PCM TC Series User manual

TC SERIES
Wide Temperature Range UPS
TC-650,1100,2000,2500,3000 System
Installation, Operation and Maintenance Manual

TABLE OF CONTENT
UNPACKING AND INSPECTION CHECKLIST -----------------------------------------------
1
SAVE THE ORIGINAL SHIPPING BOX --------------------------------------------------------
2
READ THE OPERATOR’S MANUAL -----------------------------------------------------------
3
■ Section 1: Installation & Start-Up Manual --------------------------------------------------------------
6
1.1
DESCRIPTION -----------------------------------------------------------------------------------------
7
1.1.1
System Description ---------------------------------------------------------------------
7
1.1.2
TC-650,1100,2000,2500,3000 UPS -----------------------------------------------------
8
1.1.3
Auto Transfer Switch -------------------------------------------------------------------
10
1.1.4
Batteries ------------------------------------------------------------------------------------
10
1.2
MOUNTING ---------------------------------------------------------------------------------------------
10
1.3
WIRING --------------------------------------------------------------------------------------------------
11
1.4
START-UP AND TEST -------------------------------------------------------------------------------
14
1.5
SHUTDOWN --------------------------------------------------------------------------------------------
16
1.5.1
TC UPS ------------------------------------------------------------------------------------------
16
1.5.2
ATS -----------------------------------------------------------------------------------------------
17
1.6
TROUBLESHOOTING -----------------------------------------------------------------------------------
18
1.7
SPECIFICATIONS -----------------------------------------------------------------------------------------
19
1.8
EMERGENCY SHUTDOWN PROCEDURE ------------------------------------------------------
20
■ Section 2: Operator’s Manual ---------------------------------------------------------------------------------
21
2.1.1
THE ADVANTAGES -------------------------------------------------------------------------------------
23
2.1.2
A TOUR OF THE TC SERIES ------------------------------------------------------------------------
24
2.2.1
LCD PANEL ------------------------------------------------------------------------------------------------
30
2.2.2
TC UPS OPERATING MODES -----------------------------------------------------------------------
31
2.2.3
SELF TEST -------------------------------------------------------------------------------------------------
32
2.2.4
START UP ---------------------------------------------------------------------------------------------------
33
2.2.5
SHUTDOWN ------------------------------------------------------------------------------------------------
34
2.2.6
BATTERY REPLACEMENT. --------------------------------------------------------------------------
35
2.2.7
LCD MENU TREE -----------------------------------------------------------------------------------------
36
2.2.8
STATUS SUBMENU -------------------------------------------------------------------------------------
38
2.2.9
CONFIG SUBMENU --------------------------------------------------------------------------------------
40
2.2.10
MAINTENANCE MENU ---------------------------------------------------------------------------------
42
2.2.11
ALARM MENU ---------------------------------------------------------------------------------------------
44
2.2.12
FAULT MENU ----------------------------------------------------------------------------------------------
45
2.2.13
LOW BATTERY MODE STATUS --------------------------------------------------------------------
46
2.3.1
RS232/USB SET-UP -------------------------------------------------------------------------------------
48
2.3.1.1
Wiring Set-up Procedure -----------------------------------------------------------------
48
2.3.2
HYPER TERMINAL SET UP ---------------------------------------------------------------------------
49
2.3.3
MAIN MENU ------------------------------------------------------------------------------------------------
53
2.3.4
MENU TREE & RS232/USB SUB MENUS --------------------------------------------------------
56
2.3.4.1
RS232/USB Menu Tree --------------------------------------------------------------------
56
The complete MENU Tree ----------------------------------------------------------------
57
2.3.4.2
Unit Specifications, Input/Output Values -------------------------------------------
58
2.3.4.3
Input / Output Values ----------------------------------------------------------------------
58
2.3.4.4
Maintenance ----------------------------------------------------------------------------------
59
2.3.4.5
Line Slow Detection Parameters ------------------------------------------------------
61
2.3.5
MENU TUTORIAL ----------------------------------------------------------------------------------------
66
2.4.1
BATTERY BACK-UP TIME TEST -------------------------------------------------------------------
67
2.4.2
TC SERIES RETURN INSTRUCTIONS ------------------------------------------------------------
68
2.4.3
TROUBLESHOOTING -----------------------------------------------------------------------------------
69
CONTRAST ADJUSTMENT LCD DISPLAY ------------------------------------------------------
70
2.4.4
BATTERY MAINTENANCE ----------------------------------------------------------------------------
70
2.4.5
SPECIFICATIONS ----------------------------------------------------------------------------------------
71
2.4.6
WARRANTY ------------------------------------------------------------------------------------------------
73
2.4.7
EMERGENCY SHUTDOWN PROCEDURE -------------------------------------------------------
74

