Always On GES-202TLP User manual

M1603_TLP_Installation_Manual V1.0 2012-06-12
GES-202TLP Traffic Light System
Installation Manual

M1603_TLP_Installation_Manual V1.0 2012-06-12
NOTE:
The instructions contained in this manual are not intended to cover allof 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 toAlways “On” UPS Systems Inc.
Any electrical or mechanical modifications to this equipment, without prior written consent ofAlways “On” UPS
Systems Inc, will void all warranties. Unauthorized modifications also can result in personal injury, death, or
destruction of the equipment.
IMPORTANT
EMERGENCY SHUTDOWN PROCEDURE ON THE INSIDE OF REAR COVER
SAVE THESE INSTRUCTIONS

M1603_TLP_Installation_Manual V1.0 2012-06-12
Traffic Light System UPS Controller
Please complete the Warranty Card supplied with this UPS controller and return it by mail to Always “On” UPS
Systems Inc. This activates the warranty.
If additional information or technical assistance is required contact Always “On” UPS Systems Inc:
Toll-free: 1-877-259-2976 Ext. 451 or [phone] Ext. 451
Fax: [phone]
e-mail: [e-mail]
url: www.alwayson.com
Mail: 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: ______________________________________________________________

M1603_TLP_Installation_Manual V1.0 2012-06-12
TABLE OF CONTENTS
1 DESCRIPTION……………………………………………………………………4
1.1 System Description…………………………………………………………………………..4
1.2 GES-202TLP UPS Controller…………………………………………………….………..6
1.3 External Bypass Switch…………………………………………………………………….6
1.4 Batteries……………………………………………………………………………………...7
2 MOUNTING………………………………………………………………………7
3 WIRING………………………………………………………………………….. 8
4 START-UP AND TEST…………………………………………………….…...11
5 SHUTDOWN………………………………………………………………….….13
5.1 GES-202TLP UPS……………………………………………………………………..……13
5.2 EBS…………………………………………………………………………………….……..14
6 TROUBLESHOOTING………………………………………………………….15
7 SPECIFICATIONS………………………………………………………………16
EMERGENCY SHUTDOWN PROCEDURE……………………………………..17

M1603_TLP_Installation_Manual V1.0 2012-06-12 1
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 GES-202TLP, 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 be carried out by qualified personnel only.
Indicates presence of A 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 GES-202TLP to rain or moisture.
DANGER: Total Earth ground leakage current of loads connected to the
GES-202TLP should not exceed 2.4 mA.
The GES-202TLP 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 GES-202TLP.

M1603_TLP_Installation_Manual V1.0 2012-06-12 2
IMPORTANT SAFETY PRECAUTIONS
Only qualified personnel should service the GES-202TLP.
Danger: Sealed lead-acid batteries with high energy and chemical hazards are used. This manual
contains important operation and safety instructions.
GES-202TLP Safety Checklist
• Carefully unpack the GES-202TLP. Report any shipping damage at once.
• Read this manual. If you have any questions about safe installation, operations or maintenance of the system,
contactAlways “On” 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 GES-202TLP has more than one live circuit. It is fed from an AC source as well as a Battery source. Power
may be present at the output(s) even if the system is disconnected from line power.
• When installing a system in other than an Always “On” cabinet, ensure that the environment meets the system
specifications shown in Section 7, “ Specifications” of this Manual
SAVE THIS MANUAL
It contains important installation and operating instructions.
Keep it in a safe place

M1603_TLP_Installation_Manual V1.0 2012-06-12 3
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 GES-202TLP 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 type of Battery 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 GES-202TLP 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,
2.10, “Sense Type” of the Operators Manual)
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 GES-202TLP’s input voltage requirements as
listed on both nameplates. To insure the systems smooth running, use a generator capable of supplying 2X or
twice as much power as required by the total load.

