User & Service Manual SP SERIES CONTINUOUS POWER SYSTEM MODELS COVERED: SP1250LX SP2000LX CLARY CORPORATION 150 E. Huntington Drive Monrovia, California 91016 Telephone 626-359-4486 800-44 CLARY Fax. 626-305-0254 World Wide Web HTTP: // WWW.CLARY.COM E-Mail SALES @ CLARY.COM Information contained herein is the property of Clary Corporation, is proprietary, confidential, and not to be disclosed, disseminated or used except for the purpose provided by CLARY CORPORATION P/N 510-16432, REV.
THE CONTINUOUS POWER COMPANY TABLE OF CONTENTS 1 GENERAL DESCRIPTION ....................................................................................... 5 1.1 1.2 1.3 1.4 2 GENERAL CHARACTERISTICS ............................................................................ 13 2.1 2.2 3 Installation ...................................................................................................................... 18 Preparation ....................................................................
THE CONTINUOUS POWER COMPANY LIST OF FIGURES Figure 1: FRONT PANEL VIEW SP1250LX-N SHOWN ................................................. 8 Figure 2: BYPASS BOX ...................................................................................................... 11 Figure 3: BYPASS BOX with GFCI Option ...................................................................... 12 Figure 4: UPS TO CABINET INTERCONNECTIONS....................................................
“IMPORTANT SAFETY INSTRUCTIONS” “SAVE THESE INSTRUCTIONS” This manual contains important safety instructions that should be followed during installation and maintenance of the UPS and batteries. The instructions should be followed during installation and maintenance of the UPS and batteries. Be aware of the following symbols and their meaning as they appear throughout the manual: This symbol indicates that dangerous voltage constituting a risk of electrical shock is present within the unit.
1 GENERAL DESCRIPTION 1.1 Introduction You have selected the highest quality power protection system available for your traffic control devices. You now own a SP-LX Series Traffic UPS (Uninterruptible Power System) with a programmable LCD display. The SP-LX Series is an all Digital Technology UPS product designed and manufactured by Clary Corporation, the first name in UPS reliability.
1.2 Operating Modes Clary’s SP-LX Series Uninterruptible Power Systems (UPS) are designed for powering low power (i.e., LED & NEON) traffic & pedestrian indications, plus critical traffic control devices (i.e., controllers, modems, CMU’s, etc.). The power system consists of three elements, which work together to provide critical loads with continuous, conditioned, regulated, sinusoidal waveform power that is free from disturbances such as spikes, surges, brownouts or blackouts. These elements are the: 1.
1.3 Physical Description This section will point out and illustrate the various indicators, functions and controls of the SP-LX Series UPS. The important attributes of the SP-LX Series unit are numbered to assist you in locating them on your machine and also to fully explain its function and how it relates to system operation. Numbers on the drawing will correspond to the operating component’s name at the bottom with a brief identification.
Table 1 describes items 1 – 23.
Table 1: FIGURE 1 DESCRIPTIONS PANEL VIEW DESCRIPTIONS 1 SYSTEM POWER SWITCH 13 DC IN – Input receptacle for all DC power (to Batteries) 2 INPUT AC LINE BREAKER 14 AC IN / OUT – Input terminal block for all AC power to Bypass Box 3 LCD DISPLAY 15 RELAYS – NO/NC Contacts for Flash 4 SELECT/MENU MODE 16 BATTERY TEST POINTS 5 ENTER/SHOW TIME 17 AUX. TEMP. SENSOR – Input for Optional Aux. Temp.
SUMMARY OF INDICATORS AND CONTROLS SYSTEM POWER SWITCH - The main control switch that engages utility power to the entire unit. By activating this switch it initializes normal operation. DC INPUT - A single pole, 20A (30A for SP2000LX) circuit breaker used to connect the battery to the internal UPS electronics. It also protects against over-current situations in the battery circuit. INPUT AC LINE BREAKER - The input line protection device to limit excessive current draw to the system on over-loads.
1.
