TSi Power MC60024 User manual

Operating Manual for:
VRP, Single Phase, 1.4 kVA –49.9 kVA
MC60024
January, 2024
IMPORTANT SAFETY INSTRUCTIONS: SAVE THESE INSTRUCTIONS –This
manual contains important instructions for the single phase VRP Series that
should be followed during installation and maintenance.

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 2
Table of Contents Page
1. GENERAL 5
1.1 PRODUCT APPLICATION............................................................................................5
1.2 SAFETY ALERTS.................................................................................................................6
1.3 GENERAL VRP DESCRIPTION.................................................................................6
1.4 OVERALL DIMENSIONS ..............................................................................................7
1.5 CONSTRUCTION...............................................................................................................8
1.6 VRP ENCLOSURE TOP VIEW WITH COVER REMOVED........................9
1.7 SMALL/MEDIUM SERIES HARDWIRE ACCESS.......................................... 12
1.8 SMALL/MEDIUM SERIES HARDWIRE ACCESS COVER........................ 12
1.9 LARGE SERIES (24in. CUBE) HARDWIRE ACCESS.................................. 13
1.10 SMALL/MEDIUM UNIT WITH PLUG AND RECEPTACLE...................... 13
2. MAJOR COMPONENT/CIRCUIT DESCRIPTIONS 14
2.1 SINGLE PHASE VRP WIRING DIAGRAMS......................................................14
2.2 BUCK-BOOST VOLTAGE REGULATION TRANSFORMERS..................17
2.3 CONTROL CIRCUIT BOARD ASSEMBLY..........................................................18
2.4 SURGE/FILTER BOARD ASSEMBLY...................................................................19
2.5 VRP STATUS INDICATORS........................................................................................ 21
2.6 VRP INTERNAL CIRCUIT BREAKER................................................................... 22
2.7 VRP INPUT EMI FILTER ............................................................................................. 22
2.8 VRP UNIT EXHAUST FAN......................................................................................... 23
2.9 VRP HEAT SINK COOLING FAN........................................................................... 23

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 3
3. INSTALLATION 24
3.1 SITE SELECTION & PREPARATION....................................................................24
3.2 REQUIRED TOOLS ........................................................................................................24
3.3 UNPACKING & INSPECTION ..................................................................................24
3.4 INSTALLING THE VRP ................................................................................................ 25
3.5 AC CONNECTIONS (HARDWIRE VERSIONS)............................................. 25
4. POWERING UP THE VRP 27
4.1 CHECKING FOR PROPER INPUT VOLTAGE................................................28
4.2 ENERGIZING THE VRP...............................................................................................28
5. MAINTAINING THE VRP 29
5.1 VRP OPERATION ..........................................................................................................29
5.2 ENCLOSURE INTEGRITY ..........................................................................................29
6. TROUBLESHOOTING & COMPONENT REPLACEMENT 29
6.1 VISUAL STATUS INDICATORS...............................................................................29
6.2 DECOMMISSIONING THE VRP & INSPECTING FOR DAMAGE........30
7. REPAIRS, SERVICE & SPARE PARTS 30
7.1 REPAIRING VRP.............................................................................................................30
7.2 REPAIRING THE VRP IN THE FIELD..................................................................30
7.3 SPARE PARTS .................................................................................................................. 32
7.4 REPLACEMENT OF HEAT SINK COOLING FAN ........................................ 33
7.5 REPLACEMENT OF MAIN CONTROL BOARD ASSEMBLY................. 33
7.6 REPLACEMENT OF UNIT EXHAUST FAN.......................................................34
8. CONTACT INFORMATION 34
8.1 TSI CONTACT INFORMATION ................................................................................34

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 4
COPYRIGHT
Copyright © 2024 TSI Power Corporation. All rights reserved.
The information contained in this Document is the property of TSI Power Corporation and
contains confidential and proprietary information owned by TSI Power Corporation. Any
duplication or disclosure without the written approval of TSI Power Corporation is prohibited.
TRADEMARK
TSI Power, TSI, the TSI Logo and VRP Series are trademarks of TSI Power Corporation.
LIMITED WARRANTY
TSI Power Corporation warrants this product to be free from defects in materials and
workmanship for two (2) years from the date of purchase from TSI Power or its authorized
representatives. TSI will repair (or at its option, replace) any defective component(s) during this
warranty period.
To make a request or claim for service under this limited warranty, the original purchaser must
return the product, in the original shipping container or equivalent, to TSI Power or its authorized
agent, accompanied by a written receipt showing the date of purchase and both the model name
and serial number of the product.
Warranty does not cover transportation costs. Damage by misuse, accident or unauthorized
tampering of the product is not covered by the warranty. NO OTHER WARRANTIES ARE
EXPRESSED OR IMPLIED. TSI IS NOT LIABLE FOR CONSEQUENTIAL DAMAGES. THIS WARRANTY
GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY
FROM STATE TO STATE.
LIMITATION OF LIABILITY
IN NO EVENT SHALL TSI POWER CORPORATION BE LIABLE FOR ANY DAMAGES WHATSOEVER
(INCLUDING WITHOUT LIMITATION, DAMAGES FOR LOSS OF BUSINESS PROFITS, BUSINESS
INTERRUPTION, LOSS OF BUSINESS INFORMATION, OR OTHER PECUNIARY LOSS) ARISING OUT
OF THE USE OR INABILITY TO USE THIS PRODUCT, EVEN IF TSI POWER OR ITS AGENT HAVE
BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. SOME STATES DO NOT ALLOW THE
LIMITATION OR EXCLUSION OF LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO
THE ABOVE EXCLUSIONS MAY NOT APPLY TO YOU.
REVISIONS
REV. DATE REASON FOR REVISION
1 June, 2023 Initial release
2 January, 2024 Added lever (WAGO) terminal information, page 26.
Included 17% and 15% units.