M1603_TLP_Installation_Manual V1.0 2012-06-12 4
1 Description
Purpose: Describes the operation of the GES-202TLP System (Figure 1, 2 & 3).
1.1 System Description
The GES-202TLP System provides backup power to traffic control signal equipment. It consists of the
GES-202TLP Uninterruptible Power Supply (UPS) Controller and the External Bypass Switch (EBS). Batteries
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 GES-202TLP System Block Diagram

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The traffic signal cabinet is powered continuously when the GES-202TLP system in figure 1 is installed. This
system allows connection to the utility power using standard terminal blocks or optional Generator power via
standard 30 Amp. Generator Plug.
The EBS allows utility to flow out to the traffic cabinet, when the utility line is qualified or is within the acceptable
range as programmed. The UPS input is protected with one circuit breaker located at the EBS as well as another
located on the UPS module. When the UPS internal BOOST or BUCK is enabled, the EBS 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 EBS has dual GFI power
receptacles for optional Battery heating pads or for powering a vacuum cleaner or a PC for maintenance.
The Batteries are continuously maintained and charged from a smart temperature compensated internal charger.
For the protection of the batteries, the charging is stopped when the outside temperature exceeds 50 degrees C.
When the batteries are fully charged, the smart charger provides a continuously pulsating On-Off trickle charge
to keep the batteries topped-off or fully charged. When input power is not qualified or is outside the acceptable
range, the UPS derives the DC power from the storage tank of four Batteries connected in series and maintains
output power, till the input is qualified. The traffic intersection runs full phaseAND / OR in flash mode as
programmed by user. The user programmable contacts allows the user to put the intersection into immediate
flash as soon as the input power is lost or after batteries are depleted down to a certain capacity that is
determined and programmed by the user. The amount of back-up time the batteries can provide depends on the
load and Amp-hour capacity of the Batteries used.

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1.2 GES-202TLP UPS Controller
The GES-202TLP UPS Controller shown below provides control functions and backup power as described in
section 1.1. For more information, please see section 2 of this Manual.
Figure 2
GES-202TLP UPS Controller Front Panel
1.3 External Bypass Switch
The External Bypass Switch (EBS) shown below allows the UPS to be removed for service, replacement or
maintenance without interrupting power to the traffic cabinet.
Figure 3
External Bypass Switch Front Panel
1. The utility line power is connected to the terminal block marked “UTILITY IN”.
2. The load is connected to the terminal block marked “TO LOAD”.
3. “FROM UPS OUTPUT” is connected to one of the two OUTPUTAC terminal Blocks at the GES-202TLP.
4. “TO UPS INPUT” is connected to the INPUT AC terminal Block of the GES-202TLP.
5. The EBS control wires are connected at terminals 21 & 22 of the green terminal block at the GES-202TLP.
6. The Manual Bypass switch toggles the EBS between UPS and Bypass (CAUTION: Only switch to bypass
when UPS is in normal online mode – if switched to bypass while in battery backup mode catastrophic
system failure may result.)
7. A vacuum cleaner or PC for maintenance may be plugged into this receptacle.
8. The optional battery heater mats is plugged into this receptacle.
9. This circuit breaker provides input power protection for the GES-202TLP UPS.
10. The dual receptacles are protected by this circuit breaker.

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1.4 Batteries
Different Amp-hour capacities or sizes of batteries can be used in the GES-202TLP system to provide various
backup times. Four Batteries are connected in series for the required 48 VDC. Contact customer service at
Always “On” for information on the battery best suited for your application. The Battery harness supplied with the
system is connectorized, polarized, Plug-N-Play and foolproof. Each battery can be unplugged from the system
and hot swapped as the battery harness provides a heavy-duty connector for each battery. Each of the four
batteries can be connected in any random order using the provided harness.
2 Mounting
Purpose: Describes how to mount the GES-202TLP System into an enclosure.
The GES-202TLP system components can be mounted into a single external cabinet or into the existing traffic
cabinet.
EXTERNAL MOUNT:
Afactory supplied externalcabinet can be bolted onto the existing or new traffic cabinet OR can be pad mounted
on a concrete slab OR mounted on a pole. Bolts & hardware for bolting onto the side of the traffic cabinet,
bushing for the wire ducts, brackets for pole mounting and all the required accessories including mechanical
hardware and electrical wiring are supplied to make the installation Plug-N-Play for the contractor. External
cabinets are outdoor, weather proof and have an internal exhaust fan that is temperature controlled, an intake
filter that can be cleaned or replaced, 3 point lock mechanism, lockable handle with dual keys and a unique
internal keyed lock. The factory-supplied cabinet meets or exceeds the requirements of various NEMA
classifications.
INTERNAL MOUNT:
The GES-202TLP components can also be mounted inside an existing NEMAor 332 or various other traffic
cabinets. The GES-202TLP and EBS can be bolted into an industry standard 19” rack using the supplied Ears or
brackets, OR it can be shelf mounted in NEMA type enclosures.

