PCM TC Series Installation, Operation And Maintenance Manual
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PCM TC Series Installation, Operation And Maintenance Manual

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

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  • Page 1 SERIES Wide Temperature Range UPS TC-650,1100,2000,2500,3000 System Installation, Operation and Maintenance Manual...

  • Page 2: Table Of Contents

    TROUBLESHOOTING ----------------------------------------------------------------------------------- SPECIFICATIONS----------------------------------------------------------------------------------------- EMERGENCY SHUTDOWN PROCEDURE ------------------------------------------------------ ■ Section 2: Operator’s Manual --------------------------------------------------------------------------------- 2.1.1 THE ADVANTAGES ------------------------------------------------------------------------------------- 2.1.2 A TOUR OF THE TC SERIES ------------------------------------------------------------------------ 2.2.1 LCD PANEL ------------------------------------------------------------------------------------------------ 2.2.2 TC UPS OPERATING MODES ----------------------------------------------------------------------- 2.2.3 SELF TEST ------------------------------------------------------------------------------------------------- 2.2.4 START UP --------------------------------------------------------------------------------------------------- 2.2.5...
  • Page 3 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.
  • Page 4 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 •...
  • Page 5 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.

  • Page 6: Unpacking And Inspection Checklist

    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: •...

  • Page 7: Save The Original Shipping Box

    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.

  • Page 8: Section 1: Installation & Start-Up Manual

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

  • Page 9: Description

    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.

  • Page 10: Tc-650,1100,2000,2500,3000 Ups

    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.
  • Page 11 TC-2000 UPS Front Panel TC-2500,3000 UPS Front Panel Figure 3...

  • Page 12: Auto Transfer Switch

    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.

  • Page 13: Wiring

    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 Put the Intersection in FLASH mode as soon as TC UPS...
  • Page 14 Step 1: Connect CONTROL wires. START Wrap a tie around the strain relief loop and the battery temperature Connect the Battery sensor to prevent the connector from Temperature Sensor to the disconnecting during an terminal of the middle battery, earthquake or other Plug the connector on the other severe vibrations.
  • Page 15 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 Figure 7 Power Transfer Switch Plug the Red Battery connector into the TC-2000 GO TO STEP 4 Figure 8 TC-2000 Front Panel...

  • Page 16: Start-Up And Test

    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.
  • Page 17 Step 3: Test the system START Turn OFF the upstream circuit breaker Turn ON 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 Within 30 seconds power.

  • Page 18: Shutdown

    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...

  • Page 19: Ats

    1.5.2 TIP: Verify that both the AC START and Battery Breaker are OFF at the TC UPS. Turn OFF the upstream circuit breaker Disconnect the UPS OUT Cord Disconnect the UPS IN cord Disconnect the INPUT & OUTPUT cord Figure 9 Auto Transfer Switch Remove and perform maintenance on the ATS...

  • Page 20: Troubleshooting

    1.6 Troubleshooting TC UPS System Troubleshooting Chart SYMPTOM CAUSE REMEDY Upstream utility circuit breaker or CLOSE the upstream utility fuse may be OPEN breaker or fuse Utility AC Power not available Check with the AC voltmeter & contact the Utility Company No Output available from Wiring error...

  • Page 21: Specifications

    1.7 Specifications ENVIRONMENTAL System Technical Specification Operating Temp -37 to +74°C INPUT Storage Temp -50 to +75°C 110,120 VAC +/-25% Voltage Range, VAC 220,230,240 VAC +/-25% Humidity <95% (Non-Condensing) Frequency 50,60 +/-3Hz Altitude TC-650 10.000ft/3000m (See Notes below) 120 VAC TC-1100 ATS MECHANICAL TC-2000...

  • Page 22: Emergency Shutdown Procedure

    1.8 EMERGENCY SHUTDOWN PROCEDURE The TC UPS is connected to more than one energy source. In an emergency, DISCONNECT utility input power, battery power, as well as an optional generator power, if utilized. Disconnecting all the AC and DC power sources will ensure that the output circuit is not live.

  • Page 23: Section 2: Operator's Manual

    TC UPS System Battery Backup / Uninterruptible Power Supply System ■ Section 2: Operator’s Manual...
  • Page 24 Section 2.1 Introduction This section introduces the various features of the TC UPS System 2.1.1 The Advantages 2.1.2 A Tour of the TC UPS...

