Mule Lighting OSHPD Series User manual

Single-Phase
Emergency Lighting Inverter
Installation and Operation Manual
Wave Rider 1 Standard Units
(2.1-17KW)
and
OSHPD Series, 3.0-17KW
Certification: (OSP-0499-10)
Document No.: 410-MAN, Rev. D
Contact Numbers: Phone: [phone]
Due to continuous product improvement, this document is subject to change without prior notice
All trademarks and registered trademarks are the property of their respective owners.

410-MAN Page 2 of 105
Notice of Rights
This document contains proprietary and confidential information of Mule Lighting. No part of this
manual may be reproduced, copied, translated or transmitted, in any form or by any means, without
the prior written permission of the manufacturer.
In consideration of the receipt of this document, the recipient agrees not to copy any of its contents,
nor to disclose them to or allow them to be used by any person not currently company employee or an
employee of the recipient having a need to know, without the express written consent of the company,
and further agrees to surrender this document to company when the reason for its receipt has
terminated.
Notice of Liability
Information provided in this manual is intended to be accurate and reliable. However, manufacturer
assumes no responsibility for its use, nor for any infringement of rights of third parties which may
result from its use. THIS DOCUMENT IS PROVIDED “AS IS” AND ANY EXPRESS OR
IMPLIED WARRANTIES, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED
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ARE DISCLAIMED. IN NO EVENT SHALL ABOVE COMPANY BE LIABLE FOR ANY
DIRECT, INDIRECT, INCIDENTAL, SPECIAL, EXEMPLARY, OR CONSEQUENTIAL
DAMAGES (INCLUDING, BUT NOT LIMITED TO, PROCUREMENT OF SUBSTITUTE
GOODS OR SERVICES; LOSS OF USE, DATA, OR PROFITS; OR BUSINESS INTERRUPTION)
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ANY WAY OUT OF THE USE OF THIS DOCUMENT, EVEN IF ADVISED OF THE
POSSIBILITY OF SUCH DAMAGE.
Trademarks
All trademarks and registered trademarks are the property of their respective owners.
Emergency Lighting Inverter Installation and Operation Manual
Document No.: 410-MAN, Rev. D
March 10, 2023

Table of Contents
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Table of Contents
Table of Contents ....................................................................................................... 3
Introduction............................................................................................................... 5
Warranty Registration and Warranty Certificate Request...................................................5
Scope and Audience.....................................................................................................5
Safety and Warnings.....................................................................................................5
Accessing Product Documentation.................................................................................6
Service........................................................................................................................6
Chapter 1. Overview .......................................................................................... 7
1.1 Specifications.........................................................................................................8
1.2 System Description...............................................................................................11
1.3 Models ................................................................................................................12
1.4 Product Features...................................................................................................17
Chapter 2. Safety.............................................................................................. 19
Chapter 3. Hardware Overview........................................................................ 23
3.1 Key Components ..................................................................................................24
3.2 Typical Functional Description...............................................................................28
3.3 Theory of Operation..............................................................................................31
Chapter 4. Installation...................................................................................... 33
4.1 Delivery Space Requirements.................................................................................34
4.2 Site Considerations ...............................................................................................42
4.3 Delivery and Handling...........................................................................................45
4.4 Storing the System................................................................................................54
Chapter 5. Operation ....................................................................................... 56
5.1 Starting the Unit ...................................................................................................57
Chapter 6. Maintenance ................................................................................... 60
6.1 Safety Precautions.................................................................................................61
6.2 Preventative Maintenance......................................................................................63
6.3 FRU Replacement.................................................................................................67
6.4 Calling for Service................................................................................................73
6.5 Customer Service and Support................................................................................73

