Always On GES-102NDM User manual

SLIMLINE / DOORMOUNT
UPS
For Traffic Applications
GES-102NDM – GES-152NDM
On Line: 1kVA, 1.5kVA
Operators Manual
M0301_N_Series_DM_Manual V1.4 2012-06-12

M0301_N_Series_DM_Manual V1.4 2012-06-12
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Always On UPS Systems
NoteNote
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.
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 and may void UL/cUL/CSA listing.
Unauthorized modifications also can result in personal injury, death, or destruction or the
equipment.
Any electrical or mechanical modifications to this equipment, without prior written consent of
Always On UPS Systems Inc, will void all warranties and may void UL/cUL/CSA listing.
Unauthorized modifications also can result in personal injury, death, or destruction or the
equipment.
Uninterruptible Power SupplyUninterruptible Power Supply
Please complete the Warranty Card supplied with this UPS and return it by mail to Always On
UPS Systems Inc. This activates the warranty.
Please complete the Warranty Card supplied with this UPS and return it by mail to Always On
UPS Systems Inc. This activates the warranty.
If additional information or technical assistance is required call:If additional information or technical assistance is required call:
Always On UPS Systems Inc Sales and Technical Support LineAlways On UPS Systems Inc Sales and Technical Support Line
Toll free at 1-877-259-2976 Ext. 451 or [phone] Ext. 451 or Fax [phone]Toll free at 1-877-259-2976 Ext. 451 or [phone] Ext. 451 or Fax [phone]
Or E-mail at [e-mail] E-mail at [e-mail] 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: ______________________________________________________________
M0301_N_Series_DM_Manual V1.4 2012-06-12 i

Always On UPS Systems
IMPORTANT SAFETY INSTRUCTIONS
•THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS THAT SHOULD BE
FOLLOWED DURING INSTALLATION AND MAINTENANCE OF THE UPS AND
BATTERIES.
•THE UPS 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 UPS 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.
•EXTERNAL VENTING AND OPENINGS IN THE CABINET ARE PROVIDED FOR
VENTILATION. TO ENSURE RELIABLE OPERATION OF THE PRODUCT AND
TO PROTECT FROM OVERHEATING, THESE OPENINGS MUST NOT BE
BLOCKED OR COVERED. OBJECTS MUST NEVER BE INSERTED INTO
VENTILATION HOLES OR OPENINGS.
•THE POWER TERMINAL BLOCK ON THE UPS DISTRIBUTION PANEL WILL BE
LIVE WHEN THE UNIT’S POWER SWITCH IS ON, WHETHER OR NOT THE
UNIT AC SUPPLY IS PRESENT.
•QUALIFIED PERSONNEL SHOULD BE CONSULTED WHEN:
1. LIQUID HAS BEEN SPILLED INTO THE UNIT
2. 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 UPS WAS DESIGNED TO POWER LOADS TYPICALLY FOUND IN MOST
MODERN MICROPROCESSOR CONTROLLED EQUIPMENT. DO NOT USE IT
FOR PURE INDUCTIVE OR CAPACITIVE LOADS. IT IS NOT RATED TO POWER
LIFE SUPPORT EQUIPMENT.
CAUTION:
ALL RECORDED MEDIA, SUCH AS DISKETTES, TAPES AND CARTRIDGES,
SHOULD BE KEPT A MINIMUM OF 60CM FROM THE UPS. THE MAGNETIC
FIELD CREATED BY OPERATION OF THE UPS MAY ERASE DATA ON THOSE
DEVICES.
ATTENTION:
INSTALL THE ON-LINE UPS IN A VENTILATED AREA, AWAY FROM
FLAMMABLE LIQUIDS, GASES, OR EXPLOSIVES. DO NOT LET THE UNIT COME
INTO CONTACT WITH WATER. POTENTIALLY LETHAL VOLTAGES EXIST
WITHIN THIS UNIT AS LONG AS THE BATTERIES ARE CONNECTED. DO NOT
TOUCH ELECTRICAL CIRCUITS WHEN POWER IS CONNECTED TO THE UPS.
TURN THE UPS “OFF” AND DISCONNECT THE UNIT FROM THE POWER SOURCE
BEFORE REMOVING THE COVER PLATES.
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 INSURE SAFE, RELIABLE
OPERATION OF THE UPS.
SAVE THESE INSTRUCTIONS
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M0301_N_Series_DM_Manual V1.4 2012-06-12 iii
MORE SAFETY INSTRUCTIONS
•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 UPS.
•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 UPS.
•DO NOT BLOCK AIR VENTS IN THE FRONT OF THE UPS OR AIR EXHAUSTS ON
THE SIDES.
•DO NOT PLACE OR OPERATE CLOSE TO GAS, HEATERS OR FIRE.
•DO NOT LET POWER CABLES CONTACT HOT SURFACES
•DO NOT PLUG APPLIANCES, SUCH AS HALF BRIDGE RECTIFIED LOAD, INTO
THE UPS.
•USE CAUTION WHEN SERVICING BATTERIES. BATTERY ACID CAN CAUSE
BURNS TO SKIN AND EYES. IF ACID IS SPILLED ON SKIN OR IN EYES, FLUSH
WITH FRESH WATER AND CONTACT A PHYSICIAN IMMEDIATELY.
•DO NOT OPERATE IF THE UNIT IS LEAKING LIQUID OR IF A WHITE POWDERY
RESIDUE IS PRESENT.
•BATTERIES MAY CONTAIN METALS AND OTHER CHEMICAL HAZARDOUS
WASTE. FOR PROPER DISPOSAL, CONSULT YOUR LOCAL STATE AND
FEDERAL EPA AND OTHER ENVIRONMENTAL LAWS AND REGULATIONS.
•THE POWER CONNECTION FOR UPS SHOULD BE WIRED IN ACCORDANCE
WITH LOCAL AND NATIONAL ELECTRICAL CODE SPECIFICATIONS.
•ONCE THE UPS IS CONNECTED TO AN ENERGY SOURCE SUCH AS THE
BATTERIES, THE OUTPUT TERMINALS MAY BE LIVE EVEN WHEN THE UPS IS
NOT CONNECTED TO AN AC SUPPLY.
•ONCE YOU HAVE CONNECTED THE BATTERY CONNECTORS, DO NOT
ATTEMPT TO LIFT THE BATTERIES OR BATTERY CABINETS.
•DO NOT CONNECT OR DISCONNECT BATTERY CABINETS WHILE THE UPS IS
OPERATING FROM BATTERY.
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.