  • Page 25: The Advantages

    2.1.1 The Advantages Advanced Power Protection Technology TC Series is an Uninterruptible Power Supply (UPS) also known as a Battery Backup System (BBS) designed for both indoor and outdoor applications. The TC UPS provides continuous power to traffic and signal equipment.

  • Page 26: A Tour Of The Tc Series

    2.1.2 A Tour of the TC Series Purpose: Describes the display, connections and switches on the TC Series front panel (Figures 12, 13 &14). TC-2000 TC-650,TC-1100 Figure 12 24VDC/48VDC Battery Connector Connects the battery to the unit. The battery string voltage is 24VDC/48VDC.
  • Page 27 Figure 14 USB / Serial Interface / RS232 Connector The USB and /or DB-9 female connector is used to connect the TC Series to the host computer for remote control, monitoring and calibration via RS232 commands. For the USB or DB-9 female RS232 connections use computer industry standard computer cable between the computer’s USB or RS232 port and the TC unit’s USB or RS232 ports.
  • Page 28 Figure 15 Green Control Terminal Block This 22 position terminal block provides communication with the intersection controller, controls the Power Transfer Switch (PTS) and Programmable Input contact. Figure 16 shows its layout and operation. Note: Each of the six programmable contacts can be programmed for one or more functions such as: The Timer, Low Battery and On Batt.
  • Page 29 TC Series Interior Microprocessor Note: These contacts have Note: The ATS contacts provide a direct a maximum rating of 1 Amp connection to the batteries through a on PCB at 240V. Only the first On mounted PTC Batt contact is illustrated.
  • Page 30 Figure 17 Battery Temp Sensor It attaches the battery temperature probe to the unit for monitoring battery temperature. The charging voltage is temperature dependent. The microprocessor of the smart charger adjusts the voltage for optimum charging. The temperature probe connector must be plugged in for normal operation. The sensor end should be firmly attached to the terminal of the battery.
  • Page 31 Section 2.2 Operation This section describes how to start, shutdown and operate the TC UPS : 2.2.1 The LCD Panel 2.2.2 The TC UPS Operating Modes 2.2.3 The Self-Test 2.2.4 Start-Up 2.2.5 Shutdown 2.2.6 Battery Replacement 2.2.7 LCD Menu Tree 2.2.8 STATUS Submenu 2.2.9...

  • Page 32: Lcd Panel

    2.2.1 LCD Panel Purpose: Describes the LCD display menus (Figure 18) and use of user-friendly sub-menus (Figure19). When the Output LED is : Operating Modes YY/MM/DD format • ON, the line is qualified and the input power flows to output. 24-Hour STANDBY 07/01...

  • Page 33: Tc Ups Operating Modes

    2.2.2 TC UPS Operating Modes Purpose: Describes the Operating modes. TIP: The LCD automatically displays the following modes when they change. LCD Shows Explanation This mode is displayed when the unit is first turned on. The inverter remains off and the STANBY TC UPS does not provide output power to the loads.

  • Page 34: Self Test

    2.2.3 Self Test Purpose: Describes the Self-Test. Caution: This procedure should not be performed when critical loads are running that depend on the unit for backup power. The Self Test confirms that the unit can transfer into and out of Battery mode while supporting the output load at the same time.

  • Page 35: Start Up

    2.2.4 Start Up Purpose: Describes the Start Up procedure. START One at a time, turn ON the output / loads Turn OFF: All Loads, the AC Input, Battery and Utility Power START UP FINISHED circuit breakers Turn On the upstream Battery circuit breaker Turn ON the AC input circuit breaker.

  • Page 36: Shutdown

    2.2.5 Shutdown Purpose: Describes the shutdown procedure. START Turn OFF the AC Input circuit breaker Turn OFF the Battery circuit breaker Turn OFF the upstream utility input circuit breaker and unplug the battery cable SHUTDOWN FINISHED...

  • Page 37: Battery Replacement

    2.2.6 Battery Replacement Purpose: Describes how to change the battery. Caution: While the battery is being changed, the TC UPS cannot provide backup power. This procedure should not be done while critical loads are running that depend upon the TC UPS’s backup power.

