Siemens 667/HB/47750/000 User manual

Infrastructure and Mobility, Traffic Solutions
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BH17 7ER
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Name UPS Solution General Handbook Doc. No. 667/HB/47750/000
Copyright Siemens plc 2017 All Rights Reserved
UPS Solution General Handbook
Part no.
667/HB/47750/000
THIS DOCUMENT IS ELECTRONICALLY APPROVED
AND HELD IN THE STC DOCUMENT CONTROL TOOL
Prepared By Checked and Released
Company/Dept. Siemens Traffic Solutions/Engineering Siemens Traffic Solutions/ Engineering
Name Ore Oluwatudimu David Martin
Function Product Development Engineer Hardware Engineering Manager
Signature
Date
COPYRIGHT STATEMENT
The information contained herein is the property of Siemens plc. and is supplied without liability for errors
or omissions. No part may be reproduced or used except as authorised by contract or other written
permission. The copyright and the foregoing restriction on reproduction and use extend to all media in
which the information may be embodied
Copyright Siemens plc 2017 All Rights Reserved

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Preface
SAFETY INFORMATION
Safety of Installation and Maintenance Personnel
In the interests of health and safety, when installing, using or servicing this
equipment the following instructions must be noted and adhered to:
(1) Only skilled or instructed personnel, with relevant technical knowledge
and experience, who are familiar with the safety procedures required
when dealing with modern electrical/electronic equipment, are to be
allowed to use and/or work on this equipment. All work shall be
performed in accordance with the Electricity at Work Regulations 1989.
(2) Such personnel must take heed of all relevant notes, cautions and
warnings in this Handbook and any other Document or Handbooks
associated with this equipment.
(3) The equipment must be correctly connected to the specified incoming
power supply.
(4) Mains voltages may be present within traffic system. Before any
maintenance work within the system is carried out, any mains supply to it
must be isolated or switched off.
(5) Mains voltages may still be present within traffic equipment even when
the site mains supply has been isolated or switched off. The UPS
Solution must be completely off to ensure no mains power is supplied to
connected traffic equipment.
(6) Only trained / competent persons should work on this equipment.
(7) Surfaces within the associated traffic equipment get hot, e.g. lamp, lens
and reflector. Therefore care should be taken when working in such
areas.
(8) Any power tools must be regularly inspected and tested.
(9) Any ladders used must be inspected before use to ensure they are
sound and not damaged.
(10) When using a ladder, before climbing it, ensure that it is erected properly
and is not liable to collapse or movement. If using a ladder near a
carriageway, ensure that the work area is properly signed and coned.
(11) Any personnel working on site must wear the appropriate protective
clothing with high visibility jackets and safety boots as a minimum.

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Safety of Road Users
It is important that all personnel are aware of the dangers to road users that
could arise during repair and maintenance of traffic control equipment.
Ensure that the junction area is coned and signed as necessary to warn
motorists and pedestrians of any dangers and to help protect the personnel
working on the site.
Precautions for Safe Battery Handling and Storage
Keep battery containers tightly closed when not in use.
If the battery case is broken, avoid contact with any internal components or
materials.
Do not handle near heat, sparks or open flames.
Protect battery containers from physical damage to avoid leaks or spills.
Place cardboard or other insulating material between layers of stacked
batteries to avoid damage and short circuits.
Do not allow conductive material to touch the battery terminals. A dangerous
short-circuit may occur and cause battery failure, fire, arcing, flash burns, etc.
Keep away from combustible materials, organic chemicals, reducing
substances, metals, strong oxidizers and water.
Batteries must be charged in a ventilated area. General ventilation is
acceptable.
Insulated tools must be used at all times and cases involving batteries.
For further information on proper battery handling see the Lead Crystal
Battery User Manual – 667/HB/47764/000.
Fault Protection RCDs
Any traffic controller, Siemens type or otherwise, supported by the UPS must
be fitted with a 300mA RCD at its mains input point. This ensures the quality
of fault protection, no matter what fault scenario the installation may face.
See section 7.2 of this document for more details

