Marathon Power TRTC Series User manual

TRTC SERIES
Battery Backup System
for Traffic Signals
Installation, Operation and Maintenance Manual
For Models:
TRTC-0654-N1 • TRTC-0654-N2
TRTC-1124-N1 • TRTC-1124-N1
TRTC-2005-N1 • TRTC-2005-N1

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TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS……………………………………………………………....5
BATTERY SAFETY………………………………………………………………………………………7
UNPACKING AND INSPECTION CHECKLIST……………………………………………………… 7
SECTION 1 – INSTALLATION & START-UP………………………………………………9
1.1.1 SYSTEM DESCRIPTION ...........................................………………………………………......9
1.1.2 FRONT PANEL LAYOUT ..……….................................……………………………………….10
1.1.3 AUTO TRANSFER SWITCH ...................................................…………………….…...........11
1.1.4 BATTERIES………………………………………...............................….................................12
1.2 MOUNTING .........................................................................................................................12
1.3 WIRING ...............................................................................................................................13
1.4 START-UP AND TEST .......................................................................................................16
1.5 SHUTDOWN........................................................................................................................18
1.5.1 TRTC UPS………………........................................................................................18
1.5.2 ATS …...…...........................................................……………………………………19
1.6 TROUBLESHOOTING…...........................................................................................20
1.7 EMERGENCY SHUTDOWN PROCEDURE .............................................................21
SECTION 2 - FEATURES…………………………………………………………...22
2.1.1 THE ADVANTAGES.............................................................................................22
2.1.2 A TOUR OF THE TRTC SERIES..……….............................................................23
2.2.1 LCD PANEL .........................................................................................................28
2.2.2 TRTC UPS OPERATING MODES...………..........................................................29
2.2.3 SELF TEST...........................................................................................................30
2.2.4 START UP ...........................................................................................................31
2.2.5 SHUTDOWN........................................................................................................32
2.2.6 BATTERY REPLACEMENT.................................................................................33
2.2.7 LCD MENU TREE .............................................................................................. 34
2.2.8 STATUS SUBMENU .......................................................................................... 36
2.2.9 CONFIG SUBMENU….........................................................................................38
2.2.10 MAINTENANCE MENU .....................................................................................40
2.2.11 ALARM MENU ...................................................................................................42

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2.2.12 FAULT MENU ....................................................................................................43
2.2.13 LOW BATTERY MODE STATUS ......................................................................44
2.3.1 RS232/USB SET-UP.................................................................................…........45
2.3.1.1 WIRING SET-UP PROCEDURE........................................................................45
2.3.2 HYPERTERMINAL SET UP..................................................................................46
2.3.3 MAIN MENU .........................................................................................................50
2.3.4 MENU TREE & RS232/USB SUB MENUS .................................…......................53
2.3.4.1 RS232/USB MENU TREE........................…...........................................…........53
2.3.4.2 UNIT SPECIFICATIONS, INPUT / OUTPUT VALUES ......................................54
2.3.4.3 INPUT / OUTPUT VALUES................................................................................54
2.3.4.4 MAINTENANCE..................................................................................................55
2.3.4.5 LINE SLOW DETECTION PARAMETERS.........................................................57
2.3.5 MENU TUTORIAL .................................................................................................60
2.4.1 BATTERY BACK-UP TIME TEST .........................................................................62
2.4.2 BATTERY MAINTENANCE………………... ………...............................................63
2.4.3 EMERGENCY SHUTDOWN PROCEDURE .........................................................63
2.4.4 TROUBLESHOOTING...........................................................................................64
2.4.5 SPECIFICATIONS ................................................................................................66
2.4.6 TRTC SERIES RETURN INSTRUCTIONS ..........................................................68
2.4.7 WARRANTY……………………………………........................................................69