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3 Wiring
Purpose: Describes how to wire the GES-202TLP System.
Danger: The utility input power line must have circuit breaker or fuse protection as per the local
electrical code. It is referred to as “ Upstream Circuit Breaker” in this manual.
Before wiring the system, determine the size of the load:
TIP: Each of the six contacts are of form C type, meaning Normally Open (NO), common (C) and Normally Close
(NC) dry contact rated for 1Amp at 120 VAC. Each of these contacts can be individually programmed to energize
and stay latched for ON BATTERY, LOW BATTERY, TIMER,ALARM, FAULT and many other conditions as
described in subsequent chapters. The ON BATTERY contact(s) are activated as soon as the GES-202TLP is
transferred to battery mode. LOW BATTERY contact(s) are activated only in battery mode, as soon as the
discharged batteries reaches the lower remaining battery capacity as set by user and remains latched as long as
the system remains in battery mode. The TIMER contact(s) are activated only in the battery mode after the
user-programmed time is attained, that can be set in 15-minute intervals from 15 minutes to 8 hours.
TIP: Verify that all Breakers, AC and battery breakers are OFF prior to start of wiring.
Is the load over o
r
under 2000 VA
/1500 W ?
Run the intersection in FLASH mode connected as above.
OR
Keep the intersection running normal in full phase till the battery
completely depletes down to shutdown resulting in blackout
OR
Keep the intersection running normal in full phase for certain time or till
battery depletes down to certain capacity, both of which are
programmable. Run the intersection in flash mode after that, till the
battery depletes down completely resulting in blackout if utility does not
return. Connect Traffic controller’s AUTO / FLASH circuit to any one of the
six programmable contacts at the GES-202TLP programmed for “Timer”
or “Low Battery”. This method is recommended to ride out small power
outages, which for most times are utility interruptions.
Put the Intersection in FLASH mode as soon as
GES-202TLP goes into Battery mode, by connecting any one
of the six programmed contacts to “ON BATT” and
connecting it to the AUTO / FLASH circuit of any controller.
OVER
UNDER
Start
Go to Step 1

M1603_TLP_Installation_Manual V1.0 2012-06-12 9
Step 1: Connect CONTROL wires.
Step 2: Connect EBS to the GES-202TLP.
TIP: See section 1.2, fig. 6 of the Operators Manual for
details on the layout, operation, and specifications of the
Control Terminal Block.
TIP: Torque status/self
test terminal block to a
maximum of 4.4 lb-in (0.5
Mm). Maximum wire size
is 14 AWG.
Tape the Battery Temperature
Sensor to the case of the
middle battery and plug the
connector into the
GES-202TLP.
Connect the External Cabinet
Fan and the RS232 Computer
Cable (if used).
Connect the programmable
contacts: ON BATT, LOW BATT,
TIMER or SELF TEST contacts
from the GES-202TLP to the
Traffic Controller for Flash mode
(if used).
START
Go To STEP 2
Connect the Red & Black
control wires form the EBS to
the GES-202TLP Control
Terminal Block 21 & 22
respectively.
Connect the Cord from
“FROM UPS OUTPUT” of
the EBS to one of the two AC
OUT terminal blocks of the
GES-202TLP.
START
Go To STEP 3
Connect the Cord from “TO
UPS INPUT” of the ESB to
the AC IN terminal block of
the GES-202TLP.

M1603_TLP_Installation_Manual V1.0 2012-06-12 10
Step 3: Connect the output or Signal Cabinet and Battery.
Step 4: Connect the Utility Input Line Power.
DANGER: Make sure the upstream circuit breaker feeding the Utility Power is OFF before beginning
this step. Leave the NEUTRAL and GROUND wires connected from Utility to Signal Cabinet. Extend
the NEUTRAL and GROUND wires from their corresponding Bus Bars in the Traffic Cabinet to the
Terminal block of the EBS.
TIPS:
1. The wires from Ground
and Neutral Bus Bars from
the traffic cabinet are
extended to the EBS
Terminal Block as shown
in step 4.
2. OPEN the upstream
breaker feeding utility
Power to the signal
Cabinet.
3. Cut the connection
between the Utility and
Traffic Cabinet.
4. Connect the Cabinet side
load to “TO LOAD” of the
EBS.
5. Connect the Utility side to
“UTILITY IN” of the EBS.
Connect the Utility to
“UTILITY IN” of the EBS. Run
wires from Neutral and
Ground Bus bars of the
Traffic Cabinet to the EBS
Neutral & Ground Terminal
blocks.
Start and test the
GES-202TLP as described in
Section 4
START
WIRING FINISHED
Connect the cabinet load to
the “TO LOAD” terminal of
the EBS.
Plug the Red & Black Battery
connector into the
GES-202TLP UPS.
START
Go To STEP 4

