Lamarche TPSD User manual

La Marche Manufacturing Company | www.lamarchemfg.com
TPS
D

Filtered Battery Charger / Power Supply /
Battery Eliminator
Installation and Operation Manual

106 Bradrock Dr. Des Plaines 60018-1967
Tel: [phone] Fax: [phone] CPN 127775 Instruction Drawing Number: P25-LTPSD-2 Revision A02 Rev. Date: 12/16 ECN: 21183-2

i
Important Safety Instructions
Before using this equipment read all manuals and other documents related to this unit and other equipment
connected to this unit. Always have a copy of a units manual on file nearby, in a safe place; if a replacement
copy of a manual is needed it can be found at the www.lamarchemfg.com.
Electrical Safety
WARNING: Hazardous Voltages are present at the input of power systems. The output from
rectifiers and from batteries may be low in voltage, but can have a very high current capacity that
may cause severe or even fatal injury.
When working with any live battery or power system, follow these precautions:
Never work alone on any live power system, someone should always be close enough to come to your aid
Remove personal metal items such as rings, bracelets, necklaces, and watches.
Wear complete eye protection (with side shields) and clothing protection.
Always wear gloves and use insulated hand tools.
WARNING: Lethal Voltages are present within the power system. Parts inside the unit may still be
energized even when the unit has been disconnected from the AC input power. Check with a meter
before proceeding. Do not touch any uninsulated parts.
A licensed electrician should be used in the installation of any unit.
Always disconnect the unit from the supply, batteries and loads before performing maintenance or cleaning.
If the unit is hot-swappable, simply remove it from the shelf for any maintenance or cleaning.
Always assume that an electrical connection is live and check the connection relative to ground.
Be sure that neither liquids nor any wet material come in contact with any internal components.
Do not operate this unit outside the input and output ratings listed on the unit nameplate.
Do not use this unit for any purpose not described in the operation manual.
Mechanical Safety
This unit or parts of the unit may get very hot during normal operation, use care when working nearby.
Do not expose equipment to rain or snow. Always install in a clean, dry location.
Do not operate equipment if it has received a sharp blow, been dropped, or otherwise damaged in any way.
Do not disassemble this unit. Incorrect re-assembly may result in a risk of electric shock or fire.
Battery Safety
WARNING: Follow all of the battery manufacturer’s safety recommendations when working with or
around battery systems. DO NOT smoke or introduce a spark or open flame in the vicinity of a
battery. Some batteries generate explosive gases during normal battery operation.
To reduce risk of arc, connect and disconnect the battery only when the unit is off.
If it is necessary to remove battery connections, always remove the grounded terminal from the battery first.
Remove personal metal items such as rings, bracelets, necklaces, and watches.
Always wear rubber gloves, safety glasses, and a rubber lined vest/apron when working near a battery.
Have plenty of fresh water and soap nearby in case the battery electrolyte contacts skin, clothing, or eyes.
If the battery electrolyte contacts skin or clothing, wash immediately with soap and water.
If the electrolyte enters the eye, immediately flood the eye with running cold water for at least ten (10)
minutes and seek medical attention immediately.
Do not drop metal on a battery. A spark or short-circuit could occur and could cause an explosion.

ii
Unit Location
Allow at least 6 inches of free air on all vented surfaces for proper cooling
Allow sufficient clearance to open the front panel for servicing.
Do not operate this unit in a closed-in area or restrict ventilation in any way.
Do not set any battery on top of this unit.
Never allow battery electrolyte to drip on this unit when reading the specific gravity or filling the battery.
Never place this unit directly above a standard flooded battery. Gases from the battery will corrode and
damage equipment.
A sealed maintenance free or valve regulated lead acid (VRLA) battery may be placed below this equipment.
Check for Damages
Prior to unpacking the product, note any damage to the shipping container. Unpack the product and inspect the
exterior of product for damage. If any damage is observed, contact the carrier immediately. Continue the
inspection for any internal damage. In the unlikely event of internal damage, please inform the carrier and
contact La Marche for advice on the risk due to any damage before installing the product. Verify that you have
all the necessary parts per your order for proper assembly.
CAUTION: Failure to properly file a claim for shipping damages, or provide a copy of the claim to La
Marche, may void warranty service for any physical damages reported for repair.
Returns for Service
Save the original shipping container. If the product needs to be returned for service, it should be packaged in its
original shipping container. If the original container is damaged/unavailable, make sure the product is packed
with at least three inches of shock-absorbing material to prevent shipping damage.
La Marche is not
responsible for damage caused by improper packaging of returned products.
Inspection Checklist
・Enclosure exterior and interior is not marred or dented.
・There is no visible damage components.
・all internal components are secure.
・Printed circuit boards are firmly seated.
・All hardware and connections are tight.
・All wire terminations are secure.
・All items on packing list have been included.
Handling
Equipment can be very heavy and/or top heavy. Use adequate manpower or equipment for handling. Until the
equipment is securely mounted, care must be used to prevent equipment from be accidentally tipped over.