  • Page 38: Lcd Menu Tree

    2.2.7 LCD Menu Tree and Main Screen Purpose: Shows the Menu Tree (Figure 20). TIP: • The Alarm and Fault submenus alert the operator of a problem with the TC UPS. When the alarm or fault LED is ON, press the ENTER button. One of the conditions described in Section 2.2.12 or 2.2.13 appears on the LCD screen.
  • Page 39 Purpose: Shows the Main screen. ITEM LCD SHOWS DESCRIPTION Main screen Main screen Date & Tmer Line 1 Main screen Status Line 2 Contact status 123456 Ext Fan status F AVR setting Bu: Buck , Bo: Boost Sense Type setting N: Normal , G: Generator Main screen The output voltage (ture RMS) Line 3...

  • Page 40: Status Submenu

    2.2.8 Status Submenu Purpose: Describes how to use the Status Submenu to measure the input and output parameters. Procedure: On the main screen press ENTER to get to the status menu, After entering into STATUS menu, you can press UP/DOWN to view UPS status information. ITEM LCD SHOWS DESCRIPTION...
  • Page 41 Page 7 The status of the program contact 2. Program Contact 2 status Page 8 The status of the program contact 3. Program Contact 3 status Page 9 The status of the program contact 4. Program Contact 4 status Page 10 The status of the program contact 5.

  • Page 42: Config Submenu

    2.2.9 Config Submenu Purpose: Describes how to access and program various critical parameters. Procedure: On the main screen press DOWN to get to the Configuration menu, After entering the Configuration menu, you can press UP/DOWN button to select the UPS CONFIG you wish to execute: FUNCTION LCD SHOWS ACTION...
  • Page 43 PROGRAM CONTACT 2 Indicates programmed values of contacts 2 and allows values to be changed. PROGRAM CONTACT 3 Indicates programmed values of contacts 3 and allows values to be changed. PROGRAM CONTACT 4 Indicates programmed values of contacts 4 and allows values to be changed.

  • Page 44: Maintenance Menu

    2.2.10 Maintenance Menu Purpose: Describes how to access, and view and modify various parameters for the maintenance. Procedure: On the main screen press UP to get to the MAINTENANCE menu, then use UP/DOWN button to select the Functionality Menu, See below for details. When entering this menu you will need to enter password. The default password is 1111.
  • Page 45 SET SYSTEM It indicates current system frequency. The display of the FREQUENCY frequency will be flashing and use UP/DOWN can adjust it to 50Hz or 60Hz, then press "Enter" to confirm. **This function only can be set in standby mode. **This function is only available in 2X0V systems model.

  • Page 46: Alarm Menu

    2.2.11 Alarm Menu Purpose: Describes the Alarm Submenu and how to use the LCD for troubleshooting. (Figures 21, 22 and 23) Procedure: When the Yellow ALARM LED is ON, the unit has an alarm, indicating a condition not serious enough to stop it from providing output power.

  • Page 47: Fault Menu

    2.2.12 Fault Menu Purpose: Describes the Fault Submenu and how to use the LCD for troubleshooting. (Figures 24, 25 and 26) Procedure: When the RED FAULT LED is continuously ON, the unit has a fault, indicating a condition where backup power is unavailable.

  • Page 48: Low Battery Mode Status

    2.2.13 Low Battery Mode Status Purpose: Describes the various states of the Low Battery Mode (Figure 27). Low Battery Warning default set at 23.5 / 47.5VDC, USER PROGRAMMABLE. Low Battery Shutdown @ 21 / 42VDC in 3 seconds Fully Charged 28 / 56VDC Low Battery Warning @ 23.5/ 47.5VDC Low Battery Disconnect @ 20/ 40VDC in 10 seconds...
  • Page 49 Section 2.3 Communication This section describes how to communicate with TC series using a Personal Computer via RS232 / USB communications: 2.3.1 RS232 / USB Set-Up 2.3.2 HyperTerminal Set-Up 2.3.3 The Main Menu 2.3.4 Menu Tree and Sub Menus 2.3.5...

  • Page 50: Rs232/Usb Set-Up

    The TC Series uses a standard DB-9, RS232 cable or USB cable. When the DB-9F, (female connector) on the front panel is connected to a PC with Windows terminal emulation software, the TC series can be remotely monitored, controlled and calibrated using RS232 ASCII commands.