M1603_TLP_Installation_Manual V1.0 2012-06-12 11
4 Start-up and Test
Purpose: Describes how to Start-up and test the system.
TIP: If the system does not perform as described below, see the troubleshooting section in Section 6 of this
manual.
Step 1: Turn on the Utility Input line Power
Step 2: Turn on the UPS.
Verify that the AC Input &
Output as well as Battery
Circuit Breakers on the
GES-202TLP are OFF.
Turn ON the upstream
Utility Input Circuit
Breaker.
Verify that the load is turned ON.
START
Go To Step 2
START
Turn On the battery circuit
breaker.
The LCD display shows
Standby
Turn ON the AC Input &
Output circuit breaker.
In 30 seconds, The LCD
display changes to “ O
N
LINE”, the Green
Output LED is Lit
indicating Input power to
be within acceptable
frequency and voltage
ranges and the output is
powered from Utility.
Go To Step 3

M1603_TLP_Installation_Manual V1.0 2012-06-12 12
Step 3: Test the system.
Turn OFF the upstream
circuit breaker.
The OUTPUT Green LED will
flash, the LCD displays ON
BATT, indicating that output
AC power is supplied from
Battery Power.
Observe the Red Alarm LED. If
it is on or flashes, follow the
troubleshooting sequence
below:
1. Investigate the Alarm. (See
section 2.8 of the Operators
Manual – Alarms/Faults)
2. Perform a self-test with the
load(s) connected.
3. If it passes the self-test,
verify that that loads are
operating normally.
4. See the troubleshooting
chart in the Operators
Manual, Section 4.3.
5. Contact Always “On”
technical support.
The Green Output
LED is lit and the
display shows “ON
LINE”.
Within 30 seconds
the EBS switches
back to line power.
Turn ON the
upstream circuit
breaker.
TIP: To test the UPS, perform the self-test feature via the control submenu (see Operators Manual, section 2.3, “Self
Test”).
Start Up and Testing
Finished
START

M1603_TLP_Installation_Manual V1.0 2012-06-12 13
5 Shutdown
Purpose: Describes how to shut down the system components for removal or maintenance.
5.1 GES-202TLP UPS
Danger: Shutting down the GES-202TLP does not necessarily disconnect power to the loads.
TIP: For additional information on how to operate the
GES-202TLP, see Operators Manual
Turn OFF the Battery Circuit
Breaker.
Turn OFF the AC Input &
Output Circuit Breaker.
START
Procedure Finished
Unplug the Battery
connector.
Disconnect the AC Input
wires.
Disconnect the AC
Output(s) wires.
Disconnect, mark and
insulate wires at the Green
Control Terminal Block, the
plug for Ext. Fan, the plug for
battery temperature sensor
and the RS232 connector.
Perform this procedure in
reverse order to reinstall the
unit.
Remove and perform the
maintenance on the UPS.
Danger: The “TO UPS INPUT” cord connected to the
AC input of the UPS is still HOT or live if the “UPS Input
Breaker” on the EBS has not been turned off. Insulate
the bare wires using wire nuts for safety.
Turn OFF the UPS input
Breaker on the EBS.

M1603_TLP_Installation_Manual V1.0 2012-06-12 14
5.2 EBS
Turn OFF the upstream
circuit breaker.
Disconnect the “FROM UPS
OUTPUT” at the
GES-202TLP.
START
Procedure Finished
Disconnect the “TO UPS
INPUT” at the GES-202TLP.
Disconnect the Red & Black
EBS control wires at the
GES-202TLP.
Disconnect the Utility and
Load wires from the EBS.
Perform this procedure in
reverse order to reinstall the
EBS.
Remove and perform
maintenance on the EBS.
Verify that both the AC and
Battery Breakers are OFF at
the UPS.