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IMPORTANT SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL
CAUTION
RISK OF ELECTRICAL SHOCK
To reduce the risk of electrical shock and to ensure the safe operation of the TRTC UPS, the important safety
instructions are marked with the symbols as shown below. These symbols are used throughout this manual
and wherever they appear, it indicates that the instructions should only be carried out by qualified personnel.
Indicates presence of DANGEROUS VOLTAGE in
the area. Extreme caution should be used.
Indicates ATTENTION to Important operating instructions.
Follow them as indicated.
DANGER:Do not expose the TRTC UPS to rain or moisture.
DANGER: Total Earth ground leakage current of loads connected to the TRTC UPS should
not exceed 2.4 mA.
The TRTC UPS generates, uses and can radiate radio frequencies if not installed and tested
in accordance with the instructions contained in this manual. It has been tested and found to
comply with the limits established for a Class A computing device pursuant to part 15 of FCC
rules when it is operated alone. It also complies with the radio interference regulations of DOC,
which are designed to provide a reasonable protection against such interference, when this
type of equipment is used in a commercial environment. If there is interference to radio or TV
reception, which is determined by switching it on and off. Relocate the equipment or use an
electrical circuit other than the one used by the TRTC UPS.

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IMPORTANT SAFETY PRECAUTIONS
Only qualified personnel should service or supervise the service of the TRTC UPS.
Danger: Sealed lead-acid batteries with high energy and chemical hazards are used. This manual
contains important operation and safety instructions.
TRTC UPS Safety System Checklist
• Carefully unpack the TRTC UPS. Report any shipping damage at once.
• Read this manual. If you have any questions about safe installation, operations or maintenance of the system,
contact Manufacturer’s 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 TRTC UPS has more than one live circuit. It is fed from AC as well as battery power. Power may be present
at the output(s) even if the system is disconnected from line power.
• When installing a system in other than a Manufacturer cabinet, ensure that the environment meets the
system specifications shown in Section 1.7, “Specifications” of this manual.
SAVE THIS MANUAL
It contains important installation and operating instructions. Keep it in a safe place.

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Battery Safety Checklist
• High & dangerous voltagesare present inside the system. Only qualified personnel should perform installation and
maintenance.
• Live battery wires must not touch the TRTC UPS chassis or any other metal objects. This can cause a fire or explosion.
• Inspect the batteries once a year for signs of cracks, leaks, or swelling. Replace as needed.
• When batteries are in storage, charge them at least once every three months for optimum performance and to
extend their lifetime.
• Always replace batteries with the ones of identical type and rating. Never install old or untested batteries. Never
mix old with new batteries. Never mix the different amp hour rated batteries within one system.
• Use insulated tools during servicing.
• Remove all rings, watches, jewelry, or other conductive items before working inside the enclosure.
• Follow local regulations for the disposal of batteries. Recycling is the best method.
• Never burn batteries to dispose of them. They may explode.
• Do not open the batteries. The contents are toxic.
Stand-By Generator
Note: If the TRTC UPS constantly switches between Battery and Line modes because of line fluctuations,
the input parameters should be broadened from Normal to Generator (see Section 2.2.2 “Sense Type”)
In Generator mode, the acceptable range of input frequency and voltage is expanded to accommodate the voltage and
frequency fluctuations created by a generator or a power source of such kind.
Use a generator with electronic speed and voltage controls which typically produces the Total Harmonic Distortion in
% (THD) to be less than 10%. Generators with mechanical governors can force the system to run continuously in
Battery mode.
Before installation, compare the generator’s output voltage to the TRTC UPS’s input voltage requirements as listed on
both nameplates. To insure the system’s smooth operation, use a generator capable of supplying 2X or twice as much
power as required by the total load.
Unpacking and Inspection List
Carefully remove the TRTC UPS from its box. Inspect the contents and make sure the following items are included:
• One TRTC UPS System.
• One plastic bag containing the following:
• Temperature sensor probe cable with 3-pin connector and extension cord.
• Installation, Operations and Maintenance manual.
The Auto Transfer Switch (ATS) and all the associated wiring & hardware required for installation is supplied in a
separate box.
Tip: If any items are missing or damaged, contact Manufacturer and the shipping company at once.
Most shippers have a short claim period.

