CONTROLLED POWER UltraLITE ELC Owner's Manual

600w - 2kw compact emergency lighting inverter

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UltraLITE SERIES

MODEL ELC

IMPORTANT - SAVE THESE INSTRUCTIONS - PLEASE READ THIS MANUAL

600W - 2KW

COMPACT EMERGENCY LIGHTING INVERTER

BEFORE USING EQUIPMENT

TROY, MICHIGAN

OWNERS MANUAL

112073-Rev 35

11/02/2020

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Page 1 TROY, MICHIGAN UltraLITE SERIES MODEL ELC OWNERS MANUAL 600W - 2KW COMPACT EMERGENCY LIGHTING INVERTER IMPORTANT - SAVE THESE INSTRUCTIONS - PLEASE READ THIS MANUAL BEFORE USING EQUIPMENT 112073-Rev 35 11/02/2020...
Page 2 The following symbol indicates that caution should be taken when performing the process required in this manual. Damage to the unit or personal harm could hap- pen if proper precautions are not taken. Caution The following symbol indicates that there is a risk of electrical shock if proper precautions are not followed.
Page 3: Table Of Contents
When viewing electronically, click on the subject to jump to that page. Clicking the header on the front page will launch the Controlled Power web site. Clicking anywhere else on the front page will also jump to the Table of Contents.
Page 4: Introduction
INTRODUCTION Controlled Power Company engineers and manufactures the industry’s highest quality centralized emergency lighting inverters, capitalizing on 40 years of expertise. We have an enviable reputation for quality, which is reflected in the design, workmanship, and performance of our products.
Page 5 INTRODUCTION CONTINUED STANDARDS • ANSI / IEEE C62.41 Category B3 • NFPA 101 • NFPA 111 Stored Electrical Energy Emergency and Standby Power Systems. Meets SEPSS / ECE / Level 1 and Level 2 criteria for types O, U, A, B, and 10; and Classes up to and including Class 1.5 •...
Page 6 INTRODUCTION CONTINUED COMMUNICATIONS CONTINUED Optional Remote Communications The NetMinder CS121L series of adapters integrate the Model ELC into an Ethernet TCP/IP, MODBUS TCP, or MODBUS RS485 network with a specific IP address. The NetMinder CS121L provides remote monitoring of the inverter status, battery test pass/fail results, alarm conditions, and electrical measurements via a web browser, without the need for any external software.
Page 7: Receiving The Inverter
RECEIVING THE INVERTER RECEIVING YOUR INVERTER INSPECTION, PLACEMENT, INSTALLATION, SETUP AND START-UP SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY INSPECTION Upon receipt of your lighting inverter, visually inspect the unit(s) for shipping damage. If shipping damage has occurred, the purchaser should promptly notify the carrier and file a claim with the carrier. The factory should be notified if the damages may impair the operation of the unit.
Page 8: Tools Required
RECEIVING THE INVERTER CONTINUED REMOVING THE LIGHTING INVERTER FROM THE PALLET ***CAUTION*** CABINETS AND BATTERIES ARE EXTREMELY HEAVY USE PROPER EQUIPMENT WHEN REMOVING THE CABINETS FROM THE SKID *****SHOCK HAZARD***** DO NOT SHORT BATTERY TERMINALS TOOLS REQUIRED: Forklift, dolly. 1. Remove the plastic wrapping and banding and discard. 2.
Page 9: Safety Precautions
SAFETY PRECAUTIONS NOT INTENDED FOR LIFE SUPPORT APPLICATIONS This unit is intended for installation in a temperature controlled, indoor area free of conductive contaminants. IMPORTANT SAFEGUARDS, READ AND FOLLOW ALL SAFETY INSTRUCTIONS. SAVE THESE INSTRUCTIONS. ***** CAUTION ***** A BATTERY CAN PRESENT A RISK OF ELECTRICAL SHOCK AND HIGH SHORT CIRCUIT CURRENT. THE FOLLOWING PRECAUTIONS SHOULD BE OBSERVED WHEN WORKING ON BATTERIES: •...