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MAINTENANCE PROVISION (MP)
Product Reference
UPS Solution – 667/1/47750/ETC.
Installation and Commissioning
Methods of installation, configuration and commissioning are described in this
handbook. In addition, there are a series of documents which have more
specific detail but are supplied by the OEM (Original Equipment
Manufacturer). These documents are listed in section 1.2 below.
Spares and Maintenance
The UPS system elements are designed for ‘return to base’ repair with the
exception of battery replacement.
Modifications
There are no approved modifications for this product.
Warning
Use of components other than those indicated within this document or
modifications or enhancements that have not been authorised by Siemens
will invalidate Type Approval of this product.

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Name UPS Solution General Handbook Doc. No. 667/HB/47750/000
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CONTENTS
1Introduction........................................................................................................................9
1.1 Scope....................................................................................................................9
1.2 Related Documents................................................................................................9
1.3 Definitions..............................................................................................................9
2System Overview..............................................................................................................10
2.1 Description...........................................................................................................10
2.2 Cabinet Variants ..................................................................................................10
2.3 Supported Loads..................................................................................................10
2.4 Generator Connectivity.........................................................................................11
2.5 Electrical Information............................................................................................11
3Modular Overview.............................................................................................................12
3.1 UPS Cabinet Modules..........................................................................................12
3.2 Battery Expansion Cabinet Modules.....................................................................13
3.3 Modular Elements................................................................................................14
3.3.1 Reinforced Cabinet Stool..................................................................................14
3.3.2 Vented Cabinet Outer Case..............................................................................14
3.3.3 Battery Housing Module...................................................................................14
3.3.4 UPS Housing Module.......................................................................................15
3.3.5 DC Housing Module.........................................................................................16
4Hardware Overview ..........................................................................................................17
4.1 Alpha FXM UPS unit ............................................................................................17
4.2 Universal Automatic Transfer Switch....................................................................18
4.3 Lead Crystal Batteries..........................................................................................19
5Sizing the UPS Solution...................................................................................................20
5.1 Key Considerations..............................................................................................20
5.2 Sizing Example....................................................................................................21
5.2.1 Which UPS Unit Should be Installed?...............................................................21
5.2.2 How Many Battery Packs are Required?...........................................................21
6Internal Cabling Scheme..................................................................................................23
6.1 UPS Cabinet Internal Wiring.................................................................................23
6.2 Battery Expansion Cabinet Internal Wiring............................................................24
7External Cabling Scheme.................................................................................................25
7.1 Mains Power Supply ............................................................................................25
7.2 UPS Earthing and Fault Protection RCDs.............................................................25
7.3 UPS Fault / Alarm Relay Contacts........................................................................26
7.4 Ethernet Cable.....................................................................................................26
7.5 Battery Expansion................................................................................................26
8Further UPS Connectivity ................................................................................................27
8.1 Battery Temperature Sensor ................................................................................27
8.2 RS232 Interface...................................................................................................27
8.3 LAN Interface.......................................................................................................27
9Installation........................................................................................................................28
9.1 Required Tools and Consumables........................................................................28
9.2 Preparing and Installing the Reinforced Stool.......................................................29
9.3 Pulling and Gland Ducted Cables.........................................................................30