iii
Table of Contents
Important Safety Instructions......................................................................................................................i 
Electrical Safety.......................................................................................................................................i
Mechanical Safety....................................................................................................................................i
Battery Safety.........................................................................................................................................i
Unit Location..........................................................................................................................................ii
Check for Damages ................................................................................................................................ii
Returns for Service.................................................................................................................................ii
Inspection Checklist................................................................................................................................ii
Handling................................................................................................................................................ii
Table of Contents..................................................................................................................................... iii
Table of Figures ........................................................................................................................................v
Model Scope/General Description...............................................................................................................vi
Understanding the Model Number..............................................................................................................vi
Optional Accessories Included in the Unit....................................................................................................vi
1Equipment Handling............................................................................................................................1
1.1Storing the TPSD.........................................................................................................................1
1.2Moving the TPSD.........................................................................................................................1
2Installation.........................................................................................................................................3
2.1Mounting the TPSD .....................................................................................................................3
2.1.1Wall-Mounting the TPSD (4B, 4 and 9 Cases Only) .....................................................................3
2.1.2Floor-Mounting the TPSD (All Cases) .........................................................................................5
2.1.3Rack-Mounting the TPSD..........................................................................................................6
2.2Changing Transformer Taps .........................................................................................................7
2.2.1Changing Transformer Taps Procedure......................................................................................8
2.3Making the AC Input Connections .................................................................................................9
2.4Making the DC Output Connections.............................................................................................10
2.5Alarm Connections ....................................................................................................................11
2.5.1Alarm Connection Procedure...................................................................................................11
2.5.2Understanding the Alarms ......................................................................................................12
2.6Installing External Temperature Compensation (Option 11W/11Y).................................................15
2.7Enabling Load Sharing...............................................................................................................16
2.8Enabling/Disabling Ground Detection ..........................................................................................17
2.9DNP 3 / Modbus Scada Interface (Option 21P/21Q)......................................................................17
2.10Battery side alarm sensing (Option 565)......................................................................................18
3Operation.........................................................................................................................................19
3.1Starting the TPSD......................................................................................................................19
3.1.1Checking the Installation........................................................................................................19
3.1.2Starting/Stopping the TPSD....................................................................................................19

iv
3.1.3Start-Up Sequence.................................................................................................................19
3.2Digital Control Board .................................................................................................................20
3.3Selecting the Charging Mode......................................................................................................21
3.3.1Equalize Timer Modes ............................................................................................................21
3.4Adjusting Parameters.................................................................................................................22
3.4.1Settings Menu .......................................................................................................................22
3.4.1.5. Communications Settings..........................................................................................................25
3.5Test Menu ................................................................................................................................26
3.5.1Test LEDs .............................................................................................................................26
3.5.2Test Relays...........................................................................................................................26
4Service.............................................................................................................................................28
4.1Performing Routine Maintenance ................................................................................................28
4.2Troubleshooting Procedure.........................................................................................................29
4.3Symptoms & Causes..................................................................................................................30
4.3.1AC Breaker Trips....................................................................................................................30
4.3.2Open DC Fuse or Breaker.......................................................................................................30
4.3.3Charger Operates but Output Voltage/Current Low...................................................................30
4.3.4Charger Operates but Output Voltage is High...........................................................................30
4.3.5Ground and Short Circuit Test.................................................................................................31
4.3.6Troubleshooting the TRIAC.....................................................................................................31
4.3.7Troubleshooting and Replacing Power Silicon Diodes/Modules ...................................................31
4.3.8Checking Capacitors...............................................................................................................31
Appendix A: TPSD Specifications...............................................................................................................32
Appendix B: TPSD Current Draw and Feeder Breaker Sizes..........................................................................33
Appendix C: TPSD Heat Losses.................................................................................................................35
Appendix D: Field Installable Accessory Kits...............................................................................................36
Appendix E: Manufacturer’s Warranty........................................................................................................37
Appendix F: Manufacturer’s Extended Parts Warranty.................................................................................38
Appendix G: Document Control and Revision History...................................................................................39