Page 10: Preliminary Installation
PRELIMINARY INSTALLATION TOOLS REQUIRED AND INSTALLATION CHECKLIST _______ Phillips Head Screw Driver, 3/16” Allen wrench (for input/output terminal blocks). _______ For field wiring size, based on amperage and breaker sizes in table below. Units are rated for operation up to 40 deg. C. Amb. Refer only to the matrix below for the service panel AC breaker size. The unit comes standard with terminals for hard wire installation.
Page 11 PRELIMINARY INSTALLATION ALL INVERTER SIZES WITH ALL BATTERY OPTIONS CABINET DIMENSIONS, ACCESSES, CLEARANCES AND WIRE TERMINATION SPECS...
Page 12: Cabinet Assembly And Mounting
CABINET ASSEMBLY AND MOUNTING BATTERY AND INVERTER CABINET ASSEMBLY Connecting the inverter cabinet and the battery cabinet(s) MUST be done prior to battery installation. Connect the inverter cabinet and battery cabinet(s) together using the supplied (4) 1/4” X 20 self tapping sheet metal screws, one on the left and right sides and two in the back as shown below.
Page 13 CABINET ASSEMBLY AND MOUNTING CONTINUED SECURING THE UNIT TO THE FLOOR / WALL Secure the cabinet(s) to the floor and/or wall prior to battery installation. Secure the unit to the floor and/or wall using the mounting holes as shown below. Refer to local codes for proper hardware size.
Page 14: Battery Installation And Wiring
BATTERY INSTALLATION AND WIRING BATTERY WIRING OVERVIEW REFER TO THE BATTERY WIRING DIAGRAM ON THE INNER DOOR OF THE INVERTER OR BATTERY CABINET NOTE - DO NOT PROCEED WITH FINAL BATTERY WIRING UNTIL READY FOR START UP. SECURE CABINET TO WALL OR FLOOR PRIOR TO BATTERY INSTALLATION. The DC voltage for a six (6) battery system is 72V.
Page 15: Battery Requirements
BATTERY INSTALLATION AND WIRING CONTINUED BATTERY REQUIREMENTS Batteries of a specific manufacturer and model are required to maintain the system’s UL 924 listing. Use of batteries not recognized in the product’s UL report will void its listing. BATTERIES FOR ELC’S RATED FOR 90 MINUTES MANUFACTURER BATTERY MODEL NUMBER FOR USE WITH MODELS RATED (QTY)
Page 16: Input And Output Wiring
INPUT AND OUTPUT WIRING INPUT AND OUTPUT CONDUIT ENTRY POINTS *** WARNING *** RISK OF ELECTRICAL SHOCK THE LIGHTING INVERTER RECEIVES POWER FROM MORE THAN ONE SOURCE. BE SURE ALL UTILITY CIRCUIT BREAKERS ARE IN THE OFF POSITION AND THE DC CIRCUIT BREAKER IS OFF BEFORE SERVICING. 24.25 23.25 22.17...
Page 17 INPUT AND OUTPUT WIRING CONTINUED INPUT AND OUTPUT WIRING *** WARNING *** RISK OF ELECTRICAL SHOCK THE LIGHTING INVERTER RECEIVES POWER FROM MORE THAN ONE SOURCE. BE SURE ALL UTILITY CIRCUIT BREAKERS ARE IN THE OFF POSITION AND THE DC CIRCUIT BREAKER IS OFF BEFORE SERVICING. Lighting Inverter Wiring With Distribution Input wiring is performed at the input terminal strip.
Page 18: Optional Timed Off Bus Set Up
OPTIONAL TIMED OFF BUS SET UP OPTIONAL TIMED OFF BUS SET UP DESCRIPTION In many lighting system applications, there are designated lights that remain off until a power outage occurs. Available on the model ELC is a Timed Normally Off Bus option. This option incorporates a programmable timer which controls an internal solid state switch located between the output of the inverter’s “Normally On”...
Page 19 OPTIONAL TIMED OFF BUS SET UP CONTINUED TIMED NORMALLY OFF BUS “PLUS” Provides standby power to “normally off” emergency lights. When utility power is lost or inadequate, emergency power is applied to “normally off” lights, providing a safe means of egress. User-Programmable Settings: Transfer On Delay (0 –...