Table of Contents
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Chapter 7. Troubleshooting.............................................................................. 75
7.1 Reset Instruction...................................................................................................76
7.2 Troubleshooting Guide and System Alarms..............................................................77
7.3 Using the LCD Display Panel.................................................................................79
Chapter 8. Options........................................................................................... 81
8.1 Internal Manual Bypass Switch (Make Before Break) ...............................................82
8.2 External Wrap-around Manual Bypass Switch (same Input and Output Voltage) ..........82
8.3 Audio Alarms with Silence Switch..........................................................................85
8.4 Remote Status Panel..............................................................................................85
8.5 Transient Voltage Surge-Suppressor (TVSS)............................................................86
8.6 Offline Inverter Operation......................................................................................86
8.7 Normally ON/OFF Output Aux. Circuit Breakers .....................................................86
8.8 Main Input CB Standard/Higher KAIC....................................................................86
8.9 Main Output CB Standard/Higher KAIC .................................................................86
8.10 Higher KAIC Normally ON/OFF Aux Output Circuit Breaker..................................86
8.11 Power Flow Mimic..............................................................................................86
8.12 Global Monitoring System (GMS) ........................................................................87
8.13 Simple Network Management Protocol..................................................................91
8.14 Seismic Mounting Bracket ...................................................................................92
8.15 Battery String Monitoring (Wireless).....................................................................93
8.16 Battery (Individual) Monitoring (Wireless) ............................................................93
8.17 Form “C” N/O Contacts for Alarms.......................................................................93
8.18 Dry Contact, N/O or N/C Contact with Isolated Common ........................................93
8.19 Battery Thermal Runaway Control........................................................................94
8.20 Battery Breaker alarm..........................................................................................94
APPENDIX A - Battery Connections ........................................................................ 96
Index...................................................................................................................... 104

Introduction
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Introduction
This manual tells you how to install, start and operate your unit and lets you know how to get more
information for special situations, and provide contact information
Warranty Registration and Warranty Certificate Request
Visit our web site at: www.800pwrsrvc.com under download tab
Scope and Audience
This guide is intended to be used as a reference for users responsible for installing, operating, and
maintaining this equipment.
Safety and Warnings
This guide uses the following symbols to draw your attention to certain information.
.Symbol
Meaning
Description
Note
Notes emphasize or supplement important points of the main
text.
Tip
Tips provide helpful information, guidelines, or suggestions for
performing tasks more effectively.
Caution
Cautions indicate that failure to take a specified action could
result in damage to the hardware.
DANGER
The Danger symbol warns users of possible injury or death if
instructions are not followed.
Hazardous
voltage
Hazardous voltage inside. Only authorized personnel may service
this equipment.

Introduction
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Accessing Product Documentation
The user documentation for the products is available at our website under downloads tab. Please
check this site for the most current documentation, including important updates that may have been
made after the release of the product.
Service
If you require assistance, fill out a Service Report Form at www.800pwrsrvc.com, email us at
[email protected], or call our 24-hour toll free hot line (800-797-7782). Please have the
unit’s SERIAL NO. from the Start-Up label located on the top left corner of the front door for speed
assistance.

Overview
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Chapter 1. Overview
This chapter provides an overview of the Single-Phase Lighting Inverter Standard Series.

Overview
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1.1 Specifications
Typical Specifications (Input / Output Current)

Overview
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General Specification
Voltage Regulation
+10% -15%
Frequency (Hz)
60 Hz ±3%
Power factor
0.98 to 1.0 (Typical)
Overcurrent protection
Electronic / Circuit Breaker
Number of wires
2 Wires plus Ground
Power connection
Hard Wired (Terminal Block)
Voltage (vac)
Single Phase, 120/208/240/277 VAC
Voltage regulation
±3% No Load to Full Load; ±3% High Line to Low Line
Frequency (Hz)
60 Hz ± 0.5 Hz (When on Inverter)
Waveshape
Sine Wave
Harmonic distortion
<5% THD; <3% Single Harmonic
Crest factor
Up to 3 to 1
Power factor
0.65 Lagging or Leading to Unity
Overload
115% overload for 5 to 10 minutes, 125% for 30 seconds.
Protection
Electronic / Circuit Breaker
Noise rejection
-120 dB Common Mode; -60 dB Normal Mode
Number of wires
2 Wires plus Ground
Power connection
Hard Wired (Terminal Block)
Battery run time
90 minutes minimum
Input
Output
Battery