Figure 3: BYPASS BOX with GFCI Option 11 10 1 2 1 – To Utility - H 2 – To Utility - N 3 – To UPS IN - H 4 – To UPS IN - N 5 – To UPS OUT - H 6 – To UPS OUT - N 3 4 5 6 7 8 7 – To CABINET - H 8 – To CABINET - N 9 - Generator Input (Optional) 10 - GFCI Outlet (Optional) 11 - Circuit Breaker for GFCI Table 3: BYPASS BOX DESCRIPTIONS 12 9
2 GENERAL CHARACTERISTICS 2.1 Characteristics Overview The Clary SP-LX Series Traffic UPS is a turnkey, true on-line, power conditioner and battery backup or uninterruptible power system (UPS) designed for the extreme environments found in traffic cabinets (-40 to + 74 deg C). The Clary SP-LX Series, with its standard 41Ahr battery pack, is capable of operating, a full LED intersection for over 2 hours at 700W (watts) output. A typical intersection consuming 450W can be powered for approximately 4 hours.
Description The Traffic UPS consists of three major components, the UPS Power Module, the Bypass Box, and the Battery System. The UPS Power Module consists of the following: • True on line, double conversion, pure sine wave, high frequency inverter utilizing IGBT technology. • Programmable LCD Display. • A DB9 RS232 and USB Type B connectors for remote signal alarms and true RS232 monitoring and remote communications. • Auxiliary Temp Sensor • Multi-stage, temperature compensated battery charger.
2.2 Specifications The various specifications of the UPS system are provided in the following tables. Table 4: ELECTRICAL SPECIFICATIONS Electrical Specifications Input Specification Nominal Input Voltage 120 VAC, Single Phase Input Voltage Range 75 VAC to 155 VAC Input Frequency 45 to 65 Hz (+/- 5%) Input Configuration 3 Wire (Hot, Neutral & Ground) Input Protection Input breaker 20 amps, SP2000LX 30A Output Specification Nominal Output Voltage 120 VAC, Single Phase Power Rating 1.
Table 5: Physical Specifications, UPS Electronics Module Physical Specifications, UPS Electronics Module Dimensions: Width = 19”, Depth = 10”, Height = 3.5” Weight: UPS: 27 lbs., Shipping weight: 33 lbs. Table 6: PHYSICAL SPECIFICATIONS Physical Specifications, Bypass Box Dimensions: Width = 7”, Depth =2.5”, Height =4.5” Weight: BYPASS BOX: 5 lbs., Shipping weight: 5 lbs. Table 7: ENVIRONMENTAL SPECIFICATIONS Environmental Specifications Temperature: - 40°C to +74°C.
Table 9: CLARY OutPostTM BATTERIES* Estimated Runtime (Per set @ 77°F / 25°C) (New Batteries, fully charged) Clary Volts/ Part. No.* A-hrs. OP72C (Set of 6 Batteries) 12 VDC/ 300 Watts 6.3 500 700 875 Watts Watts Watts 3.8 2.5 1.8 Hrs.** Hrs.** Hrs.** Hrs.** Unit Weight Overall Dimensions Per Battery Inches (cm.) Lbs. Length Width Height (Kg.) L W H 29 7.68 5.15 7.9 (13.2) (19.6) (13.1) (20.1) 41 AH Clary Part. No.* Volts/ A-hrs.
3 INSTALLATION AND OPERATIONS 3.1 Installation The UPS system is typically rack or shelf mounted in standard traffic cabinets. When determining how to position the UPS system inside your cabinet, the following requirements MUST be met. • The installation site MUST maintain an ambient air temperature of less than 165oF (74oC). • The air inlets, vents and fan MUST NOT be obstructed or blocked in any way. There MUST BE clearance around each air-inlet and vent.
• • • • • Unpack and ensure that all UPS System components are on-hand and operative: o UPS System Module o (Bypass Box) o Battery Module (6 or 8 batteries w/cabling) Collect appropriate mounting hardware for the particular installation. o For 170/332 cabinets only, one or two battery trays (per shipping documents, depends on version purchased) Assemble your tools and inventory your equipment. Table 10 is a checklist of items that have proved useful during previous installations.
3.3 Procedure The recommended installation procedure is presented in Table 11 . The Table refers to, which presents a schematic wiring diagram. Read through the entire procedure before beginning. If any steps are unclear, do not begin the installation process – please contact Clary Corporation for assistance. Finish each step completely before continuing to the next. See Figure 4 for diagram. Table 11: TYPICAL INSTALLATION PROCEDURE FOR TRAFFIC UPS 1. Mount Bypass Box and position switch to Bypass. 2.
3.4 Operating Configuration and Setup: Figure 3 shows how the UPS System is connected to the traffic cabinet. This schematic diagram illustrates the interconnections.
