Controlled power company ELU Owner's Manual
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Controlled power company ELU Owner's Manual

Single phase centralized emergency lighting inverter
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UltraLITE Series
MODEL ELU
IMPORTANT - SAVE THESE INSTRUCTIONS - PLEASE READ THIS MANUAL
1.5KW - 14KW
SINGLE PHASE
CENTRALIZED EMERGENCY LIGHTING INVERTER
BEFORE USING EQUIPMENT
TROY, MICHIGAN
OWNERS MANUAL
112152-44
11/06/2020

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  • Page 1 TROY, MICHIGAN UltraLITE Series MODEL ELU OWNERS MANUAL 1.5KW - 14KW SINGLE PHASE CENTRALIZED EMERGENCY LIGHTING INVERTER IMPORTANT - SAVE THESE INSTRUCTIONS - PLEASE READ THIS MANUAL BEFORE USING EQUIPMENT 112152-44 11/06/2020...
  • 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 happen if proper pre- cautions 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

    TABLE OF CONTENTS INTRODUCTION ...............................5 RECEIVING THE INVERTER ...........................7 INSPECTION ..............................7 STORAGE................................7 INSTALLATION AND SAFETY PRECAUTIONS ......................9 INSTALLATION ...............................10 TOOLS REQUIRED AND INSTALLATION CHECKLIST ..................10 AC INPUT BREAKER, WIRING AND CURRENT MATRIX ................10 AC OUTPUT BREAKER, WIRING AND CURRENT MATRIX ................11 CABINET DIMENSIONS, ACCESSES AND CLEARANCES................12 1.5KW - 3.5KW ............................12 4.2KW - 7KW ..............................13...
  • Page 4 TABLE OF CONTENTS MAINTENANCE PROCEDURES ..........................73 GENERAL MAINTENANCE ........................73 SYSTEM OPERATION ..........................73 VISUAL INSPECTION ..........................73 GENERATOR TEST ...........................73 BATTERY MAINTENANCE ........................74 BATTERY TESTING - STANDARD MONITOR ..................74 MANUAL BATTERY TEST - STANDARD MONITOR .................74 AUTOMATIC PERIODIC BATTERY TEST - STANDARD MONITOR ............75 AUTOMATIC ANNUAL BATTERY TEST - STANDARD MONITOR............

  • Page 5: Introduction

    INTRODUCTION Controlled Power Company engineers and manufactures the industry’s highest quality centralized emergency light- ing inverters, capitalizing on 4 decades of expertise. We have an enviable reputation for quality, which is reflected in the design, workmanship, and performance of our products.
  • Page 6 INTRODUCTION CONTINUED Display Monitor & Diagnostics Advanced Digital Monitoring — The Intellistat The UltraLITE’s full-featured monitoring system in- cludes: The Intellistat TS’s features include: • Self-test diagnostics. • LCD display of all electrical parameters. • Automatic battery test. • NFPA-compliant automatic battery testing / log- •...

  • Page 7: Receiving The Inverter

    RECEIVING THE INVERTER INSPECTION, PLACEMENT, INSTALLATION, SETUP AND START-UP SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY INSPECTION Upon receipt of the 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 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: 1/2” Socket, Forklift, dolly. Batteries on same pallet as the lighting inverter 1.

  • Page 9: Installation And Safety Precautions

    INSTALLATION AND SAFETY PRECAUTIONS 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: Installation

    INSTALLATION TOOLS REQUIRED AND INSTALLATION CHECKLIST This unit is intended for installation in a temperature controlled, indoor area free of conductive contaminants. _______ 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.

  • Page 11: Ac Output Breaker, Wiring And Current Matrix

    INSTALLATION CONTINUED AC OUTPUT BREAKER, WIRING AND CURRENT MATRIX OUTPUT MATRIX (KVA=KW) 1.5KVA/KW 2.2KVA/KW 3KVA/KW 3.5KVA/KW 4.2KVA/KW 5KVA/KW 6KVA/KW OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT VOLTAGE CURRENT CURRENT CURRENT CURRENT CURRENT CURRENT CURRENT 120V 12.5 18.3 29.2 41.7 ----- 277V 10.8...