v
Table of Figures
Figure 1 - Mounting configurations (4B Case front view) ...............................................................................3
Figure 2 - Mounting configurations (4B Case top view)..................................................................................3
Figure 3 - 4B Case Bolt Pattern...................................................................................................................4
Figure 4 - 4 Case Bolt Pattern.....................................................................................................................4
Figure 5 - 9 Case Bolt Pattern.....................................................................................................................4
Figure 6 - TPSD Case Footprint...................................................................................................................5
Figure 7 - Rack-Mounting Configurations (4B Case) .....................................................................................6
Figure 8 - Input Terminals Connection (Schematic – 240VAC input shown).....................................................8
Figure 9 - Customer Alarm Connection Card...............................................................................................11
Figure 10 - Example Connections (Customer Provided Equipment)...............................................................12
Figure 11 - Temperature Compensation Connection (External and Internal)..................................................15
Figure 12 - Load Sharing Connection (Schematic wiring).............................................................................16
Figure 13 – Digital Control Card S2A-341S (Back View)...............................................................................17
Figure 14 - DNP 3 / Modbus Communication Card ......................................................................................18
Figure 15 - TPSD Front Panel....................................................................................................................20
Table 1 - Case Type and Weight (Single Phase, 6-100 ADC)..........................................................................1
Table 2 - Case Type and Weight (Three Phase, 25-200 ADC).........................................................................2
Table 3 - Available mounting methods for each of the TPSD case sizes...........................................................3
Table 4 - Available Rack Mount Configurations .............................................................................................6
Table 5 - Input Terminal Connections..........................................................................................................8
Table 6 - Wire Size Minimum Requirements .................................................................................................9
Table 7 - Wire Size/Area Table..................................................................................................................10
Table 8 – Alarm Form “C” Contact Ratings.................................................................................................11
Table 9 – State of each Alarm Relay (No alarms present)............................................................................13
Table 10 – Factory setting for alarm time delays ........................................................................................14

vi
Model Scope/General Description
The La Marche model TPSD is a controlled ferroresonant float charger designed to power a load while charging
the battery. The TPSD is filtered and may be used without the battery. The all solid state electronic control
circuit provides excellent line-load voltage regulation, current limiting, and a power failure relay with light and
Form “C” contacts. The TPSD is offered with DC output voltages of 24, 48 or 130VDC with output currents from
6 to 200 Amps. These chargers may be powered with 120, 208, 240, or 480VAC.
Understanding the Model Number
The TPSD model number is coded to describe the options that are included. Find the model number on the
nomenclature nameplate of the charger. Then follow the chart to determine the configuration of your battery
charger.
Optional Accessories Included in the Unit
This unit may have been outfitted with a number of optional accessories or option packages. To find out what
options this unit has (if any) refer to the very first page of the manual package.