IMPORTANT SAFETY INSTRUCTIONS ARE
CONTAINED IN THIS MANUAL
CAUTION
RISK OF ELECTRICAL SHOCK
To reduce the risk of electrical shock and to ensure the safe operation of the TC 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 TC UPS to rain or moisture.
DANGER: Total Earth ground leakage current of loads connected to the
TC UPS should not exceed 2.4 mA.
The TC 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 TC UPS.
1

IMPORTANT SAFETY PRECAUTIONS
Only qualified personnel should service or supervise the service of the TC UPS.
Danger: Sealed lead-acid batteries with high energy and chemical hazards are used. This manual
contains important operation and safety instructions.
TC UPS Safety System Checklist
• Carefully unpack the TC 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 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 TC 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
2

Battery Safety Checklist
• High & dangerous voltages are present inside the system. Only qualified personnel should perform installation
and maintenance.
• Live battery wires must not touch the TC 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 TC 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 TC 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.
3

Unpacking and Inspection Checklist
Purpose: Describes the unpacking and inspection procedures.
Carefully remove the TC UPS from its box. Inspect the contents and make sure the following items are included:
• One TC UPS System.
• One plastic bag containing the following:
• Temperature sensor probe cable with 3-pin connector and extension cord.
• Installation, Operations and Maintenance manual.
Tip: If any items are missing or damaged, contact Manufacturer and the shipping company at once.
Most shippers have a short claim period.
4

SAVE THE ORIGINAL SHIPPING BOX
When returning the TC 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 TC 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 No.: TC-__________________________________________________
Serial No.:
(Above items can be found on the nameplate label attached to the side of the unit)
Products Sales Order No.____________________________
TC- P/N: _
Your Purchase Order No.:__________________________
Purchased from: _
(Following details are for installation location)
Installation date: _
Installed by: _
City: _
State/Province: _
Zip/Postal Code: _
Country: _
Telephone #: _
Fax #: __
E-Mail:__________________________________________
Street names of location: ____________________________
Cabinet / controller type: ___________________________
5

TC UPS
Uninterruptible Power Supply
■ Section 1: Installation & Start-Up Manual
6

1.1 Description
Purpose: Describes the operation of the TC UPS System (Figure 1, 2 & 3).
1.1.1 System Description
The TC UPS System provides backup power to traffic control signal equipment. It consists of the TC
Uninterruptible Power Supply (UPS) System, the Auto Transfer Switch (ATS), and batteries that provide back up
power when the line is unqualified. These three components can be mounted inside an enclosure to provide
protection from most weather conditions.
Figure 1
Simplified TC UPS 120V System Block Diagram
7
TC-2000 UPS
*ACTIVATE WHEN BUCK / BOOST IS ENABLED
CONTINOUS
RS232 & USB
CONNECTION
UPS OUTPUT
Fault

The traffic signal cabinet is powered continuously when a TC 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
TC 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 batteries connected 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 allows 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 TC-650,1100,2000,2500,3000 UPS
The TC UPS System shown below provides control functions and backup power as described above. For more
information, please see Section 2 of this manual.
TC-650,1100 UPS Front Panel
Figure 2
8

TC-2000 UPS Front Panel
TC-2500,3000 UPS Front Panel
Figure 3
9

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.
Figure 4
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
1.1.4 Batteries
Different Amp-hour capacities or sizes of batteries can be used in the TC 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,soitispossible tounplug 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 TC UPS System into an enclosure.
The TC 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 TC UPS 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 TC UPS 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.
10

1.3 Wiring
Purpose: Describes how to wire the TC 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
Is the load over or
under spec.
capacity ?
OVER
Put the Intersection in FLASH mode as soon as TC UPS
goes into Battery mode, by connecting any one of the six
programmed contacts to “ ON BATT ” from C, NO or NC type
at the TC UPS to the AUTO / FLASH circuit of any controller.
Go to Step 1
UNDER
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 TC UPS 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.
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 TC 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.
11