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SAVE THE ORIGINAL SHIPPING BOX
When returning the TRTC UPS for servicing, use the original shipping box with the supplied Styrofoam protectors.
Manufacturer is not responsible for damage caused by improper packaging of returned systems.
READ THE OPERATOR’S MANUAL
Before installation, become familiar with the TRTC UPS by reviewing the procedures and drawings in this manual. If you
have any questions about safe installation, operation, or maintenance, contact Manufacturer customer service department.
Complete the following for records & future servicing
Model & Serial # can be found on the nameplate label attached to the side of the unit
Model # TRTC-
Serial #
Products Sales Order #
Purchase Order #
Purchased from
Telephone #
Fax #
E-Mail
The following details are for installation location
Installation date
Installed by
Street names
City
County / State
Zip / Postal Code
Country

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Section 1: Installation & Start-Up
Purpose: Describes the operation of the TRTC UPS System (Figure 1, 2 & 3).
1.1.1 System Description
The TRTC UPS System provides backup power to traffic control signal equipment. It consists of the TRTC Uninterruptible
Power Supply (UPS) System, the Auto Transfer Switch (ATS), and batteries that provide backup power when the line is
unqualified. These three components can be mounted inside an enclosure to provide protection from most weather conditions.
Simplified TRTC 120V System Block Diagram
TRTC UPS
*ACTIVATE WHEN BUCK / BOOST IS ENABLED
CONTINOUS
RS232 & USB
CONNECTION
UPS OUTPUT
Fault

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The traffic signal cabinet is powered continuously when a TRTC UPS system is installed. The system allows connection for
the normal utility power (using standard terminal blocks or Anderson PP45 Quick connector or IEC Socket) or an optional
generator power. The optional bypass switch redirects utility power to the load and allows the TRTC UPS to be removed for
service on a temporary or permanent basis without disrupting the operation of the traffic signal.
With a fully functioning UPS system, the ATS allows utility power to flow out to the traffic cabinet, when the utility line is
qualified (within the acceptable range as programmed). If the UPS is not functioning, the ATS will bypass the UPS allowing
the utility to flow out to the traffic cabinet. The UPS input is protected with one circuit breaker located on the ATS as well as
another one located on the UPS module. When the UPS internal BOOST and BUCK is enabled, the ATS is activated
allowing UPS to continuously boost the output when input is lower, buck or lower the output when input is higher or run from
batteries when input power is outside the specified acceptable range.
The smart, temperature compensated internal charger continuously monitors and maintains the batteries in a fully charged
state. For the protection of the battery, the charging process is automatically discontinued when the battery temperature
exceeds 50 degrees C. When input power is not qualified or is outside the acceptable range, the UPS derives the DC power
from the storage tank of four batteries connected in series and maintains output power until the batteries are depleted down
to a specified level or the utility power returns within its specified levels. The traffic intersection will continue to operate in
full operation AND / OR in flash mode as programmed by the user. Programmable contacts allow the user to place the
intersection in flash mode as soon as the input power is lost or after the batteries are depleted down to a certain capacity
that is determined and programmed by the user. The amount of back-up time battery power can provide depends on the
Amp-hour capacity of the batteries as well as the intersection watt load that requires support.
1.1.2 Front Panel Layout
The TRTC UPS System shown below provides control functions and backup power as described above. For more
information, please see Section 2 of this manual.
TRTC-0654-N2 and TRTC-1124-N2
TRTC-0654-N1 and TRTC-1124-N1

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TRTC-2005-N2
TRTC-2005-N1
1.1.3 Auto Transfer Switch
The Auto Transfer Switch (ATS) shown below allows the UPS to be removed for service, replacement or maintenance
without interrupting power to the traffic cabinet.
Auto Transfer Switch Front Panel
1. Bypass/UPS switch allows the switching of the supply to the load between the incoming supply and the UPS, so the
UPS can be isolated for maintenance.
2. Utility/Generator switch allows the switching of the supply to the load between the Utility power and the
Backup Generator. so that the generator may provide temporary electrical power if the utility source fails.
3. The Input line power is connected to the input receptacle.
4. Generator input receptacle.
5. The Output power is connected to the output receptacle.
6. Output receptacle to feed UPS input.
7. Input receptacle to receive the output from the UPS
8. UPS input and output circuit breaker
9. ATS Bypass control signal.
10. Auxiliary output receptacle to optional battery heater mat.