1
1 Equipment Handling
1.1 Storing the TPSD
If the TPSD is to be stored for more than a few days after delivery, it should be stored within its shipping
container. The location chosen for storage should be within an ambient temperature of -40 to 185° F (-40 to
85° C) with a non-condensing relative humidity of 0 to 95%. Storage should not exceed 2 years due to the
limited shelf life of the DC filter capacitors when they are not in service.
1.2 Moving the TPSD
After careful inspection and upon verification that the TPSD is undamaged, identify the enclosure style and
weight of the TPSD unit. Refer to the tables below.
Output
Voltage Frequency Ampere Rating
6 ADC 12 ADC 20 ADC 25 ADC 30 ADC 35 ADC 50 ADC 75 ADC 100 ADC
24 VDC
60 Hz
4B Case 4B Case 4 Case 4 Case 4 Case 4 Case 4 Case 4 Case 9 Case
90 lbs 90 lbs 100 lbs 125 lbs 150 lbs 154 lbs 175 lbs 211 lbs 225 lbs
(40.8 kg) (40.8 kg) (45.4 kg) (56.7 kg) (68 kg) (69.9 kg) (79.4 kg) (95.7 kg) (102.1 kg)
50 Hz
4 Case 4 Case 4 Case 4 Case 4 Case 4 Case 9 Case
110 lbs 138 lbs 165 lbs 170 lbs 193 lbs 233 lbs 248 lbs
(49.8 kg) (62.6 kg) (74.8 kg) (77.1 kg) (87.5 kg) (105.7 kg) (112.5 kg)
48 VDC
60 Hz
4B Case 4B Case 4 Case 4 Case 4 Case 4 Case 4 Case 9 Case 9 Case
90 lbs 110 lbs 150 lbs 150 lbs 155 lbs 180 lbs 205 lbs 295 lbs 321 lbs
(40.8 kg) (49.9 kg) (68 kg) (68 kg) (70.3 kg) (81.7 kg) (93 kg) (133.8 kg) (145.6 kg)
50 Hz
4 Case 4 Case 4 Case 4 Case 4 Case 9 Case 9 Case
165 lbs 165 lbs 171 lbs 198 lbs 225 lbs 325 lbs 354 lbs
(74.8 kg) (74.8 kg) (77.6 kg) (89.8 kg) (102.1 kg) (147.4 kg) (160.6 kg)
130 VDC
60 Hz
4 Case 4 Case 4 Case 4 Case 9 Case 9 Case 9 Case
140 lbs 175 lbs 225 lbs 250 lbs 319 lbs 372 lbs 532 lbs
(63.5 kg) (79.4 kg) (102.1 kg) (113.4 kg) (144.7 kg) (168.7 kg) (241.3 kg)
50 Hz
4 Case 4 Case 4 Case 4 Case 9 Case 9 Case 9 Case
154 lbs 193 lbs 233 lbs 275 lbs 352 lbs 410 lbs 586 lbs
(69.9 kg) (87.5 kg) (105.7 kg) (124.7 kg) (159.7 kg) (186 kg) (265.8 kg)
Table 1 - Case Type and Weight (Single Phase, 6-100 ADC)

2
Output
Voltage Frequency Ampere Rating
25 ADC 30 ADC 35 ADC 50 ADC 75 ADC 100 ADC 125 ADC 150 ADC 200 ADC
24 VDC 60 Hz
72 Case 72 Case 72 Case 72 Case
400 lbs 475 lbs 530 lbs 600 lbs
(181.4 kg) (215.5 kg) (240.4 kg) (272.2 kg)
48 VDC 60 Hz
72 Case 72 Case 72 Case 72 Case 72 Case
400 lbs 575 lbs 600 lbs 700 lbs 755 lbs
(181.4 kg) (260.8 kg) (272.2 kg) (317.5 kg) (342.5 kg)
130 VDC
60 Hz
72 Case 72 Case 72 Case 72 Case 72 Case 72 Case 44 Case 44 Case
420 lbs 490 lbs 550 lbs 600 lbs 660 lbs 800 lbs 850 lbs 900 lbs
(190.5 kg) (222.3 kg) (249.5 kg) (272.2 kg) (299.4 kg) (362.9 kg) (385.6 kg) (408.2 kg)
50 Hz
72 Case 72 Case
727 lbs 882 lbs
(329.8 kg) (400.1 kg)
Table 2 - Case Type and Weight (Three Phase, 25-200 ADC)
The 4B & 4 enclosures do not feature lifting eyes for moving. Instead, whenever possible move these units
with a forklift truck using the supplied shipping pallet. To hoist the unit into a wall-mount or rack-mount
location, use a heavy-duty sling applicable to the enclosure size and unit weight. To relocate the 4B & 4
enclosures, use the aforementioned sling on a hoist or forklift truck.