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9.4 Fitting the Vented Cabinet Outer Case and Sealing the Base...............................31
9.5 Fitting and Connecting the Battery Housing Module..............................................32
9.6 Mounting and Connecting the UPS Housing Module.............................................34
9.7 Mounting and connecting the DC Housing Module................................................35
9.8 Terminating External Cables into the UPS Connection Panel ...............................36
9.9 Terminating External Cables into the DC Connection Panel..................................37
9.10 Terminating and Connecting the Ethernet Cable...................................................37
9.11 Fitting and Connecting the Batteries.....................................................................38
9.12 Fitting the Battery Temperature Sensor................................................................39
10 Isolation Switches............................................................................................................40
10.1 Housing Module MCBs.........................................................................................40
10.2 Universal Automatic Transfer Switch (UATS)........................................................40
10.3 FXM UPS Unit......................................................................................................41
11 Commissioning ................................................................................................................42
11.1 Electrical Safety Testing.......................................................................................42
11.2 TT Earth Electrode Test.......................................................................................42
11.3 Putting the UPS Solution in BYPASS...................................................................43
11.4 Powering and Commissioning the Controller........................................................43
11.5 Starting Up the UPS Solution...............................................................................43
11.6 Testing the UPS Battery Support Function ...........................................................44
12 UPS System Operation.....................................................................................................45
12.1 Operating Modes .................................................................................................45
12.2 Active Fault Monitoring.........................................................................................45
12.2.1 Fault / Alarm Relay Contacts........................................................................45
12.2.2 Fault Monitoring using Siemens RMS and UTMC Systems...........................47
12.3 Communicating with the UPS Solution .................................................................48
12.3.1 Three-Button Interface..................................................................................48
12.3.2 RS232 Interface...........................................................................................48
12.3.3 LAN Interface...............................................................................................50
12.4 Battery Charging..................................................................................................52
12.5 Temperature De-Rating........................................................................................53
12.5.1 Power output................................................................................................53
12.5.2 Battery Charging ..........................................................................................54
12.5.3 Battery Support Hold Up Times ....................................................................54
12.6 Generators...........................................................................................................54
12.6.1 The Generator Connect Feeder Pillar...........................................................54
12.6.2 Generator Selection......................................................................................55
12.6.3 Protection and Reference Earthing...............................................................55
12.6.4 Connecting a Generator to the UPS Solution................................................56
12.6.5 Disconnecting a Generator from the UPS Solution:.......................................56
13 Maintenance .....................................................................................................................57
13.1 Periodic inspection...............................................................................................57
13.2 Maintenance Bypass Switching............................................................................58
13.3 Switching Off the UPS Solution............................................................................59
13.4 First Line Maintenance.........................................................................................60
13.4.1 Replacing the Alpha FXM UPS unit ..............................................................60
13.4.2 Replacing a Battery Pack .............................................................................61
13.4.3 Replacing an Alpha UATS unit......................................................................63
13.5 Second Line Maintenance....................................................................................63
14 Disposal............................................................................................................................64
14.1 Under Maintenance Contract................................................................................64
14.2 End of Life and Scrapping....................................................................................64