Page 20: Optional Zone Saver 2
OPTIONAL ZONE SAVER 2 Specifications Voltages ........... 277VAC 50/60Hz Max Load Requirements LED Lighting..........18A @277VAC Ballast............. 20A @277VAC Incandescent...........10A @120VAC ZONESAVER-2, “LOCAL CONTROL OVERRIDE” INSTALLATION CONTROL DEVICE OVERRIDE The ZoneSaver-2 emergency lighting control unit is a UL 924 listed load control relay wired to shunt around a local control device (e.g.
Page 21 OPTIONAL ZONE SAVER 2 CONTINUED ZONESAVER-2, “ZONE SENSING” INSTALLATION ZONE SENSING AND CONTROL OF NORMALLY OFF EMERGENCY LIGHTING The ZoneSaver-2 emergency lighting control unit is a UL 924 listed load control relay, wired for zone sensing and independent control of normally off (standby) emergency lighting fixtures. The ZoneSaver-2 senses the voltage at an individual zone lighting panel.
Page 22 OPTIONAL ZONE SAVER CONTINUED MULTIPLE ZONESAVER-2 UNITS CONNECTED TO ONE EMERGENCY LIGHTING INVERTER - WIRING DIAGRAM ZONE 1 LIGHTING PANEL EMERGENCY POWER OUT (RED 12AWG) ZONE 1 EMERGENCY LIGHTING EMERGENCY NEUTRAL (GRAY 18AWG) EMERGENCY EMERGENCY POWER IN (BLACK 12AWG) NORMAL POWER SENSE (BLACK 18AWG) LINE NORMAL NEUTRAL (WHITE 18AWG) EMERGENCY...
Page 23: Optional Remote Annunciator
Turn off all power before installing or servicing! REMOTE ANNUNCIATOR Controlled Power Company’s Remote Annunciator is capable of displaying status conditions of an Emergency Lighting Inverter and alarming under critical conditions. The following installation instructions include operation, wiring, and mounting your Remote Annunciator.
Page 24 OPTIONAL REMOTE ANNUNCIATOR CONTINUED ALARM TERMINALS - LOCATED IN THE TO REMOTE 120VAC POWER, 50/60Hz COMMUNICATIONS CAVITY ANNUNCIATOR CABLE. 2 WIRE W/ GROUND (TOP OF UNIT) TERMINAL SUPPLIED BY OTHER L1 - 120V - BLACK TO INVERTER N - WHITE OUTPUT - 120V UPS ON (ORANGE) GROUND - GREEN (BARE)
Page 25 OPTIONAL REMOTE ANNUNCIATOR CONTINUED NOTES: 1. All wires to connector must be stranded, maximum 12 AWG. 2. If using solid conductor for AC power, splice in length (minimum 4”) of stranded wire to connector. 3. Strip outer sheathing and foil back minimum 2”. 4.
Page 26: Other Optional Devices
OPTIONAL AUTOMATIC MESSAGE DIALER An Automatic Message Dialer is available on the Controlled Power Company line of Emergency Lighting Inverters. The Automatic Message Dialer is a device that notifies certain personnel if there is a problem with the lighting inverter via an analog phone line.
Page 27 MCM is provided standard with 2 dry contact inputs for battery test pass/fail results, plus 6 additional input channels to optionally monitor environmental conditions or safety-related alarms. Consult factory for interface options. The MCM is available for Controlled Power Company Lighting Inverter models provided with the Intellistat or Intel- listat TS (touchscreen) monitor.
Page 28: Optional Remote Communications
OPTIONAL REMOTE COMMUNICATIONS Netminder Remote Communications (CS141) The NetMinder CS141 series of adapters integrate a Controlled Power UPS or lighting inverter into an Ethernet TCP/ IP, MODBUS TCP, or MODBUS RS485 network with a specific IP address. The NetMinder CS141 adapters provide remote monitoring of UPS / Inverter status, alarm conditions and electrical measurements via a web browser, without the need for any external software.
Page 29: Normal Mode Start Up