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 5
1GENERAL
1.1 PRODUCT APPLICATION
The VRP is a highly sophisticated automatic precision AC voltage regulator that
ensures maintenance free operation of electronic equipment over a very wide
input voltage range. TSI Power’s VRP series is designed to provide high precision
power with industry leading response time of one-half line cycle (10 ms or less).
Common applications include but are not limited to: graphics, broadcast, telecom,
industrial, analytical equipment and digital copiers. The VRP series of products may
provide enhanced operation, extended operating life, reduced downtime and
lower service costs.
Figure 1: The VRP Enclosures
Hardwire terminal
access panel

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 6
IMPORTANT SAFETY INSTRUCTIONS: SAVE THESE INSTRUCTIONS –This manual
contains important instructions for the single phase VRP Series that should be followed
during installation and maintenance.
1.2 SAFETY ALERTS
SAFETY SIGNAL WORD DEFINITIONS
This document contains safety alert pictorial Symbols and Words that point out areas and
procedures that require special attention with regards to safety. These Symbols and
Words are defined in ANSI Z535.4-1998, Product Safety Signs and Labels.
DANGER:
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING:
WARNING indicates a potentially hazardous situation which, if not avoided, will
result in death or serious injury.
CAUTION:
CAUTION indicates an imminently hazardous situation which, if not avoided, may
result in minor or moderate injury. It may also be used to alert against unsafe
practices.
The safety alert pictorial symbol appears in this document to make users aware of
important operating and safety concerns.
1.3 GENERAL VRP DESCRIPTION
•Enclosure with access panel for Hardwire terminations
•Vented cover or sides for cooling
•AC input over voltage protection circuit board
•DC fan for cooling, larger powered units have additional AC fans for cooling
•System status display LEDs
•AVR control circuit board
•AC input circuit breaker and system on/off switch, not present in large (24in. Cube)
units

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 7
1.4 OVERALL DIMENSIONS -See Figures 2, 3 and 4
Figure 2: Small Series VRP Dimensions
Figure 3: Medium Series Dimensions

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 8
Figure 2: Outdoor
XUPS-600-0562
Dimensions
1.5 CONSTRUCTION
The VRP Series enclosures are constructed of Galvaneal Steel and finished with a
black or light gray polyester powder coat and are intended for installation in a
protected environment. The small and medium units are black while the large
(24in. Cube) unit is light gray. Small unit Enclosure base is 2 mm (0.075") thick and
Enclosure cover is 1.2 mm (0.048") thick. Medium unit Enclosure base is 2.7 mm
(0.108") thick and Enclosure cover is 1.3 mm (0.052") thick. Large unit Enclosure
base is 3.2 mm (0.125") thick and Enclosure sides and cover are 1.6 mm (0.063")
thick.
Figure 4: Large Series (24in. Cube) Dimensions

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 9
1.6 VRP ENCLOSURE TOP VIEW WITH COVER REMOVED -See Figures 5, 6 and 7
Figure 5: Top View of Small Series VRP with Cover Removed
AC Input/Output
Wiring Terminals
Mounted on DIN-rail
Hardwire Units
Control
Circuit Board
AC
Input/Output
Surge
Protection
and Filter
Board
Heat Sink
Cooling Fan
System Status
Display LEDs
Buck-Boost
Transformer
Input AC
Filter
On/Off Switch
and Internal
Circuit Breaker
Control
Circuit Board
Heat Sink
4 Pin Power
Connector