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1.1.4 Batteries
Different Amp-hour capacities or sizes of batteries can be used in the TRTC UPS system to provide various backup times.
Two or Four batteries are connected in series for the required 24VDC or 48VDC. Contact customer service at Manufacturer
for information on the battery best suited for your application. The battery harness supplied with the system is polarized and
equipped with APP® SB50 type connectors. The battery harness provides a heavy-duty connection for each battery, so it
is possible to unplug or hot swap them. Each of the four batteries may be connected in any order using the provided harness.
1.2 Mounting
Purpose: Describes how to mount the TRTC UPS System into an enclosure.
The TRTC UPS system components can be mounted into a single external cabinet or into an existing traffic cabinet.
EXTERNAL MOUNT:
The factory supplied external cabinet can be bolted onto an existing or new traffic cabinet or this external cabinet can be
pad mounted on a concrete slab or be pole mounted. The separate base for the cabinet for installation in the concrete slab,
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 easy
for the contractor. External cabinets such as BC100, BC80, etc. are outdoor type, weather proofed provided with internal
exhaust fan that is temperature controlled, an intake filter that can be cleaned or replaced, a non-corrosive rubber mat for
batteries, 3 point locking mechanism, lockable handle with dual keys and a unique internal keyed lock. The quality of cabinets
bears a reputable industry trade name such as Manufacturer. The factory-supplied cabinet meets or exceeds the
requirements of various NEMA classifications.
INTERNAL MOUNT:
The TRTC components can also be mounted inside an existing NEMA or 332 or various other traffic cabinets. The special
Swing Tray designed to hold the four batteries is easily mounted inside an existing 332 type or other equivalent cabinet
using the hardware that is provided, or they can be shelf mounted in a NEMA or equivalent cabinet. The TRTC can be bolted
into an industry standard 19” rack using the supplied ears or brackets, or it can be shelf mounted in a NEMA type enclosure.
The ATS supplied with or without optional Generator & Bypass switch comes in many configurations that can be shelf mount,
19” rack mount, back plate mount, etc.

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1.3 Wiring
Purpose: Describes how to wire the TRTC UPS System.
Danger: The utility input power line must have circuit breaker or fuse protection as per the local
electrical code. It is referred as “Upstream Circuit Breaker” in this manual.
Before wiring the system, determine the size of the load:
START
TIP: Each of the six contacts are of form C type, meaning Normally Open (NO), Common (C) and Normally Closed (NC)
dry contact rated for 1 Amp at 240VAC. 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 TRTC UPS is transferred to Battery
mode. LOW BATTERY contact/(s) are activated only in the Battery mode, as soon as the discharged battery reaches the
lower value 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 minutes interval from 15 minutes to 8 hours.
TIP: Verify that all breakers, AC and battery breakers are OFF prior to wiring.
Go to Step 1
Is the load over
or under spec
capacity?
Put the Intersection in FLASH mode as soon
as TRTC goes into Battery mode, by connecting
any one of the six programmed contacts to “
ON
BATT ” from C, NO or NC type at the TRTC to
the AUTO / FLASH circuit of any controller.
OVER
Run the intersection in FLASH mode connected as above
OR
Keep the intersection running normal in full phase until the
battery completely depletes down to shutdown resulting in
blackout
OR
Keep the intersection running normal in full phase for certain
time or until battery depletes down to certain capacity, both
of which are programmable. Run the intersection in flash
mode after that, until 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 on the TRTC programmed for the
“Timer” or “Low Battery”. This method is recommended to
ride out small power outages, which is what occurs during
most utility interruptions.
UNDER

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Step 1: Connect CONTROL wires
START
Connect the Battery
Temperature Sensor to the
terminal of the middle battery,
Plug the connector on the other
end into the TRTC.
Connect the External
Cabinet Fan and the RS232/
USB Computer Cable (if used).
Connect the programmable
contacts: ON BATT, LOW BATT,
TIMER or SELF TEST contacts
from TRTC to traffic cabinet for
Flash mode (if used).
Figure 5
TRTC Front Panel
GO TO STEP 2
Step 2: Connect ATS to the TRTC
START
Connect the cord from UPS
OUT at ATS to the AC OUT
receptacle on TRTC.
Connect the cord from UPS
IN on ATS to AC IN
receptacle on TRTC.
Connect the cord from
Bypass control on ATS
to PTS on TRTC.
GO TO STEP 3
TRTC Front & Power Transfer Switch
TIP: Torque status/self-test terminal
block to a maximum of 4.4 lb in (0.5
Nm). Maximum wire size is 14 AWG.
TIP: (See Section 2.1.2, Fig. 16) of
this manual for details on the layout,
operation, and specifications of the
Control Terminal Block.