3
2 Installation
2.1 Mounting the TPSD
When mounting the TPSD in ANY configuration, consider the size and weight of the unit. The wall, rack, and/or
floor must be able to support the weight of the unit as well as an additional safety factor. Verify the method of
mounting and the weight of the TPSD, using Tables 1, 2, and 3. The location chosen for the charger should be
within an ambient temperature range of 32 to 122˚F (0 to 50˚C) with a non-condensing relative humidity no
higher than 95%. The TPSD should be mounted in an area free of explosive materials and away from drips and
splatter. The TPSD utilizes convection cooling so a clearance of at least 6in (152mm) of free air must be
maintained on the top, bottom and both sides for cooling air. Maintain 36in (914mm) or more of clearance at
the front of the charger in order to allow for operation and maintenance.
Case Number Cable Entry Mounting
AC Input DC Output
4B Right Left
19/23” Rack, Wall/Floor
(see Fig. 1a and 1b)
4 Right Left
19/23” Rack, Wall/Floor
(see Fig. 1a and 1b)
9 Top Right Top Left 23/30” Rack, Wall/Floor
(see Fig. 1a and 1b)
72 Right / Bottom Bottom Floor
44 Left Right Floor
Table 3 - Available mounting methods for each of the TPSD case sizes
Figure 2 - Mounting configurations
(4B Case top view)
Figure 1 - Mounting configurations
(4B Case front view)

4
2.1.1 Wall-Mounting the TPSD (4B, 4 and 9 Cases Only)
The 4B, 4 and 9 cases of the TPSD are shipped from the factory with the necessary brackets installed for wall-
mounting
(The same bracket is used for rear mounting on a relay rack, 4B and 4 – 19/23” rack, 9 – 23/30”
rack)
The 72 & 44 cases do not come with wall mounting equipment, it is not recommended to attempt to
mount these cases on any wall.
Wall-Mount Procedure
To wall-mount the TPSD, install four 0.5 in (12.7 mm) bolts on the wall rated to support the charger weight plus
a safety factor of at least two times. Place the TPSD on the bolts, add appropriate mounting hardware and
tighten. Refer to the figures below for mounting dimensions and specifications.
NOTE: All above dimensions are in inches. For further TPSD cabinet information, see the outline drawings for
the 4B case (4B, 4B-23) 4 case (4, 4_23) and 9 case (9, 9_30) online at
http://www.lamarchemfg.com/info/enclosure-drawings.html
Figure 5 - 9 Case Bolt Pattern
Figure 3 - 4B Case Bolt Pattern
Figure 4 - 4 Case Bolt Pattern

5
2.1.2 Floor-Mounting the TPSD (All Cases)
Floor-mounting the 72 & 44 cases is standard. If it is desired to floor mount a charger with the 4B, 4 or 9case
the floor-mount bracket is provided.
NOTE: The floor mount bracket adds an additional 2 in (51 mm) to the overall height of 4B, 4 and 9 cases. 72
and 44 cases include the height of the bracket in their overall height
Floor-Mounting Procedure
To floor-mount the TPSD, install four bolts into the floor. Place the TPSD on the bolts, add appropriate
mounting hardware, and tighten securely. The figure below shows the footprint and the bolt size of each TPSD
case style. (All dimensions are in inches)
A
B Bolt Size
4B 15.5
11.219
1/4
4 15.25 1/4
9 19.238 5/16
72 25.75 17.5 1/4
44 22 17.06 3/8
Figure 6 -
T
PSD Case Footprint

6
2.1.3 Rack-Mounting the TPSD
The TPSD can be installed in most relay racks with standard EIA hole spacing. If a relay rack is needed they are
available for purchase from La Marche. The 4B, 4 and 9 cases are shipped from the factory with the necessary
brackets installed for rear mounting on a relay rack
(The same bracket is used for wall mounting). The rack
mounting bracket for the 4B and 4 cases allows for mounting on either a 19” or 23” rack. The rack mounting
bracket for the 9 case allows for mounting on a 23” or 30” rack.
Before installing the charger on the rack locate the conduit entrances and be sure the knockouts on the sides or
bottom of the charger are accessible after the charger is rack-mounted.
The table and figure below shows rack-mounting options for TPSD.
Rack Mounting Procedure
To rack mount the TPSD, first mount the unit onto the
rack-mounting brackets using the hardware supplied.
Second, install the brackets onto the rack. Provide at
minimum 6in (152mm) of air space above and below
to allow for cooling.
If you are center-mounting the charger, install the bracket on the front side of the relay rack. If you are
rear-mounting the charger, install the bracket to the back side of the relay rack, as pictured in the Figure 4
above-left.
Case
Number Rear Mounting Center Mounting
4B Yes
(19” rack only) Yes
4 Yes
(19” rack only) Yes
9No Yes
72 No No
44 No No
T
able 4 -
A
vailable Rack Mount Configurations
Rear
Mounting
Center
Mounting
Figure 7 - Rack-Mounting Configurations
(4B Case)