Overview
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Battery type
Sealed, Maintenance-Free, AGM, VRLA type
Battery type
Sealed, Maintenance-Free, AGM, VRLA type
Unit Rating (KW)
2.1 / 3
3.5 / 5
6
5.25 / 7.5
8
7 / 10
8.75 / 12.5
10.5 / 15
14 / 17
Nominal dc voltage
96 VDC
120 VDC
144 VDC
120 VDC
192 VDC
192 VDC
192 VDC
240 VDC
240 VDC
Overcurrent protection
Circuit Breaker
Packaging
Batteries Housed in Same Enclosure and/or additional battery cabinet for other battery run time
LCD Screen
Input Voltage; Battery Charger; UPS Output; On Battery; Low Battery; Summary Alarm
Indicators
LCD Display Panel (Back lit)
Relay interface
Dry Contacts for: Low Battery, On Bypass, Summary Alarm, Input Fail
Contact rating
125 Volts (AC or DC) Maximum; 1.25 Amperes Maximum; 30 Watts / 50 VA Maximum
Interface connection
Hard Wired (Terminal Block)
Surge with standability
ANSI C62.41-1980 categories A & B
Operating temperature
Meets NEMA requirements
Operating relative
humidity
0 to 95% non-condensing
Altitude
Up to 6,000 feet (1,829 meters) with no de-rating
Cooling
Air cooled-forced air (fan)
Unit Rating (KW)
2.1 ~ 3KW
3.5 ~
5KW
6KW
5.25
7.5KW
8KW
7.0 ~
10KW
8.75 ~
12.5KW
10.5 ~
15KW
14 ~
17KW
Dimensions
(W x H x D in Inches)
39 x 48 x 18
39 x 68 x 18
51 x 70 x 30.5
39 x 68 x 18
51 x 70 x 30.5
Construction
Painted Steel Enclosure, Lockable Double front door, Full length hinged, for indoor installation,
Color
Black
Accessibility
Front all Servicing is through the front no side or rear access required
Cable entry
Sides and top
Mounting
Four (4) mounting holes are provided for anchoring to floor, Hardware to be supplied by others
Due to continuous product improvement, this document is subject to change without prior notice.
Monitoring and communications
Environmental
Physical

Overview
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1.2 System Description
The Single-Phase Lighting Inverter is manufactured to provide critical power for lighting during a
power outage. The Lighting Inverter meets or exceeds the life safety codes of UL924 and UL1778.
These codes were established to allow emergency lighting inverters to provide critical power to the
lighting circuits during a power failure.
If input power to the inverter is lost during a power outage, the system draws clean sine wave power
automatically from its internal battery supply without any interruption. Power is provided for 90
minutes, sufficient time for safe and orderly evacuation from the facility.
An optional output transformer allows multiple output voltages as well as input voltages that are
different from output voltages. The internal valve regulated lead-acid (VRLA), maintenance-free
batteries provide 90 minutes of backup power. When input power is restored, the Lighting Inverter
resumes normal operation automatically and begins recharging the batteries immediately.
An internal bypass circuit maintains power to the load in case an internal unit failure occurs.
Comprehensive monitoring capabilities include a Liquid Crystal Display (LCD) panel and Optional
dry relay contacts for remote monitoring.

Overview
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1.3 Models
The Single-Phase Lighting Inverters are available in two series:
✓Standard series
✓Seismic series
1.3.1 Standard Series
The Standard Series Single-Phase Lighting Inverters are on-line single phase PWM inverters. The
systems support power ratings from 2.1 to 17KW power ratings.
All Standard Series systems comply with UL1778, UL924, UL924A, and CSA107.1 standards. They
are available with input or output voltages of 120, 208, 240, 277 or 480 VAC, single phase. This
information is shown on the nameplate located on the inside front door of the unit.
Table 1-1 lists the cabinet dimension and types, and Figure 1-1 shows them.
Table 1-1. Standard Series Cabinet Dimensions and Types
/KW
Cabinet Size (Including Battery)
(W x H x D in Inches)
Cabinet
Height
Cabinet
Type
Cabinet
For Zone 4
Zone 4 Approved
2.1 ~ 3KW
39 x 48 x 18
48”
See Figure 4-1
See Figure 4-6
46.75 x 48 x 18 (Including brackets)
*3.5KW ~ 8KW
39 x 68 x 18
68”
See Figure 4-2
See Figure 4-6
46.75 x 68 x 18 (Including brackets)
All other
51 x 70 x 30.5
70”
See Figure 4-3
See Figure 4-7
58.75 x 70 x 30.5 (Including brackets)
*Consult factory for all other configurations per requirements
Figure 1-1. Standard Series Single-Phase Lighting Inverter Cabinets