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 10
Figure 6: Top View of Medium Series VRP with Cover Removed
Heat Sink
Cooling Fan
Buck-Boost
Transformer
Input AC
Filter
AC Input/Output
Wiring Terminals
Mounted on DIN-
rail Hardwire Units
On/Off Switch
and Internal
Circuit Breaker
Output
Chokes
Control
Circuit Board
AC Input/Output
Surge Protection
and Filter Board
System Status
Display LEDs
Control
Circuit Board
Heat Sink
Unit
Exhaust Fan
(Optional)
4 Pin Power
Connector

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 11
Figure 7: Top View of Large Series (24in. Cube) with Covers Removed
Control Circuit
Board
Assemblies
AC Input/Output
Filter Board
Unit Exhaust
Fans
System Status
Display LED
Board
Buck-Boost
Transformers
Input AC
Terminals
Input AC
Filter
Output AC
Terminals
Input Surge
Protection
MOV Board
Output
EMI Filter
Board
Input and output AC
Damping Resistors
4 Pin Power
Connectors

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 12
1.7 SMALL/MEDIUM SERIES HARDWIRE ACCESS
Figure 8: Small Series VRP Shown With Rear Access Cover Removed
1.8 SMALL/MEDIUM SERIES HARDWIRE ACCESS COVER
Figure 9: Rear View Medium Series VRP Shown With Rear Access Cover Attached
Input/Output
Wiring Terminals
Mounted on DIN-rail
On/Off Switch
and Internal
Circuit Breaker
On/Off Switch
and Internal
Circuit Breaker
Incoming/ Outgoing
Wire Entrance Holes
Hardwire
Access Cover

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 13
1.9 LARGE SERIES (24in. CUBE) HARDWIRE ACCESS
Figure 10: Large Series (24in. Cube) Shown With Wiring Access Cover Removed
1.10 SMALL/MEDIUM SERIES WITH PLUG AND RECEPTACLE
Figure 11: Small Series Shown With NEMA L6-20R Outlet and IEC-320 Inlet
Input Power Wiring
Terminals Mounted
on DIN-rail
Incoming/
Outgoing Wire
Entrance
Holes
Output Power
Wiring Terminals
Mounted on DIN-rail
On/Off Switch
and Internal
Circuit Breaker
Output
Receptacle
Input
Receptacle
Input/Output
Ground
Terminals
Input Surge
Protection
MOV Board
Output
EMI Filter
Board

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 14
2MAJOR COMPONENT/CIRCUIT DESCRIPTIONS
2.1 SINGLE PHASE VRP WIRING DIAGRAMS -See Figures 12, 13 and 14
Figure 12: Single Phase Small Series VRP Wiring Diagram

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 15
Figure 13: Single Phase Medium Series VRP Wiring Diagram

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 16
Figure 14: Single Phase Large Series (24in. Cube) VRP Wiring Diagram

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 17
2.2 BUCK-BOOST VOLTAGE REGULATION TRANSFORMERS -See Figure 15
These transformers supply current to the load through the secondary winding. The
primary winding is used to impose the correction voltage.
Figure 15: Buck-Boost Transformer for VRP-2800-700A Shown
NOTE: Figure for reference only, actual component may vary in appearance.

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 18
2.3 CONTROL CIRCUIT BOARD ASSEMBLY -See Figure 16
The proprietary voltage regulation control board is powered by a DSP
microcontroller. The Control Board’s Firmware Version is located on a label affixed
to the microcontroller (see Figure 16). It senses the incoming mains voltage and
corrects the output continuously. It incorporates advanced algorithms to ensure
the fastest possible response time while maintaining control loop stability.
Figure 16: PZ00073 Main Control Circuit Board Assembly Shown
Bypass
Relay
LED Display
Socket
Inverter
Transistors
Rectifier
Transistors
Bypass
Fuse
Heat Sink
Cooling
Fan
4 Pin Power
Connector
Firmware
Version

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 19
2.4 SURGE/FILTER CIRCUIT BOARD ASSEMBLY -See Figures 17, 18, 19 and 20
These circuit board assemblies provide two functions:
1. Surge voltage diversion
2. Output filtering to reduce voltage distortion
Figure 17: PZ00205 Small/Medium Series VRP Surge/Filter Circuit Board Assembly
Figure 18: PZ00203 Large Series (24in. Cube) VRP Filter Circuit Board Assembly
Thermally
Protected
MOVs
Input Filter
Capacitor
Output Filter
Capacitor
Output Chokes
(not used in
Medium Units)
Output Filter
Capacitors
Input Filter
Capacitors

TSI Power Corporation MC60024
VRP, Single Phase, 1.4 kVA –49.9 kVA REV. 2, January, 2024
TSI Power Corporation Proprietary Information 20
Figure 19: PZ00204 Large Series (24in. Cube) Input Surge Circuit Board Assembly
Figure 20: PZ00206 Large Series (24in. Cube) Output EMI Filter Circuit Board
Assembly
Thermally
Protected
MOVs
EMI Filter
Capacitors