7
2.2 Changing Transformer Taps
NOTE: This procedure refers only to TPSD battery chargers that accept three input voltages of 120, 240 and
208 VAC [Voltage code: ABD]. All other TPSD battery chargers do not include transformer taps.
Before wiring AC power to the TPSD, check the wiring of the power transformer PT, to be sure it is connected
for the correct AC input voltage. The TPSD accepts standard input voltages of 120, 208 or 240 VAC by changing
the connections to the input terminals. No other changes are required.
NOTE: The TPSD is wired at the factory for 240 VAC, except on special request...
Before changing the PT taps, be sure that AC supply and DC loads to the TPSD are turned off and locked out.
Verify that no voltage is present by using a voltmeter at all input and output terminals. Turning off the AC and
DC circuit breakers on the TPSD
does NOT eliminate live voltages inside the enclosure. Also de-energize any
external wiring to the alarm relay contacts.
Verify that all voltages within the enclosure are de-energized and locked out. Change the connections to the
input terminals as shown in the table and figure on the following page.
NOTE: A TPSD battery charger rated for 480 VAC or 600 VAC input uses a special transformer that has no taps.
The 480 VAC and 600 VAC transformers cannot be used for any other input voltage.

8
2.2.1 Changing Transformer Taps Procedure
Before beginning any work inside the charger enclosure ensure that all incoming AC supply and DC load wires
are de-energized. Verify that no voltage is present inside the case by using a voltmeter at all input and output
terminals.
For 120 VAC Input Voltage:
1. For terminal strip TS-3, connect a jumper
wire from terminal 1to terminal 2.
2. For terminal strip TS-4, connect wire
marked Dto terminal 3.
3. For terminal strip TS-4, connect wire
marked Eto terminal 1.
Note that AC input 1 connects to terminal L1
Note that AC input 2 connects to terminal L3
For 208 VAC Input Voltage:
1. For terminal strip TS-3: connect a jumper wire from
terminal 2to terminal 3.
2. For terminal strip TS-4: connect wire marked Dto
terminal 2.
3. For terminal strip TS-4: connect wire marked Eto
terminal 3.
Note that AC in 1 connects to terminal L1
Note that AC in 2 connects to terminal L2
For 240 VAC Input Voltage:
1. For terminal strip TS-3: connect a jumper wire from
terminal 2to terminal 3.
2. For terminal strip TS-4: connect wire marked Dto terminal 1.
3. For terminal strip TS-4: connect wire marked Eto terminal 3.
Note that AC in 1 connects to terminal L1
Note that AC in 2 connects to terminal L2
ACin1 ACin2 TS-3
Jumper
Connection
TS-4
DE
INPUT
VAC
120 L1 L3 1-2 3 1
208 L1 L2 2-3 23
240 13
Figure 8 - Input Terminals Connection
(Schematic – 240VAC input shown)
Table
5
-
Input Terminal Connections