Overview
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Figure 1-2 Standard Series Single-Phase Lighting Inverter Cabinets (for Zone 4)
1.3.2 Seismic (OSHPD Shake Table Tested) Series
The Seismic Series are OSHPD-certified Single-Phase PWM Lighting Inverters that support power
ratings from 3kw to 17kw. In addition to complying with UL1778, UL924, and CSA107.1 standards,
these models meet the requirements for CBC 2016 and IBC 2015. They have been shake table-tested
in accordance with the ICC-ES AC156 procedure to SDS level 3.0g. The systems have received
special seismic certification from the California Office of Statewide Health Planning and
Development (OSHPD), which are the most rigid seismic standards available.
Table 1-2 lists the cabinet dimensions and types, and
Figure 1-3 shows them.
Table 1-2. Seismic Series Cabinet Dimensions and Types
KW
Cabinet Size (Including Battery)
(H x W x D in Inches)
Cabinet
Height
Cabinet Type
3KW, 5KW, 6KW, 8KW
68 X 46 X 18 (including brackets)
68”
See Figure 4-4
All Others
70 X 58.75 X 30.5 (including brackets)
70”
See Figure 4-5
Note: All Seismic Series models have an SV-prefix in their model number.

Overview
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Figure 1-3. Seismic Series Lighting Inverter Cabinets
Table 1-3. Shock- and Vibration-Approved Model Numbers
KW
Input/Output Voltage
Model Number
Inverter Battery
Weight (lbs.)
Mounting Dim
(H x W x D) in Inches
3.0
120 / 120
SV-WR3.0A0100N1
1,284
68 X 46 X 18
(including brackets)
120 / 120, 208, 240, 277
SV-WR3.0A5800T1
208 / 208
SV-WR3.0B1300N1
208 / 120, 208, 240, 277
SV-WR3.0B5800T1
240 / 240
SV-WR3.0D0400N1
240 / 120, 208, 240, 277
SV-WR3.0D5800T1
277 / 277
SV-WR3.0R2500N1
277 / 120, 208, 240, 277
SV-WR3.0R5800T1
480 / 480
SV-WR3.0H1100T1
480 / 277
SV-WR3.0H2500T1
480 / 120, 208, 240, 277
SV-WR3.0H5800T1
277 / 480
SV-WR3.0R1100T1
5.0
120 / 120
SV-WR5.0A0100N1
1,284
68 X 46 X 18
(including brackets)
120 / 120, 208, 240, 277
SV-WR5.0A5800T1
208 / 208
SV-WR5.0B1300N1
208 / 120, 208, 240, 277
SV-WR5.0B5800T1
240 / 240
SV-WR5.0D0400N1
Note: All Seismic Series models have an SV-prefix in their model number.

Overview
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KW
Input/Output Voltage
Model Number
Inverter Battery
Weight (lbs.)
Mounting Dim
(H x W x D) in Inches
240 / 120, 208, 240, 277
SV-WR5.0D5800T1
277 / 277
SV-WR5.0R2500N1
277 / 120, 208, 240, 277
SV-WR5.0R5800T1
480 / 480
SV-WR5.0H1100T1
480 / 277
SV-WR5.0H2500T1
480 / 120, 208, 240, 277
SV-WR5.0H5800T1
277 / 480
SV-WR5.0R1100T1
6.0
120 / 120
SV-WR6.0A0100N1
1,340
68 X 46 X 18
(including brackets)
120 / 120, 208, 240, 277
SV-WR6.0A5800T1
208 / 208
SV-WR6.0B1300N1
208 / 120, 208, 240, 277
SV-WR6.0B5800T1
240 / 240
SV-WR6.0D0400N1
240 / 120, 208, 240, 277
SV-WR6.0D5800T1
277 / 277
SV-WR6.0R2500N1
277 / 120, 208, 240, 277
SV-WR6.0R5800T1
480 / 480
SV-WR6.0H1100T1
480 / 277
SV-WR6.0H2500T1
480 / 120, 208, 240, 277
SV-WR6.0H5800T1
277 / 480
SV-WR6.0R1100T1
8.0
120 / 120
SV-WR8.0A0100N1
1,795
68 X 46 X 18
(including brackets)
120 / 120, 208, 240, 277
SV-WR8.0A5800T1
208 / 208
SV-WR8.0B1300N1
208 / 120, 208, 240, 277
SV-WR8.0B5800T1
240 / 240
SV-WR8.0D0400N1
240 / 120, 208, 240, 277
SV-WR8.0D5800T1
277 / 277
SV-WR8.0R2500N1
277 / 120, 208, 240, 277
SV-WR8.0A0100N1
480 / 480
SV-WR8.0A5800T1
480 / 277
SV-WR8.0B1300N1
480 / 120, 208, 240, 277
SV-WR8.0B5800T1
277 / 480
SV-WR8.0D0400N1
10.0
120 / 120
SV-WR010A0100N1
2,438
70 X 58.75 X 30.5
(including brackets)
120 / 120, 208, 240, 277
SV-WR010A5800T1
208 / 208
SV-WR010B1300N1
208 / 120, 208, 240, 277
SV-WR010B5800T1
240 / 240
SV-WR010D0400N1
240 / 120, 208, 240, 277
SV-WR010D5800T1
277 / 277
SV-WR010R2500N1
277 / 120, 208, 240, 277
SV-WR010R5800T1