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15 Part Numbers / Spares List..............................................................................................65
15.1 Hardware Spares.................................................................................................65
15.2 Housing Modules.................................................................................................65
15.3 Outer Case and Stool...........................................................................................65
15.4 Connection Panel and MCB Spares.....................................................................65
15.5 Connection Accessories.......................................................................................65
15.6 Generator Connect Feeder Pillar..........................................................................65
APPENDIX A – Estimated Hold Up Times ..............................................................................66
APPENDIX B – FXM UPS Faults and Alarms..........................................................................69
APPENDIX C – Hardware Datasheets.....................................................................................70
Alpha FXM Series UPS Unit.............................................................................................70
Alpha Universal Automatic Transfer Switch (UATS)..........................................................72
Betta Batteries 6CNFT-55 12V 55Ah Front Terminal Lead Crystal Battery........................74
APPENDIX D – UPS Commissioning Certificate....................................................................76
Figure 3-1: UPS Cabinet Modules.......................................................................................12
Figure 3-2: Battery Expansion Cabinet Modules (Cabinet removed).....................................13
Figure 3-3: Reinforced Stool – FRONT VIEW (CET plate attached).....................................14
Figure 3-4: Battery Housing Module.....................................................................................15
Figure 3-5: UPS Housing Module ........................................................................................15
Figure 3-6: DC Housing Module (shown fitted on top of a battery housing module)..............16
Figure 4-1: Alpha FXM Series UPS Unit..............................................................................17
Figure 4-2: Universal Automatic Transfer Switch..................................................................18
Figure 4-3: 6CNFT-55 Lead Crystal Battery with Key Electrical Information..........................19
Figure 5-1: Battery Hold up times at 20°C and 0°C..............................................................20
Figure 5-2: Sizing Example – Battery Pack Selection...........................................................22
Figure 6-1: UPS Cabinet Internal Wiring Diagram................................................................23
Figure 6-2: Battery Expansion Cabinet Internal Wiring Diagram...........................................24
Figure 7-1: Mains Power Supply Chain................................................................................25
Figure 9-1: Reinforced Stool and CET plate.........................................................................29
Figure 9-2: Stool Installation Diagram..................................................................................30
Figure 9-3: Reinforced Stool – LEFT HAND SIDE VIEW......................................................31
Figure 9-4: Battery Housing Modules stacked on the Reinforced Stool (Cabinet removed)...32
Figure 9-5: Battery Housing module mount..........................................................................33
Figure 9-6: Earth Connection between Battery Housing modules.........................................33
Figure 9-7: UPS Housing mounted on Battery Housing within Cabinet.................................34
Figure 9-8: Battery Cable Loom Connectors........................................................................35
Figure 9-9: UPS Connection Panel......................................................................................36
Figure 9-10: Battery Terminals Connected with the Terminal Linking Bar.............................38
Figure 9-11: Battery Temperature Sensor............................................................................39
Figure 10-1: UATS Switches................................................................................................40
Figure 10-2: Alpha FXM UPS Circuit Breakers.....................................................................41
Figure 12-1: Fault Monitoring Connectivity Example ............................................................47
Figure 12-2: Alpha FXM Series UPS RS232 Interface Screenshot.......................................49
Figure 12-3: LAN Interface Screenshot – Relay Contact Configuration.................................51
Figure 12-4: Battery Charging Cycle....................................................................................53
Figure 12-5: Generator Connect Feeder Pillar......................................................................54
Figure 12-6: Three-position Changeover Switch ..................................................................56
Figure 13-1: Battery Terminals Connected with the Terminal Linking Bar.............................62
Figure A-0-1: Estimates of UPS Solution Performance at +20°C..........................................66
Figure A-0-2: Estimates of UPS Solution Performance at 0°C..............................................67
Figure A-0-3: Estimates of UPS Solution Performance at -25°C...........................................68

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Table 2-1: UPS Load Suitability...........................................................................................10
Table 2-2: UPS Solution Electrical Information.....................................................................11
Table 3-1: UPS Cabinet Module Quantities..........................................................................12
Table 3-2: Battery Expansion Cabinet Module Quantities.....................................................13
Table 4-1: FXM Series UPS – Key Electrical Information.....................................................17
Table 4-2: UATS – Key Electrical Information......................................................................18
Table 7-1: Alarm Contact Cable Specification......................................................................26
Table 7-2: Ethernet Cable Specification...............................................................................26
Table 7-3: Battery Expansion Cable Specification................................................................26
Table 9-1: Installation Steps for the UPS and Battery Expansion Cabinets...........................28
Table 9-2: RJ45 Interface Cable Connection........................................................................37
Table 12-1: Key UPS Solution Operating Modes..................................................................45
Table 12-2: Default Fault Contact Settings...........................................................................46
Table 12-3: RMS Bit Labelling and Description....................................................................47
Table 12-4: RS232 Interface Connection Information...........................................................48
Table 12-5: LAN Interface Connection Information...............................................................50
Table 12-6: Maximum Output Power against Ambient Temperature.....................................53
Table B-1: FXM UPS Unit Fault and Alarms.........................................................................69
CHANGE HISTORY
Version
Date
Author
Change
1 – 4 Jan
2014 Ore Oluwatudimu Produce Document
5Nov
2014 Ashley Thorpe Section 15 – added black outer case variant to parts list
6Sept
2016 Ore Oluwatudimu Change note TS008289 applies.
7Jan
2017 Ore Oluwatudimu Change note TS008468 applies.