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Step 3: Connect the Input and Battery
START
Connect the supplied black
wire from the input receptacle
at ATS to the INPUT
terminal in the signal cabinet.
Plug the Red Battery
connector into the TRTC.
UNIT IS READY
FOR START UP
13
TRTC Front Panel
Power Transfer Switch

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1.4 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 1.6 of this manual.
Step 1: Turn on the Utility Input Line Power
START
GO TO STEP 2
Step 2: Turn on the UPS
START
GO TO STEP 3
Verify the load is turned ON.
Verify that the AC Input &
Output as well as Battery
Circuit Breakers on the
TRTC are OFF.
Turn ON the upstream Utility
Input Circuit Breaker.
STARTUP PROCEDURE TIPS
The TRTC automatically starts up in Standby
mode. After the AC line is qualified (default 30
seconds) the UPS switches to On Line mode.
The ATS is a safeguard that the cabinet will
always revert to utility power if there is ever a
failure of the TRTC or batteries.
Turn On the Battery
circuit breaker.
Turn On the AC Input
circuit breaker.
The LCD display shows
Standby.
In 30 seconds, The LCD display
changes to “ONLINE”, the
Green Output LED is lit
indicating Input power to be
within acceptable frequency and
voltage ranges and the output is
powered from utility.

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Step 3: Test the system.
START
Turn OFF the upstream circuit breaker.
The OUTPUT Green LED will flash
and the LCD displays ON BATT,
indicating that output AC power is
supplied from battery power.
Observe the Yellow Alarm
LED. If it is on, follow the
troubleshooting sequence as below:
TIP: In ON LINE mode, press and hold “ESC” for 3 seconds to perform the self-test feature.
Turn ON the upstream
circuit breaker.
1. Investigate the alarm.
2. Perform a self-test with the load(s) connected.
3. If it passes the self-test, verify that loads are operating normally.
4. See the troubleshooting chart in the TRTC manual, Section 2.4.3.
5. Contact Manufacturer technical support.
Within 30 seconds the
ATS switches back to
line power.
The Green Output LED is
lit and the display shows
“ON LINE”.
START UP AND TESTING FINISHED

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1.5 Shutdown
Purpose: Describes how to shut down the system components for removal or maintenance.
1.5.1 TRTC UPS
Turn OFF the AC Input
Circuit Breaker
Turn OFF the Battery Circuit Breaker
Unplug the battery connector.
Disconnect the AC input wires.
Disconnect the AC output 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 or USB connector.
Remove and perform the
maintenance on TRTC.
Perform this procedure in reverse
order to reinstall the unit.
START
Danger: Shutting down the TRTC does not
necessarily disconnect power to the loads.
Danger: The AC input wires from ATS are still HOT
or Live. Insulate the bare wires using wire nuts.
PROCEDURE FINISHED
TIP: For additional information on how to operate the TRTC manual, (see Section 2.2).

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1.5.2 ATS
START
Turn OFF the upstream
circuit breaker
TIP: Verify that both the AC and Battery
Breaker are OFF at the TRTC.
Disconnect the UPS OUT Cord
Disconnect the UPS IN cord
Disconnect the INPUT &
OUTPUT cord
Remove and perform
maintenance on the ATS
Perform this procedure in reverse
order to reinstall the ATS
PROCEDURE FINISHED
Auto Transfer Switch

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1.6 Troubleshooting
TRTC System Troubleshooting Chart
SYMPTON CAUSE REMEDY
No Output
Available from ATS
Upstream utility circuit breaker or
fuse may be OPEN
Utility AC Power not available
CLOSE the upstream utility breaker
or fuse
Check with the AC voltmeter &
contact the Utility Company
Wiring error Correct wiring at ATS
Faulty ATS Replace the ATS
ATS won’t allow transfer to
Battery mode
TRTC output power not connected
to ATS
“UPS OUTPUT” circuit breaker at
ATS is open
Verify that “UPS OUT” cord is
properly connected to the AC
OUTPUT receptable at the TRTC
Reset the breaker and clear the
fault
Faulty ATS Replace ATS
TRTC does not return back to
Input Line Mode Utility input line power is missing
Verify that “UPS IN” cord from the
ATS is properly connected to the
AC INPUT receptable at the TRTC.
Verify that the “UPS INPUT” circuit
breaker at the ATS is closed.
Ensure that the utility input is
present.