M1603_TLP_Installation_Manual V1.0 2012-06-12 15
6 Troubleshooting
GES-202TLP System Troubleshooting Chart
SYMPTOM CAUSE REMEDY
No Output
available from EBS
Upstream Utility circuit breaker or
Fuse may be OPEN. CLOSE the Upstream Utility Breaker or Fuse.
Utility AC Power not Available. Check with anAC Voltmeter &
contact the Utility company.
Wiring error at EBS Terminal
Block. Correct wiring at EBS.
Faulty EBS. If 120 VAC is present at “UTILITY IN” at the EBS Terminal Block,
replace the EBS.
EBS will not
allow transfer to
Battery mode.
GES-202TLP output power not
connected to EBS.
Verify that “FROM UPS OUTPUT”
cord from EBS is properly
connected to the AC OUTPUT
Terminal Block at the
GES-202TLP.
“UPS INPUT” circuit breaker at
EBS is open. Reset the Breaker & clear the fault.
Red and Black control wires from
EBS are not connected at the
Green Control Terminal Block
TB21 & 22, at the GES-202TLP.
Check the connection at the
GES-202TLP.
48 VDC signal missing at TB 21
and 22 of Green Control Terminal
Block at the GES-202TLP.
Refer to Section 4.3 of the
Operators Manual for further
troubleshooting.
Faulty EBS. Replace EBS.
GES-202TLP
does not Return
back to Input Line
Mode.
Utility Input Line Power is Missing.
Verify that “TO UPS INPUT” cord
from EBS is properly connected to
the AC INPUT Terminal Block at
the GES-202TLP.
Verify that the “UPS INPUT” circuit
breaker at EBS is closed.
Ensure that the Utility Input is
present.

M1603_TLP_Installation_Manual V1.0 2012-06-12 16
7 EBS Specifications
System Technical Specifications
INPUT
Voltage Range, VAC 100~130VAC (120 VAC
Nominal) Prog. 90–150VAC
Frequency 60 +/- 5 Hz
Current 25A (Resistive) MAX
Step Load Response
(50% Load Change) 1/2 Cycle Full Recovery (Full resistive load)
Short Circuit
Protection 30 A Circuit Breaker
Battery String Voltage 48 VDC (Four 12VDC
Battery)
OUTPUT
Power, VA / W (Line
or Inverter mode) 2000 VA / 1500 W
Power Factor 0.75
Output Voltage,
VAC Line and Boost
Mode
Inverter Mode
100~130 +/- 2 VAC (follows
the Input voltage)
120 VAC +/- 5%
Output Waveform Sine Wave
Output Waveform
THD < 3% (Resistive Load)
Load Crest Factor 3:1 (Max)
Overload Capacity 110% for 3 min.
PERORMANCE
EBS Transfer Time < 8 ms
ENVIROMEMENTAL
Operating Temp
(See Notes below) –37 to + 74 ℃.
Storage Temp –50 to +75 ℃.
Humidity
(Non-Condensing) < 95%
Altitude (Note 2) 10,000ft /3000 m
EBS MECHANICAL
Dimensions (W x
D x H) inch/mm 17/ 432(W)
8.75/222(D)
3.56/89 (H)
Weight (lb/kg) 4.0/1.8
Mounting Wall Mount EARS, 4 points. 19”
rack mount.
Input Connection Terminal Block
Output Connection
To Loads Terminal Block.
Output Connection
To UPS Terminal Block
Cooling Convection (Approx 7 W
contactor coil dissipation)
CERTIFICAITONS AND APPROVALS
Electrical Safety UL –1778, CSA-107.1,
UL 1950
EMI FCC Class A
Surge Immunity Tested to:
IEC 1000-4-5, IEEE C62.41
Note:
1. Between 55 ~ 74 ℃, the system is de-rated to a maximum rectified-capacitive load of 1500 VA /1200 W.
2. De-rate operating temperature above 4900 ft (1500m) by 2℃per 1000 ft (300m).
3. Refer to section 2.4.5 at the end of this Manual for additional Specifications.
Due to ongoing product improvements, specifications are subject to change without notice.