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1 Introduction
1.1 Scope
This handbook provides a general description of the Siemens UPS Solution and its key
elements, outlining the detailed procedures for installation, commissioning and
maintenance.
1.2 Related Documents
Reference Title Author/Contact
667/HB/47760/000 Alpha FXM Series UPS Installation and Operation
Manual Alpha Technologies Europe Ltd.
667/HB/47761/000 Alpha Universal Automatic Transfer Switch
Installation Manual Alpha Technologies Europe Ltd.
667/HB/47764/000 Lead Crystal Battery User Manual Betta Batteries
667/US/47764/000 Lead Crystal Battery Material Safety Data Sheet Betta Batteries
667/HE/45950/000 ST950 ELV Installation, Commissioning and
Maintenance Handbook Dave Martin
667/HE/46950/000 ST950 LV Installation, Commissioning and
Maintenance Handbook Dave Martin
667/HB/45040/000 Isolators and Feeder Pillars General Handbook Peter Lings
1.3 Definitions
Abbreviation
Explanation
DNO Distribution Network Operator
GUI Graphical User Interface
LAN Local Area Network
LC Lead Crystal (refers to battery technology)
LCD Liquid Crystal Display
MCB Miniature Circuit Breaker
MET Main Earth Terminal
OEM Original Equipment Manufacturer
OMU Outstation Monitoring Unit
OTU Outstation Transmission Unit
SNMP Simple Network Management Protocol
SOC State of Charge
UATS Universal Automatic Transfer Switch
UPS Uninterruptable Power Supply
VRLA Valve Regulated Lead Acid (refers to battery technology)

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2 System Overview
2.1 Description
The UPS Solution has been designed to provide seamless battery support to a Siemens
type traffic controller in the event of a loss of mains supply. The solution offers a line-
interactive uninterruptable power supply unit to constantly monitor the status of the mains
supply, maintaining a battery bank when power is present and switching to battery back
up when it is not. The switch from mains power to battery back up, and back again, is
almost instantaneous, ensuring that the traffic intersection controller sees no significant
break in power and remains operational.
The UPS Solution can be scaled to suit a range of power and battery hold up time
requirements. Hold up times can be extended further still with the connection of an
external generator as described in section 2.4.
2.2 Cabinet Variants
The UPS solution has been designed to be housed within a standard Siemens traffic
controller cabinet outer case to reduce its visual impact. When installed, the controller
and UPS solution cabinets appear identical. Two cabinet variants are available, as
described below.
UPS Cabinet - Houses the UPS system equipment and up to two
48V 55Ah battery banks.
Battery Expansion Cabinet - Houses up to three 48V 55Ah battery banks only.
The Battery Expansion cabinet can be installed
alongside the UPS cabinet, providing additional
battery support in cases when an extended period of
support time is required.
WARNING: No more than one Battery Expansion Cabinet can be connected to
any one UPS Cabinet.
2.3 Supported Loads
The UPS solution is ideally suited to support ELV LED traffic controllers, but can also
support LV installations. It caters for intersection loads up to 2000W in two optimised
steps via a choice of UPS unit:
UPS Unit
Max Power Output
Suitable for
Alpha FXM1100 1100W / VA Loads up to and including 1000W
Alpha FXM2000 2000W / VA Loads from 1000W to 2000W
Table 2-1: UPS Load Suitability
WARNING: Both UPS units are subject to de-rating at high temperature. This
must be considered when specifying each solution. See sections 4.1 and 12.5.1
for details. See section 5.2 for a solution sizing example.
WARNING: Any traffic controller, Siemens type or third party, which is powered
via the UPS solution must be fitted with a 300mA RCD. See section 7.2 for
more details.