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