenthebreak-before-makerotaryswitchisturnedto:
•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 isconnected to theload.
Forinstallationandstartupinstructions, see Sections 2.6 and 2.7.
Figure 1.6.1
SimplifiedBlockDiagramfor the Novus 1800TP System WithManualBypassModule
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