START UP PROCEDURE DO NOT ATTEMPT TO OPERATE THE UNIT UNTIL ALL SET UP PROCEDURES HAVE BEEN COMPLETED NORMAL MODE START UP THIS PRODUCT IS SHIPPED WITH THE PERIODIC AUTOMATIC BATTERY TEST ENABLED FOR EVERY 30 DAYS STARTING WITH THE 15th DAY OF THE FOLLOWING MONTH FROM THE ACTUAL SHIP DATE AT 10 P.M. NOTE THAT THE UNIT WILL GO INTO THE AUTOMATIC BATTERY TEST UPON INITIAL START UP IF THE START UP DATE IS AFTER THE 15TH OF THE MONTH, ONE MONTH AFTER THE ORIGINAL SHIP DATE.
Page 30 START UP PROCEDURE CONTINUED *** WARNING *** The AC Input breaker and the DC circuit breakers MUST be in the “OFF” position prior to switching to Bypass Mode. Failure to follow proper bypass procedures can cause serious damage to the inverter. 12.
Page 31: Monitor Operation
OPERATION MONITOR OPERATION 1. LED indicates that high input voltage is present (+10%). 9. LED indicates that the system alarm is “ON”. 2. LED indicates that the input line voltage is nominal. 10. This scale indicates the charge / discharge level of the batteries.
Page 32 OPERATION CONTINUED MONITOR OPERATION CONTINUED *NOTE: When performing a power outage test or the inverter has been on battery for a few minutes and returns to normal power, the battery indicator lights may only display one indicator light, this is normal. Wait approximately 15 minutes and the battery indicator lights should return to full.
Page 33: Bypass Switch
BYPASS SWITCH The purpose of the bypass switch is to connect the loads to utility power in case of inverter failure. ***** CAUTION ***** Do not switch if the Inverter is on battery or the “Static Bypass” light on the display is NOT illuminated. ***** CAUTION ***** NOT A MAINTENANCE BYPASS.
Page 34: Communications Description
COMMUNICATIONS DESCRIPTION The ELC provides user access to system status, alarm conditions, electrical measurements, system logs, and battery test pass/fail results, via RS232 from a DB9 connector or a USB port. Optionally, this information is available via an Ethernet TCP/IP, MODBUS TCP or MODBUS RS485 network connection. (See “Optional Remote Communications”) Remote communication of inverter on battery, low battery, and a general alarm are available via normally open contacts rated at 120 VAC and .5 amps.
Page 35 COMMUNICATIONS DESCRIPTION CONTINUED 5. Eleven (11) position contact closure terminal. Provides R.E.P.O., Test Active, General Alarm, Low Battery and On Battery. Contacts are rated for 0.5 at 125VAC. R.E.P.O. Customer supplied, Normally Open, CHASSIS COMMON Dry Contact Input GROUND +5.5VDC (Normally Open, TEST ACTIVE Dry Contact Output*)
Page 36: Communications
COMMUNICATIONS MINIMUM SYSTEM REQUIREMENTS: Computer/Laptop with Windows 3.1 or later. “Hyperterminal” (Windows 3.1, Windows XP) or “PuTTY” for Windows Vista and Windows 7 or later. (download at http://www.putty.org/). USB Port and Type B USB Cable, Setup USB 0.4 Drivers (Windows XP, Vista, Windows 7 and 8) and “Hyperterminal” or “PuTTY” emulation programs.
Page 37 COMMUNICATIONS CONTINUED SYSTEM SETPOINTS (pp) To access system set points, send a lower case “pp” to the Inverter from the terminal. NOTE: Not necessarily in order shown. Sample Display Description Explanation Setting which informs the Control Module of the output Output VA = 2,000 AC volt-amps output of the unit apparent power...
Page 38 COMMUNICATIONS CONTINUED LOG FUNCTIONS (ll) To access a log of the outages and overloads, send a lower case “ll” to the Inverter from the terminal. Sample Display Description Number of outages = 4 Indicates number of power outages Power outage was at: 11:12:51 Date 03/16/02 Date and time of power outage Number of overloads = 1 Indicates number of overloads...