3.5 Start-up Once the system has been properly installed, it is ready to operate. The following procedures will explain how to start-up the system while wired into rated electrical power and also how to start-up with no AC power available. Note: When Powering up for the first time or if unit has not been powered up for more than 10 days, the LCD Display should be initialized. Please see page 28 ST45 for instructions.
3.6 Optional Communication Procedure The UPS system includes additional interfaces for communications to host computers or other similar devices. Their use is optional, but allows for remote monitoring and control of the power system. Effective utilization of these capabilities will enhance the reliability of the traffic power system. There is one DB-9, subminiature, female connector and one USB type B connector.
4 PROGRAMMABLE LCD DISPLAY 4.1 Introduction The LCD display on the UPS front panel is used to show various operational parameters of the UPS (in real time) as well as other important system information. It is also used to program options and set points for many UPS functions. The LCD display operates in two main modes: 1. Normal Mode - The default mode of operation for displaying real time UPS parameters. When left unattended, the display will always revert back to normal mode. 2.
4.2 Normal Mode The Normal mode’s main screen shows the Load and Battery percentage, AC input status and Inverter status. The Normal mode display will look something like the following. SP1250LX ONLINE VAC: 120.0, 60.0Hz LOAD:100% BAT:95% AC LINE OK, INV ON To see the time and date, press the ENTER/SHOW TIME button. SP1250LX mm/dd/yy ONLINE hh:mm:ss 4.3 Battery System Status STATUS: BATTERY Syst Once at this screen, press the ENTER/SHOW TIME button.
St23: BACKUP Events 2 Events Shows number of times UPS went to Battery Power. To clear events, press and hold both the UP and Down Arrow buttons simultaneously until the event count clears. St24: Battery Type 72 Volts 41 Ahr Shows the nominal battery voltage and the battery Amp hours. St25: Battery Ahr ALTER> Ahr = 41 This screen allows the user to enter the Battery Capacity within the range of 10Ahr to 150Ahr. To change Ahr rating, Press Enter. Press the Arrow buttons until the desired rating is displayed.
4.4 Power System Status STATUS: POWER System Once at this screen, press the ENTER/SHOW TIME button. Then press the SELECT/MENU MODE button to go through the Battery System Status menu. St30: Input Line Pwr 115Vrms 60Hz 1.5A Shows the Input line power Voltage, Frequency and Current going into the UPS. St31: Power Source UTILITY Shows the power source which the UPS is currently running off of (UTILITY or BATTERY). St32: Output Pwr/Ld 120Vrms 60Hz 50% Shows the Output Voltage, Frequency and Load percentage.
4.5 UPS System Status STATUS: UPS SYSTEM Once at this screen, press the ENTER/SHOW TIME button. Then press the SELECT/MENU MODE button to go through the Battery System Status menu. St40: Operating Mode NORMAL Shows the operating status of the UPS (NORMAL, BACKUP,……..etc). St41: Alarm Status 1 ALARM Shows the Alarm status and number of alarms which are currently active (OVERTEMP, OVERLOAD, OUTPUT BAD, INPUT IS BAD………...etc).
4.6 UPS Information Status: UPS Info NORMAL Once at this screen, press the ENTER/SHOW TIME button. Then press the SELECT/MENU MODE button to go through the UPS Information menu. St50: UPS Base Model # SP1250I Shows UPS Base Model# St51: UPS User Model My Model # NORMAL Shows the model of the UPS. To change the model #, Press the enter key. Hold down the Enter, Up Arrow and Down Arrow until display clears. Use the arrow keys to increment to the character you want. Press Enter to go to the next position.
4.7 Time and Date Status: TIME/DATE This screen allows you to set the time and date. Once at this screen, press the ENTER/SHOW TIME button. display TIME & DATE Press the Select/Menu Mode button to go to the time or date that you want to change. You can set hours, minutes, seconds, day of week, month, year and day of month. Once you are at the screen that you want, press the Enter/Show Time button. Use the Arrow buttons to select the value that you want. Press the Enter/Show Time button to save.
4.8 Miscellaneous Item’s ADJUST LCD DISPLAY This screen allows you to adjust the LCD display settings. Once at this screen, press the ENTER button. SET LCD BRIGHTNESS % BRIGHTNESS now 50% This screen allows you to set the LCD brightness. Once at this screen, press the ENTER button. Use the arrows to adjust to desired setting. Press Enter when done. SET LCD CONTRAST % CONTRAST now 50% This screen allows you to set the LCD contrast. Once at this screen, press the ENTER button.