Always On UPS Systems
M0301_N_Series_DM_Manual V1.4 2012-06-12 iv
Table of Contents
1.0 INTRODUCTION..........................................................1
1.1. MODES OF OPERATION................................................................................................................... 1
2.0 PRODUCT DESCRIPTION .........................................2
2.1. THEORY OF OPERATION .................................................................................................................2
2.2. BLOCK DIAGRAM............................................................................................................................2
2.3. DESCRIPTION OF EACH BLOCK ...................................................................................................... 3
2.4. OPERATIONAL FEATURES............................................................................................................... 4
3.0 HANDLING....................................................................6
3.1. DELIVERY .......................................................................................................................................6
3.2. INITIAL INSPECTION........................................................................................................................6
3.3. UPS STORAGE.................................................................................................................................6
3.4. BATTERY STORAGE........................................................................................................................ 6
4.0 INSTALLATION...........................................................7
4.1. LOCATION....................................................................................................................................... 7
4.2. CABINET VIEW................................................................................................................................ 7
4.3. ELECTRICAL CONSIDERATIONS......................................................................................................7
4.3. ELECTRICAL CONSIDERATIONS......................................................................................................8
4.4. INPUT,OUTPUT AND EXTERNAL BATTERY CONNECTION.............................................................9
4.5. BATTERY CONNECTION.................................................................................................................. 9
5.0 START-UP/SHUTDOWN...........................................11
5.1. TURN ON PROCEDURE:................................................................................................................. 11
5.2. TURN OFF /SHUTDOWN PROCEDURE:......................................................................................... 11
6.0 FRONT CONTROL PANEL......................................12
6.1. NORMAL DISPLAY ........................................................................................................................12
6.2. UPS METERING DISPLAY .............................................................................................................12
6.3. BUTTON OPERATION ....................................................................................................................13
6.4. CONTROL PANEL FUNCTIONS ...................................................................................................... 13
6.5. UPS CONFIGURATIONS.................................................................................................................13
7.0 AUDIBLE ALARM......................................................16
7.1. BACKUP MODE..............................................................................................................................16
7.2. LOW BATTERY..............................................................................................................................16
7.3. BYPASS .........................................................................................................................................16
7.4. FAULT ........................................................................................................................................... 16
8.0 BATTERY MAINTENANCE.....................................16
9.0 ENVIRONMENTAL PROTECTION........................16
10.0 SOFTWARE SETUP FOR STANDARD SOFTWARE
APPLICATIONS........................................................................17
10.1. CONNECTING THE UPS TO A COMPUTER.....................................................................................17
10.2. RS- 232 STANDARD INTERFACE PORT .........................................................................................17
10.3. EPO PORT (EMERGENCY POWER OFF).........................................................................................17
10.4. PROCEDURE FOR (OPTIONAL)EXTENDED BATTERIES ................................................................ 18
10.5. SNMP (NETWORK MANAGEMENT)ADAPTER (OPTIONAL)........................................................19
10.6. EXTENDED TEMPERATURE OPERATION.......................................................................................19
10.7. UPS STATUS MODULE FOR TRAFFIC APPLICATIONS ..................................................................19
10.8. AS-400 AND RELAY CONTACT (OPTIONAL ON STANDARD TEMPERATURE MODELS)................20
11.0 TROUBLESHOOTING...............................................21
12.0 TECHNICAL DATA ...................................................22
13.0 CONTACT INFORMATION.....................................23
13.1. ADDITIONAL PURCHASES OR UPGRADES ....................................................................................23
13.2. QA /WARRANTY QUESTIONS ......................................................................................................23
13.3. SOFTWARE QUESTIONS ................................................................................................................23