Page 39 COMMUNICATIONS CONTINUED BATTERY TEST SETUP (bb) CONTINUED ANNUAL: ENABLE/DISABLE – Enter a “1” to enable the annual test or a “0” to disable the annual test. Factory default = 0 (Disabled). SET ANNUAL BATTERY TEST TIME AND DATE – First enter the hours of the test time. The “:” will be inserted after entering the second hours’...
Page 40 COMMUNICATIONS CONTINUED BATTERY TEST LOGS (BB) Upon typing a ‘BB’ the battery test logs will appear. The log will include up to 13 tests. Included in each log is the time, date, whether it passed or failed, and if it was an annual test or not. If the log was an annual test it will have an ‘A’...
Page 41: General Maintenance
MAINTENANCE PROCEDURES *** DANGER - HIGH VOLTAGE *** GENERAL MAINTENANCE The best preventive maintenance is to operate the lighting inverter in a clean environment with proper ventilation and no restrictions on air intakes and cooling fan outputs. Battery connections should be tightened annually by qualified electrical personnel. Batteries should be replaced as indicated by battery testing.
Page 42: Battery Maintenance
MAINTENANCE PROCEDURES CONTINUED BATTERY MAINTENANCE Batteries of a specific manufacturer and model are required to maintain the system’s UL 924 listing. Use of batteries not recognized in the product’s UL report will void its listing. ***** WARNING ***** Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions.
Page 43 MAINTENANCE PROCEDURES CONTINUED BATTERY TESTING CONTINUED AUTOMATIC PERIODIC BATTERY TEST GENERAL - The inverter is preset at the factory for automatic monthly testing enabled and takes place on the programmed calendar date. See “Battery Test Durations” at the end of this section. During this time, the battery discharge rate is evaluated to determine the health of the battery string.
Page 44: Warranty
Controlled Power Company. 4. This Warranty is in lieu of all other warranties, expressed or implied. Controlled Power Company neither assumes, nor authorizes any person to assume for it, any liability other than that specifically set forth in this Warranty. Except for its obligations, Controlled Power Company assumes no liability or responsibility for personal injury, loss of life, consequential or other damages resulting from defects in, or failure of, the system or any of its components.
Page 45: Customer Support
HOT LINE: 24 hour toll free 1-800-521-4792. REMEDIAL MAINTENANCE : Covers all on-site repairs, parts, freight, labor and travel expenses. RESPONSE: Immediate 24 hour phone support. If problem is not solved Controlled Power will make every effort to have your system running within 48 hours.
Page 46 APPENDIX A APPENDIX A RELATIVE DRAWINGS & SCHEMATICS...
Page 47: Cabinet Outline
CABINET OUTLINE 600W...
Page 48 CABINET OUTLINE 1KW - 2KW...
Page 49 CABINET OUTLINE ALL SIZES - ALL BATTERY CABINET OPTIONS...
Page 50: Adding Output Breakers
ADDING OUTPUT BREAKERS 1. Loosen the breaker hold down bracket and slide the bracket up to make room for the new breaker. 2. Install the new breaker by snapping it in place on the din rail. Slide the breaker hold down bracket back down so it is tight against the new breaker and tighten into place.
Page 51: One Line Diagram
ONE LINE DIAGRAM...
Page 52: Customer Notes And Settings
CUSTOMER NOTES AND SETTINGS...
Page 53 CUSTOMER NOTES AND SETTINGS...