4.9 Status: Relays RELAY’s Once at this screen, press the ENTER/SHOW TIME button. Then press the SELECT/MENU MODE button to go through the three main Relay menus. 4.9.1 ASSIGN RULE TO RELAY SEE TABLES 12 & 13 FOR DETAILED RULE DESCRIPTIONS AND ALARMS/FAULTS. ASSIGN RULE to RELAY This menu allows you to select a “Rule” for each of the eight relays. Once at this screen, press the ENTER/SHOW TIME button. To scroll thru the eight relays, press the SELECT/MENU MODE button.
4.9.2 MODIFY RULE PARAMETERS MODIFY RULE PARAM’s This menu allows you to change the parameters of each rule. Once at this screen, press the ENTER/SHOW TIME button. To scroll thru the sixteen “Rules”, press the SELECT/MENU MODE button. RULE 02: LOW_BAT_1 New TRIP PT = 40% Once at the desired “Rule”, press the arrow buttons to set new value for the “Rule”. When finished, press the ENTER/SHOW TIME button.
4.9.3 TOGGLE RELAY ON/OFF TOGGLE RELAY ON/OFF This menu allows you to manually control the Relays. Once at this screen, press the ENTER/SHOW TIME button. To scroll thru the eight relays, press the SELECT/MENU MODE button. STATE of MANUAL MODE Current state = OFF When the Relay’s Manual mode is off, the current state of each relay can only be read but may not be changed. To manually change the state of a relay, Manual mode must be first activated.
Table 12: LIST OF RULES # Rule Description Parameters 00 01 Relay Off On_Bat None None 02 Low_Bat_1 03 Bat_Timer_1 04 Alarms_1 Turns Relay OFF. Activates when UPS is on Battery Mode. Activates when batteries reach user settable capacity level. Activates after user settable time when UPS is in Battery mode. Activates when Alarm conditions occur.
Table 13: ALARMS AND FAULTS Alarms/Faults Heat Sink is Hot Input is bad Output Strange System Overload Bypass Failure Charger Failure Fan Fail Fuse Failure Sleep Alarm General Fault All Outputs Off Shut Off Pending Shut Off Imminent System Shutdown Description Heat Sink on main Board temperature too high. AC input to UPS is not within limits. Bad UPS output. Load is higher than UPS rated load. Bypass Line failed. Charger not functioning properly. Fan not functioning properly. Open Fuse in system.
5 CARE AND MAINTENANCE 5.1 Safety There are hazardous high voltages and materials present in the UPS system which present safety risks. You MUST follow basic safety procedures when maintaining the UPS. In addition please note the following: ELECTRICAL SAFETY • • • • • Hazardous high voltages are present in this product, which can cause electrical shock. Do not work alone under hazardous conditions. Always wear eye-protection when servicing energized power electronics.
5.2 Preventive Maintenance CLEANING This device is designed to be maintenance-free. It can be cleaned with a damp cloth or nonabrasive cleanser. WARNING: Do not use ACETONE-BASE cleaning solutions. Keep cleaning solutions out of the electrical receptacles on this device. Be sure filters, vents and fans are kept free from accumulation of dust, dirt or lint.
BATTERY RECYCLING • • • The batteries used in this equipment are recyclable. Proper disposal is required and mandated by law. The batteries contain lead and pose a hazard to the environment and human health if not dispose of properly. Refer to local codes for proper disposal requirements or return the batteries to the factory. ALWAYS contact the factory for information concerning shipment, disposal, or replacement of batteries.
5.4 Service and Repair Your SP-LX Series UPS is backed by one of the finest customer service teams available. Write or call them at any time to obtain more information about your unit. Clary Corporation 150 E. Huntington Drive Monrovia, CA 91016 1-800-551-6111 If a problem should occur, it is important that you obtain a Return Material Authorization (RMA) number from the Service Department to process any unit returned to the factory.
WARRANTY 1. 2. 3. TIME AND SCOPE OF WARRANTY: 1.1. Clary Corporation hereby warrants parts shipped under this Agreement to be free from defective workmanship for a period of 2 years following date of shipment. Accidental damage, misuse or normal wear and tear shall not be construed as a defect. 1.2. The date of shipment as used herein will be the date on the Bill of Lading. If no Bill of Lading is issued the date of shipment shall be shown on seller's shipping document. 1.3.