  • Page 51: Hyperterminal Set Up

    2.3.2 HyperTerminal Set Up Purpose: Describes how to set up TC series RS232 / USB port using Windows Hyper Terminal program (see Figurers 28 to 35) The following Hyper Terminal setting is recommended for local or remote communication between TC series & PC.
  • Page 52 Step 3: The Connect To screen (Figure 30) appears. TC series Select the COM port from the drop down menu as shown, that will be used. Click Figure 30 Connect To Screen Step 4: The COM Properties screen appears (Figure 31).
  • Page 53 The COM Properties Screen reappears Advanced Port Settings Screen (Figure 31). Click OK. Step 7: A blank window with the entered file name appears (Figure 33). In the File menu, go to Properties and Click. Figure 33 TC Series Hyper Terminal Screen...
  • Page 54 34) reappears. ASCII Setup Screen Step 12: Click OK HyperTerminal setup is completed. Press Enter to go to TC Series screen (Figure 33). Press Enter to access the unit via RS232 / USB communications. The Main Menu (Figure 36) appears.

  • Page 55: Main Menu

    TIP: The factory set default password 1111 is required to access and set many functions, such as in menu 34 & menu 35. Procedure: To access a particular sub menu, type in the sub menu number and press Enter. To update the screen, press Enter. PCM Products - TC-2000-E [0-MAIN MENU]  Sub Menu Numbers 1 Unit Specification...
  • Page 56 Tabulation of various items that appears under the Line Status, Output Status, Faults and Alarms are shown in Figures: 37, 38 and 39. Line Status: [Current Status] LINE STATUS Output Status: [Current Status] Normal Input power is normal Content Status: [Current Status] Boost Input power is out of tolerance.
  • Page 57 FAULT DISPLAYS Line Status: [Current Status] Short-Circuit Output Short Circuit Output Status: [Current Status] Vout_Hi Output Voltage High Content Status: [Current Status] Vbat_Hi Battery Voltage High Ext. Fan Status: [Current Status] Vbat_Lo Battery Voltage Low Faults: [If any, otherwise blank] Temp_Hi Ambient Battery Temperature High or Internal Temperature High...

  • Page 58: Menu Tree & Rs232/Usb Sub Menus

    2.3.4 Menu Tree & RS232 / USB Sub Menus Purpose: Describes the RS232 / USB Menu Tree that include: Unit Specifications, Input/Output Values, Maintenance and Line Slow Detection Setup Sub Menus (Figures 40 to 45) 2.3.4.1 RS232 / USB Menu Tree The complete MENU Tree is shown on the next page with all default values.

  • Page 60: Unit Specifications, Input/Output Values

    2.3.4.2 Unit Specifications, Input/Output Values Menu 1 below (Figure 41) lists the TC series specifications. Procedure: At the main menu, type 1 and press Enter. The screen displays the Unit Specifications as shown below. To return to the main menu, press Enter.

  • Page 61: Maintenance

    2.3.4.4 Maintenance Menu 3 below (Figure 43) lists the various maintenance options. Procedure At the main menu, type 3 and press ENTER. The Maintenance Menu shown below is displayed. To return to the main menu, press ENTER. [ 3 - Maintenance ] 30 Battery Test Options The start - stop for the Battery Test / Self Test is initiated here.
  • Page 62 37 Resets The Resets INV, BUBK, BOOST Event to 0 Event/Timer Counters Resets INV, BUBK, BOOST Timer to 0 38 Battery Charging Temperature compensated smart charger is utilized in TC UPS. Temperature The rate of charging is adjusted here based on the battery case Compensation temperature.

  • Page 63: Line Slow Detection Parameters

    (lower) or boost (raise) the supply voltage without having to go onto battery or involve any other active TC UPS board level components. The TC series input transformer has a second tap off the primary winding. When activated, the transformer will automatically switch to the secondary tap to buck or boost the voltage output 10%, thereby keeping the output within an acceptable range.
  • Page 64 2.3.4.5.2 TC 110/120V series Parameter Descriptions (All levels are user programmable; some values are interdependent) 110V 120V AVR Feature AVR Feature Disable Enable Enable Disable 40 Slow Detect High Voltage TLV 121VAC 140VAC 150VAC 130VAC On Battery Mode When input voltage exceeds this level, TC 1X0V series transfers to Battery Mode from either Buck Line / Buck to Battery (110~140V)
  • Page 65 2.3.4.5.3 TC 220/230/240V series Parameter Descriptions (All levels are user programmable; some values are interdependent) 220V 230V 240V Default Default Default RANGE RANGE RANGE Setting Setting Setting 40 Slow Detect High Voltage TLV 275VAC 287VAC 300VAC On Battery Mode When input voltage exceeds this level, TC 2X0V 275VAC 287VAC 300VAC...