9
2.3 Making the AC Input Connections
Before making any connections to the TPSD ensure that the AC Power is off at the main breaker box and that
both of the unit’s breakers are off. Check that the source voltage and frequency matches the voltage and
frequency listed on the charger nameplate. For units with transformer taps, verify that the tap has been set to
the correct AC input. (See Section 2.2.1 for instructions on changing the transformer tap). Select wire size,
using the table below, based on an overload current of 110-115% of the input current listed on the charger
nameplate.
BREAKER\FUSE
SIZE
(AMPS)
WIRE SIZE
REQUIREMENT
FOR CUSTOMER
CONNECTION
EQUIPMENT
GROUNDING
CONDUCTOR
MINIMUM
1 #14 #14
3 #14 #14
4 #14 #14
5 #14 #14
6 #14 #14
10 #14 #14
15 #12 #12
20 #12 #12
25 #10 #12
30 #10 #10
35 #8 #10
40 #8 #10
45 #8 #10
50 #8 #10
60 #6 #10
70 #6 #8
80 #4 #8
90 #4 #8
100 #4 #8
110 #2 #6
125 #2 #6
130 #2 #6
140 #1 #6
150 #1 #6
Table 6 - Wire Size Minimum Requirements
NOTE: These are recommended sizes. All National and Local Wiring Codes must be followed
AC Connection Procedure
First connect an adequate earth ground lead (use table above for sizing) to the terminal marked “GROUND” or
“GND”. Run the input AC wiring to terminals marked L1 and L2 or L3 on the terminal block TB1 inside the unit
(for units with transformer taps use the table on page 8 for input connections). To make these connections,
strip the insulation about 0.5 inches (13 mm) and install the lugs on the incoming wires, then connect the wires
to the appropriate terminals.

10
2.4 Making the DC Output Connections
Before making any of DC output connections make sure you have read and fully understand the DC Connection
Procedure below.
Select proper size for the DC wiring from the wire size table on the previous page. If the
distance between the unit’s DC output and the DC load exceeds 10 feet, use the Power Cable Guide below to
minimize the voltage drop across the wire distance.
Power Cabling Guide
Use the following formulas and table to determine proper wire size for minimal voltage drop.
Table of Conventions
CMA = Cross section of wire in circular MIL area
A = Ultimate drain in amperes
LF = Conductor loop feet
MaxAmp = Maximum allowable amperes for given voltage drop
AVD = Allowable voltage drop
K = 11.1 for commercial (TW) copper wire (KS5482-01)
= 17.4 for aluminum (KS20189)
Calculating Wire Size Requirements
AVD KLFA
CMA  
Calculating Current Carrying Capacity of Wire
KLF AVDCMA
MaxAmp 


DC Connection Procedure
To prevent the DC circuit breaker from tripping when connecting the battery, connections should be done in the
following order.
1. Turn off the unit’s AC and DC circuit breakers.
2. Connect AC input line to the unit’s input terminals as described in Section 2.3.
3. Connect the battery cables to the unit’s DC output terminals.
OBSERVE PROPER POLARITY.
4. Energize the power supply by turning on the unit’s AC breaker. This will charge the capacitors inside the
unit and eliminate heavy arcing when the battery is connected.
5. After about 30 seconds, turn on the DC breaker
SIZE
(AWG) AREA CIR.MILS SIZE (MCM) AREA CIR.MILS
18 1620 250 250000
16 2580 300 300000
14 4110 350 350000
12 6530 400 400000
10 10380 500 500000
8 16510 600 600000
6 26240 700 700000
4 41740 750 750000
3 52620 800 800000
2 66360 900 900000
1 83690 1000 1000000
0 105600 1250 1250000
00 133100 1500 1500000
000 167800 1750 1750000
0000 211600 2000 2000000
T
able 7 - Wire Size/Area Table

11
2.5 Alarm Connections
Eight alarms are included as a standard feature of the TPSD. The included alarms are Low DC Current, Low DC
Voltage, High DC Voltage, High Voltage Shutdown, AC Failure, Negative Ground Detection, Positive Ground
Detection and Summary. Each alarm includes two form “C” contacts enabling the customer to connect multiple
remote annunciators.
Max. Operating Voltage 125 VAC
125 VDC
Max. Operatin
g
Current 2 A
Max. Switching Capacity 62.5 VA
30 W
2.5.1 Alarm Connection Procedure
Before making any connections to the TPSD ensure that the AC Power is off at the main breaker box and that
both of the unit’s breakers are off. Verify that no voltage is present by using a voltmeter at all input and output
terminals.
For High DCV, High DCV Shutdown, Positive Ground, and Negative Ground:
If it is desired that the annunciator be active until the alarm triggers connect the annunciator leads to the
Normally Closed and Common contacts of the desired alarm (located on the Customer Alarm Connection
Card
S2A-198A ). If it is desired that the annunciator be activated after the alarm triggers connect the
annunciator leads to the Normally Open and Common contacts of the desired alarm.
For Low DCV, AC Power Failure, Low DCA, and Summary:
If it is desired that the annunciator be active until the alarm triggers connect the annunciator leads to the
Normally Open and Common contacts of the desired alarm (located on the Customer Alarm Connection Card
S2A-198A ). If it is desired that the annunciator be activated after the alarm triggers connect the annunciator
leads to the Normally Closed and Common contacts of the desired alarm.
Table 8
–
A
larm Form “C” Contact Ratings
Figure 9 - Customer
A
larm Connection Card