Overview
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KW
Input/Output Voltage
Model Number
Inverter Battery
Weight (lbs.)
Mounting Dim
(H x W x D) in Inches
480 / 480
SV-WR010H1100T1
480 / 277
SV-WR010H2500T1
480 / 120, 208, 240, 277
SV-WR010H5800T1
277 / 480
SV-WR010R1100T1
12.5
120 / 120
SV-WR012A0100N1
3,681
70 X 58.75 X 30.5
(including brackets)
120 / 120, 208, 240, 277
SV-WR012A5800T1
208 / 208
SV-WR012B1300N1
208 / 120, 208, 240, 277
SV-WR012B5800T1
240 / 240
SV-WR012D0400N1
240 / 120, 208, 240, 277
SV-WR012D5800T1
277 / 277
SV-WR012R2500N1
277 / 120, 208, 240, 277
SV-WR012R5800T1
480 / 480
SV-WR012H1100T1
480 / 277
SV-WR012H2500T1
480 / 120, 208, 240, 277
SV-WR012H5800T1
277 / 480
SV-WR012R1100T1
15.0
120 / 120
SV-WR015A0100N1
3,852
70 X 58.75 X 30.5
(including brackets)
120 / 120, 208, 240, 277
SV-WR015A5800T1
208 / 208
SV-WR015B1300N1
208 / 120, 208, 240, 277
SV-WR015B5800T1
240 / 240
SV-WR015D0400N1
240 / 120, 208, 240, 277
SV-WR015D5800T1
277 / 277
SV-WR015R2500N1
277 / 120, 208, 240, 277
SV-WR015R5800T1
480 / 480
SV-WR015H1100T1
480 / 277
SV-WR015H2500T1
480 / 120, 208, 240, 277
SV- WR015H5800T1
277 / 480
SV- WR015R1100T1
17.0
120 / 120
SV-WR017A0100N1
4,512
70 X 58.75 X 30.5
(including brackets)
120 / 120, 208, 240, 277
SV-WR017A5800T1
208 / 208
SV-WR017B1300N1
208 / 120, 208, 240, 277
SV-WR017B5800T1
240 / 240
SV-WR017D0400N1
240 / 120, 208, 240, 277
SV-WR017D5800T1
277 / 277
SV-WR017R2500N1
277 / 120, 208, 240, 277
SV-WR017R5800T1
480 / 480
SV-WR017H1100T1
480 / 277
SV-WR017H2500T1
480 / 120, 208, 240, 277
SV-WR017H5800T1