Always On UPS Systems
M0301_N_Series_DM_Manual V1.4 2012-06-12 1
1.0 Introduction
Congratulations on your choice of the Always On NDM Series On-Line Uninterruptible Power
System (UPS). The NDM Series Slimline/Doormount features the very latest, top of the line,
microprocessor technology and IGBT transistors for clean, highly regulated, PWM (Pulse
Width Modulated) True Sine Wave power all in a convenient, lightweight package. This
package allows for the easy installation of the UPS into a compact enclosure or cabinet doors
with the batteries located remotely for simple power conditioning and battery backup retrofit.
For ease of use, the NDM Series Slimline/Doormount utilizes an LCD display to indicate load
percentage, battery capacity, input voltage, output voltage, input frequency, output frequency,
internal UPS temperature and the mode of operation. It also provides self-diagnostics, a
combination On/Alarm Silence/Manual Battery Test button, a combination Off/Bypass button,
and two levels of alarms when the unit is operating on battery.
The NDM Series Slimline/Doormount incorporates an interface port for communications
between a status contact module, with dry contacts and programmable timer relay, or a PC and
provisions to connect an external charger and additional monitoring features described later in
the manual.
1.1. Modes of Operation
The NDM Series Slimline/Doormount UPS is designed to continuously operate on-
line as a dual conversion system in the following modes:
Normal - The critical AC load is continuously supplied by the UPS Inverter. The
input Rectifier derives power from a utility AC source and supplies power to the
Inverter while simultaneously float-charging the storage batteries.
Back-Up - Upon failure of utility AC power, the Inverter obtains power from the
batteries without interruption. There are no interruptions in power to the critical load
upon failure or restoration of the utility AC source.
Recharge - Upon restoration of utility AC power after an outage, the Rectifier will
automatically restart and supply power to the inverter and battery charger. For larger
battery banks, an external boost charger may be necessary to aid in reducing recharge
time.
Automatic Restart - Upon restoration of utility AC power, after an extended outage
and complete battery discharge, the UPS will automatically restart and resume
supplying power to the critical load. Also the battery charger will automatically
recharge the batteries. This feature is enabled in the factory and is capable of being
disabled (consult factory).
Static Bypass - The bypass will provide an alternate path for power to the critical
load and is capable of operating in the following manner:
Automatic - In the event of the inverter overload capacity being exceeded or
should an internal failure occur, the UPS will perform an automatic transfer of
the critical AC load from the inverter to the bypass source.
Manual - Should the UPS need to be taken out of service for limited
maintenance or repair, manual activation of the bypass will cause an immediate
transfer of the critical AC load from the inverter to the bypass source. The input
rectifier, inverter, and battery charging operations will be inhibited until the user
transfers the UPS back to normal operation.