  • Page 66: Menu Tutorial

    2.3.5 Menu Tutorial Purpose: shows how to use the menus (Figures 47 to 50) This tutorial shows how to change the Battery Test Options. The other menus function in the same manner. At the main menu (Figure 36), type 3 and press Enter. The Maintenance Menu 3 appears as below (Figure 47).
  • Page 67 To change the battery test period, type 300 and press Enter. The words “Enter Password” appear on the screen. Type the password (the factory set password is 1111) and press Enter. If the wrong password is typed, the screen displays “Error in entering data… please try again.” Type the correct password and press Enter.
  • Page 68 Section 2.4 Maintenance This section describes how to maintain the TC series: 2.4.1 Battery Back-Up Time Test 2.4.2 TC UPS Return Instruction 2.4.3 Troubleshooting 2.4.4 Battery Maintenance 2.4.5 Specification 2.4.6 Warranty 2.4.7 Emergency Shutdown Procedure...

  • Page 69: Battery Back-Up Time Test

    2.4.1 Battery Back-Up Time Test Purpose: Describes how to measure the back up capacity of batteries. This test provides the measurement of back-up time during power outage by actually discharging the batteries. The back-up time is load as well as battery dependent, thus more back-up time is available with a lower load (in Amps or Watts) and less time with more load.

  • Page 70: Tc Series Return Instructions

    2.4.2 TC Series Return Instructions Purpose: Describes how to return the TC series for repairs. Note: Manufacturer does not assume responsibility for damage caused by improper packaging of returned units. The TC UPS should only be shipped in a box or carton of sufficient thickness to withstand handling.

  • Page 71: Troubleshooting

    Purpose: Describes the most common problems with the TC Series. There are NO Maintenance items inside the TC Series and it should be opened or serviced only by factory authorized service personnel, failure to do so will void the WARRANTY. If it fails to perform a specific function, Figure 50 below lists typical symptoms, causes and solutions.

  • Page 72: Contrast Adjustment Lcd Display

    Check that battery connection have proper torque Check battery cable harness for connection error, loose / open connections Battery circuit OPEN Check battery voltage is correct Batteries will NOT Check if battery breaker is closed charge Replace the bad battery, if any Wrong or bad temperature probe Use Factory supplied temperature probe reading connected at front panel...

  • Page 73: Specifications

    2.4.5 Specifications Functions Electrical Specifications Output Apparent Power, 650/1100/2000/2500/3000 Brownout Protection This unit boosts the output voltage (or (Inverter Mode) transfers to Battery) during Brownout Output Active Power, 650/1100/2000/2500/3000 or Low input line conditions and 2000 (Line Mode) (Inverter Mode) & (Line Mode) returns to Normal when input power stabilizes and returns to Normalcy.
  • Page 74 22 Position Terminal Block Functions A. Provides 6 sets of programmable contacts at pin 1 thru pin 18 for intersection flash control, Remote Alarms, Pagers or other user interface. 1. “Low Batt”: batteries have reached approximately 40% capacity remaining 2. “On Batt”: unit is in inverter mode 3.

  • Page 75: Warranty

    2.4.6 WARRANTY LIMITED 24-MONTH WARRANTY Manufacturer warrants its equipment to be free of manufacturing defects in material and workmanship for a period of 24 months from the date of shipment. The liability of Manufacturer under this warranty is solely limited to repairing, replacing, issuing credit for such equipment (at the discretion of Manufacturer) provided that: Manufacturer’s Customer Service Department is promptly notified, by facsimile or telephone, that a failure or defect has occurred.

  • Page 76: Emergency Shutdown Procedure

    2.4.7 EMERGENCY SHUTDOWN PROCEDURE TURN-OFF BOTH THE AC & BATTERY BREAKER IN AN EMERGENCY. The TC UPS contains more than one live circuit. In an emergency, AC line power may be disconnected at the system’s input, but output AC power may still be present from batteries. START Turn OFF the AC input circuit...

This manual is also suitable for:

Tc-650Tc-1100Tc-2000Tc-2500Tc-3000

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