12
Example of connecting a “Summary” alarm
Before making any connections to the TPSD ensure that the AC Power is off at the main breaker box and that
both of the unit’s breakers are off. Verify that no voltage is present by using a voltmeter at all input and output
terminals.
EXAMPLE: A customer wants a Green Lamp to be
illuminated at all times and wants a Red Lamp to
illuminate and a speaker to sound when the summary
alarm triggers. The customer would make the connections
to the NC and C contacts on one set of the SUMMARY
relay contacts between the speaker and a power supply.
On the other set of SUMMARY relay contacts they would
connect the NO and C contacts between the Green Lamp
and power supply, and would connect the NC and C
contacts between the Red Lamp and power supply.
Figure 10 - Example Connections (Customer
Provided Equipment)

13
2.5.2 Understanding the Alarms
Each alarm indication relay in the TPSD is designed as fail-safe. This means that under a complete system
malfunction with all alarm relays de-energized, each alarm will indicate its correct state. Table 9 shows what
state each alarm relay is in under normal running conditions of the charger, no alarms are present.
A
larm Rela
y
State of the Rela
y
Normally Open
contacts Normally Closed contacts
HVSD De-ener
g
ized Open Closed
HIGH DCV De-ener
g
ized Open Closed
LOW DCV Ener
g
ized Closed Open
NEG GND De-ener
g
ized Open Closed
POS GND De-ener
g
ized Open Closed
AC POWER FAIL Ener
g
ized Closed Open
SUMMAR
Y
Ener
g
ized Closed Open
LOW DCA Ener
g
ized Closed Open
The HVSD ALARM will trigger if the output DC voltage of the charger rises above the alarm threshold for
longer than 20 seconds, red “HVSD” LED will turn on. This is usually due to the failure of an internal charger
component, but could also be the result of maladjustments of the output voltage settings. If the high DC
voltage shut down alarm activates the DC output of the charger shuts off the charger to prevent irreversible
damage to the battery. See Section
3.5.1 CUSTOMER CALIBRATION for information on viewing and adjusting
the threshold value.
The
HIGH DCV ALARM will trigger if the output DC voltage rises above the specified voltage threshold of the
alarm for longer than 5 seconds, red “HIGH VOLTAGE” LED will flash. This is usually caused by maladjustments
of the output voltage settings, or in rare cases by a failure of an internal charger component. See Section 3.5.1
CUSTOMER CALIBRATION
for information on viewing and adjusting the threshold voltage.
The
LOW DCV ALARM will trigger if the DC voltage drops below the specified voltage threshold of the alarm
for longer than 5 seconds, red “LOW VOLTAGE” LED will turn on. This is usually due to an AC Failure, or the
charger is overloaded into deep-current limit. It could also be caused by maladjustments of the output folage
settings, or in rare cases by a failure of an internal charger component. See Section
3.5.1 CUSTOMER
CALIBRATION
for information on viewing and adjusting the threshold voltage.
The
NEG GND ALARM will trigger if any current between the negative terminal of the battery and earth
ground is measured, red “GROUND DETECTION” LED will turn on. A negative ground alarm would signify that
the negative terminal of a floating battery has become grounded. If the charger has ground detection disabled
this alarm will not function.
The POS GND ALARM will trigger if any current between the positive terminal of the battery and earth ground
is measured, red “GROUND DETECTION” LED will flash. A positive ground alarm would signify that the positive
terminal of a floating battery has become grounded. If the charger has ground detection disabled this alarm will
not function.
Table 9
–
State of each Alarm Relay (No alarms present)