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 TC UPS (TC-2000)
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 TC UPS to traffic cabinet for
Flash mode (if used)
Wrap a tie around the
strain relief loop and the
battery temperature
sensor to prevent the
connector from
disconnecting during an
earthquake or other
severe vibrations.
TIP: Torque status/self
test terminal block to a
maximum of 4.4 lb-in (0.5
Nm). Maximum wire size
is 14 AWG.
Figure 5
TC-2000 Front Panel
TIP: (See Section 2.1.2, Fig. 16) of this manual for details
on the layout, operation, and specifications of the Control
Terminal Block.
GO TO STEP 2
Step 2: Connect ATS to the TC-2000.
START
Connect the cord from UPS
OUT at ATS to the AC OUT
receptacle on TC-2000.
And connect the cord from
UPS IN on ATS to AC IN
receptacle on TC-2000.
Connect the cord from
Bypass control on ATS
to PTS on TC-2000.
GO TO STEP 3
UPS INMP 20
12
Figure 6
MP 20 TC-2000 Front & Power Transfer
Switch

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 TC-2000
UPS
GO TO STEP 4
13
Figure 8
TC-2000 Front Panel
Figure 7
Power Transfer Switch

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 STARTUP PROCEDURE TIPS
The TC UPS automatically starts up in Standby mode. After the AC line
Verify that the AC Input & is qualified (default 30 seconds) the UPS switches to On Line mode.
Output as well as Battery The ATS is a safeguard that the cabinet will always revert to utility
Circuit Breakers on the power if there is ever a failure of the TC UPS or batteries.
TC UPS are OFF
Turn ON the upstream Utility
Input Circuit Breaker
GO TO STEP 2
Step 2: Turn on the UPS.
START
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 “ ON
LINE”, the Green
Output LED is lit
indicating Input power to
be within acceptable
frequency and voltage
ranges and the output is
powered from utility.
GO TO STEP 3
14
Verify the load is turned ON

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.
Turn ON the
upstream circuit
breaker
Within 30 seconds
the ATS switches
back to line power
Observe the Yellow Alarm
LED. If it is on, follow the
troubleshooting sequence as
below:
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 TC UPS
manual, Section
2.4.3
5. Contact Manufacturer
technical support
The Green Output
LED is lit and the
display shows “ON
LINE”
START UP AND
TESTING FINISHED
TIP: In ON LINE mode, press and hold “ESC” for 3 seconds to perform the self-test feature.
TIP: In STANDBY mode, press and hold “ESC” for 3 seconds to perform the cold start feature.
15

1.5 Shutdown
Purpose: Describes how to shut down the system components for removal or maintenance.
1.5.1 TC UPS
DANGER: Shutting down the TC UPS does not necessarily
disconnect power to the loads.
START
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(s) wires
Danger: The AC input wires from ATS are still HOT or Live.
Insulate the bare wires using wire nuts.
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 TC UPS.
Perform this procedure in
reverse order to reinstall the
unit.
PROCEDURE FINISHED
TIP: For additional information on how to operate the TC UPS manual, (see Section 2.2).
16

1.5.2 ATS
START
Turn OFF the upstream
circuit breaker
TIP: Verify that both the AC
and Battery Breaker are OFF
at the TC UPS.
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
17
Figure 9
Auto Transfer Switch

1.6 Troubleshooting
TC UPS System Troubleshooting Chart
SYMPTOM CAUSE REMEDY
Upstream utility circuit breaker or
fuse may be OPEN
CLOSE the upstream utility
breaker or fuse
No Output
Utility AC Power not available Check with the AC voltmeter &
contact the Utility Company
available from
ATS
Wiring error Correct wiring at ATS
Faulty ATS
replace the ATS
TC UPS output power not
connected to ATS
Verify that “UPS OUT” cord is
properly connected to the AC
OUTPUT receptacle at the TC
UPS
ATS won’t allow
transfer to Battery
mode
“UPS OUTPUT” circuit breaker at
ATS is open
Faulty ATS
Reset the breaker & clear the
fault
Replace ATS
Verify that “UPS IN” cord from ATS
is properly connected to the AC
INPUT receptacle at the TC UPS
TC UPS does not
return back to
input Line mode
Utility input line power is missing
Verify that the “UPS INPUT”
circuit breaker at ATS is closed
Ensure that the utility input is
present
Figure 10
Troubleshooting Table
18