Always On UPS Systems
2.0 Product Description
2.1. Theory of Operation
The UPS (Uninterruptible Power Supply) is designed for installation between utility
(commercial supplied power) and your loads. The dual conversion online UPS
provides a totally reconstructed and regulated true sine wave. Thus it may be used to
protect your loads from any power fluctuations (e.g. blackouts, brownouts, over-
voltage conditions). The UPS will supply a sufficient amount of steady, constant AC
power during these power fluctuations.
To go further, the slimline/doormount UPS is designed to provide total power
protection to the sensitive equipment of your traffic cabinets.
2.2. Block Diagram
Figure 2.2.1
Block Diagram for N Series
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Always On UPS Systems
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2.3. Description of Each Block
Input Fuse:Provides secondary circuit protection and a further reduces possible
damage to the system.
EMI/RFI Filter: This filter attenuates the electrical noise associated with the
polluted utility power to the UPS or noise (THD) generated by the UPS.
Rectifier / Power Factor Correction (PFC): During normal operation, the
rectifier/power factor correction (PFC) circuit converts the utility power (AC power)
to DC power, which in turn is used by the inverter, while ensuring that the waveform
of the input current used by the UPS is close to ideal. This type of conversion and
technology maintains two key objectives: the utility power is used as efficiently as
possible, and the amount of distortion reflected back to the utility is minimized
therefore providing cleaner power to other devices in the building not being protected
by the N Series.
PFC Control: By utilizing control circuits, the current drawn from the utility
power is in-phase with the input voltage. The control circuit also allows the
UPS to have a broader input voltage range (±25%).
Charger: During normal operation, it converts AC voltage drawn from utility power
into regulated DC voltage, which charges or maintains the batteries at the desired
level by a float charge.
Batteries: Sizes will vary in series and series-parallel configurations. Batteries are
Sealed Lead-Acid Valve regulated gel cells.
DC-to-DC Converter: The converter utilizes energy from the battery system and
raises the DC voltage to the DC Bus operating voltage for the inverter. This allows
the inverter to operate continuously at its optimum efficiency and voltage, thus
increasing reliability.
Inverter: The term inverter will denote the solid-state equipment and controls used
to convert power from the input rectifier or batteries to regulated pure sine wave AC
power for supporting the loads. The inverter will produce 50 or 60Hz (auto-
selectable) using Insulated Gate Bipolar Transistors (IGBT’s) switching at
approximately 20kHz, above the audible frequency range, and without low frequency
magnetic components. The inverter is of pulse width modulated (PWM) design
capable of providing the specified AC output with a very small tolerance (±2%), with
little to no distortion.
CPU/Control/User Interface: The CPU controller monitors and maintains all
systems within the UPS while permitting communication between the UPS, user and
peripheral devices.
Static By-pass: A static transfer switch and bypass circuit is provided as an integral
part of the UPS. The inverter has an overload rating of 125% rated load for one
minute, 150% rated load for 20 seconds, 200% rated load for one and a half cycles.
The static bypass will auto transfer to bypass if these overload conditions are
exceeded. The static transfer switch control logic will contain an automatic transfer
control that senses the status of the inverter logic signals, and operating and alarm
conditions. This control circuit will provide an uninterrupted transfer of the load to a
normal input source (or alternate bypass source). Transfers are made when an
overload or malfunction occurs within the UPS, without exceeding the transient limits
specified herein.

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M0301_N_Series_DM_Manual V1.4 2012-06-12 4
2.4. Operational Features
Normal Mode
System operates within user-defined settings. The input operating range is based on
the Input Frequency Setting and the Input/Bypass Voltage Setting (Chapter 6.5). The
output is synchronized with the input until the AC supply falls outside of the
operating window, at which time the system will go the back-up mode and remain
there until the AC supply returns to the user defined operating window or the batteries
are exhausted.
Free Run Mode
The UPS synchronizes the output of the inverter with the AC supply as long as the
input frequency and voltage are within the user selected Input Frequency Setting and
the Input/Bypass Voltage Setting (Chapter 6.5). When the AC supply parameters are
outside of the selected window the inverter will lock to the frequency determined on
start-up (50 or 60Hz) and maintain that setting until the AC supply is back with
operating parameters or the batteries are exhausted. The static (or automatic) bypass
in this mode is available when the AC supply is within the selected operating
parameters. If the AC supply is outside the operating window the bypass will be
disabled (as per factory default). This function can be changed and the system can be
programmed to go to bypass without the inverter and AC supply being synchronized.
Please refer to chapter 6.5 if you want bypass available while running in free run
mode.
Efficiency Optimizer function (HE Mode see Front Display functions)
The high efficiency function adds cost effectiveness, maximizes efficiency and
reduces power consumption. Alternating between bypass and on-line modes is
achieved automatically and in accordance with the conditions of the AC supply
power. On-line mode may be used during times of intermittent power, and bypass
mode when the utility is within user selectable parameters (see Front Display
Functions) in order to obtain greatest efficiency. Irregularities can be detected in less
than a second, and on-line mode reactivated immediately. Switching back to on-line
mode occurs when input voltage is outside ±10% of nominal (± 15% selectable),
when input frequency is outside of ±3Hz or when no input utility is present.
Although high efficiency is standard, the default operation is in on-line mode. The
bypass can be activated in the LCD panel, though on-line can be run permanently if
preferred.
Generator Mode
The inverter of the UPS system is locked to the frequency determined on start-up (50
or 60Hz) within ±0.25Hz. The bypass is disabled and cannot be enabled because the
AC supply can vary independently of the output. The operating parameter for the
input is 45 to 65Hz and 60 to 144VAC (depending on load). This function is highly
recommended for any application with a generator involved or an AC supply that can
vary in frequency (VFD’s and other harmonic issues). See chapter 6.5 for
programming.
Diagnostic tests
When you start the UPS, a diagnostic test is automatically executed that checks
electronics, battery, and reports any problems on the LCD display.
An advanced battery management system always monitors the conditions of the
batteries sending any forewarnings if replacement is needed. Otherwise every 30 days
of normal operation, a battery discharge test is performed and, if a problem arises it
will be reported on the LCD display.