Overview
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KW
Input/Output Voltage
Model Number
Inverter Battery
Weight (lbs.)
Mounting Dim
(H x W x D) in Inches
277 / 480
SV-WR017R1100T1
1.4 Product Features
The following describes the major blocks within the System. See Figure 3-1. Key Components on
page 24 to find specific components.
Table 1-4. Major blocks within the system
Item
Components
Function
1
Input Contactor K1
The input contactor is multifunctional. First, it provides
connections for the input power to the unit. Secondly, the
contactor disconnects the input line when an outage
occurs so that there is no back feeding of power into the
power line. Finally, the contactor allows for automatic
unit operation upon a complete discharge of the batteries.
No operator intervention is required when power to the
unit is restored after a complete battery discharge.
2
Battery Charger
The battery charger maintains the batteries at full charge.
After a battery discharge, the charger will automatically
recharge the batteries upon restoration of input power.
This circuit is on the Power Board.
3
Power Board Assembly with IGBTs
The Power Board is bolted onto the IGBT (Insulated Gate
Bipolar Transistor) blocks that are mounted on a heat
sink. The complete Heat Sink Assembly with IGBTs and
Power Board is replaceable as a single part. This FRU
(Field Replaceable Assembly) converts all the power, i.e.
input AC power converted to DC bus, battery power
boosted to DC bus, and finally DC bus power converted
to output AC power using PWM technology for a smooth
AC sine wave. In case of a catastrophic failure, the
complete Heat Sink Assembly is easily replaceable using
only a screwdriver. The Power Board also contains the
housekeeping power supplies and drivers for the IGBTs.
The entire assembly provides the landing place for all
internal input, output, DC cables and metering devices for
control and monitoring of the unit input and output
currents.
4
Control Board
The microprocessor with unit specific firmware and
control circuitry is located on the Control Board. The
Control Board is mounted on the cabinet door and
communicates with the Power Board (A2) via a ribbon
cable. It monitors the input and output voltages and
generates the command to close or open the input
contactor and to sense and change the status of the bypass
static switch. The Control Board sends data to the LCD
panel located on the door where actual status and
parameters are displayed. It additionally provides optional
AS400, RS232, and RS485 output capabilities and
supports various communication including SNMP
options.

Overview
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Item
Components
Function
5
Output Static Switch
This SCR solid-state switch connects the output of the
inverter (UPS) to the load. It is connected on the primary
side of the optional output isolation transformer. This
switch shuts off in case of a problem or failure within the
unit and transfers the load directly to the utility input via
the bypass static switch. It maintains its status opposite to
that of bypass switch.
6
LCD Display Panel
The LCD (Liquid Crystal Display) panel provides all the
input, output, battery metering and alarm data, and UPS
status for customer use on a constantly scrolling set of 2
default screens with continuous update.
7
Optional Output Isolation Transformer
The output isolation transformer provides isolation
between the inverter and protected output. The power to
the primary of this transformer is received from the unit
and is transformed to required output voltage levels. It
will also add another screen to the main menu.
8
Optional Maintenance Bypass Switch
The MBS (Maintenance Bypass Switch) removes the
critical load from the backup power and provides utility
input directly to the load in case of a unit malfunction or
during system maintenance.
9
Battery Bank
The battery bank consists of sealed, maintenance-free
batteries. The batteries provide emergency power during
power outages. The battery bank includes a breaker for
over current protection and DC disconnect.

Safety
410-MAN Page 19 of 105
Chapter 2. Safety
This chapter contains safety precautions to observe when operating or servicing electrical equipment.
The symbols shown are used extensively throughout this manual. Always heed these precautions
because they are essential to the safe operation and servicing of this product.

Safety
410-MAN Page 20 of 105
DANGER: This Equipment is intended to be permanently connected. Only factory-trained
or authorized personnel should attempt to install or repair the unit or its battery system.
Improper installation has proven to be the single most significant cause of start-up
problems. High AC and DC electrical voltages are present throughout the unit(s) and
incorrect installation or servicing could result in electrocution, fire, explosion, or
equipment failure.
DANGER: Read this manual in its entirety before performing the installation, start-up,
operation, or maintenance of the UPS unit or battery systems. Failure to do so could result
in electrocution, fire, explosion, or equipment failure.
DANGER: All power connections must be completed by a licensed electrician who is
experienced in wiring this type of equipment. Wiring must be installed in accordance with
all applicable national and local electrical codes. Improper wiring may cause damage to the
equipment, injury or death of personnel. Verify that all high and low voltage input power
circuits are de-energized and locked out before installing cables or making any electrical
connections.
DANGER: Exercise extreme care when handling unit and batteries to avoid equipment
damage or injury to personnel. Cabinets weigh several hundred pounds.
DANGER: Test lift and balance the cabinets before moving. Maintain minimum tilt from
vertical at all times. The bottom structure will support the unit only if the forklift forks are
completely underneath the unit.