  • Page 12: Cabinet Dimensions, Accesses And Clearances

    INSTALLATION CONTINUED CABINET DIMENSIONS, ACCESSES AND CLEARANCES 1.5KW - 3.5KW This unit is intended for installation in a temperature controlled, indoor area free of conductive contaminants. LIGHTING INVERTER PLACEMENT Refer to the drawing below for installation clearances and ventilation requirements. The lighting inverter should be placed in a dry, well ventilated or temperature controlled area.

  • Page 13: Kw - 7Kw

    INSTALLATION CONTINUED CABINET DIMENSIONS, ACCESSES AND CLEARANCES 4.2KW - 7KW This unit is intended for installation in a temperature controlled, indoor area free of conductive contaminants. LIGHTING INVERTER PLACEMENT Refer to the drawing below for installation clearances and ventilation requirements. The lighting inverter should be placed in a dry, well ventilated or temperature controlled area.

  • Page 14: Kw-10Kw - W/ Ext. Battery Cabinet

    INSTALLATION CONTINUED CABINET DIMENSIONS, ACCESSES AND CLEARANCES 7.5KW-10KW - W/ EXT. BATTERY CABINET This unit is intended for installation in a temperature controlled, indoor area free of conductive contaminants. LIGHTING INVERTER PLACEMENT Refer to the drawing below for installation clearances and ventilation requirements. The cabinets should be placed in a dry, well ventilated or temperature controlled area.

  • Page 15: Kw-14Kw - W/ Ext. Battery Cabinet

    INSTALLATION CONTINUED CABINET DIMENSIONS, ACCESSES AND CLEARANCES 12.5KW-14KW - W/ EXT. BATTERY CABINET This unit is intended for installation in a temperature controlled, indoor area free of conductive contaminants. LIGHTING INVERTER PLACEMENT Refer to the drawing below for installation clearances and ventilation requirements. The cabinets should be placed in a dry, well ventilated or temperature controlled area.

  • Page 16: Battery Requirements

    INSTALLATION CONTINUED BATTERY REQUIREMENTS MINIMUM CHARGE TIME FOR FULL BATTERY CAPACITY = 24 HOURS 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 ELU’S RATED FOR 90 MINUTES MANUFACTURER BATTERY MODEL NUMBER...
  • Page 17 INSTALLATION CONTINUED BATTERY REQUIREMENTS MINIMUM CHARGE TIME FOR FULL BATTERY CAPACITY = 24 HOURS 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 ELU’S RATED FOR 30 MINUTES MANUFACTURER BATTERY MODEL NUMBER...

  • Page 18: Battery Installation And Wiring

    INSTALLATION CONTINUED BATTERY INSTALLATION AND WIRING REFER TO THE BATTERY WIRING DIAGRAM ON THE INNER DOOR OF THE INVERTER OR BATTERY CABINET BATTERY INSTALLATION Batteries must be installed with the proper orientation. Note the orienation shown on the battery wiring diagrams at- tached to the inner door of the inverter or battery cabinet.

  • Page 19: Input And Output Conduit Entry Points

    INSTALLATION CONTINUED 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 BATTERY CONNECTOR IS UNPLUGGED BEFORE SERVICING. Do not remove the debris shield from the top of the unit until ready for start up.

  • Page 20: Input And Output Wiring

    INSTALLATION 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 BATTERY CONNECTOR IS UNPLUGGED BEFORE SERVICING. Lighting Inverter Wiring With Distribution Input wiring is performed at the input terminal strip.
  • Page 21 INSTALLATION CONTINUED OUTPUT WIRING NOTE: On units with 120/208V or 120/240V outputs the loads must be split evenly between X1 - XN and X2 - XN. This also applies to X1A - XN and X2A - XN where applicable. INPUT TERMINAL TO EXTERNAL 18 AWG - 6 AWG LOAD...

  • Page 22: 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 ELU is a Timed Normally Off Bus option. This option incorporates a programmable timer which controls an internal contactor located between the output of the inverter’s “Normally On”...
  • Page 23 OPTIONAL TIMED OFF BUS SET UP CONTINUED OPTIONAL TIMED OFF BUS SET UP TIMED OFF BUS LOGIC AND CIRCUIT BOARD SETTING UP THE DIP SWITCHES AND OFF BUS TIMING CIRCUITS ONLY APPLICABLE WITH STANDARD MONITOR SEE “APPENDIX A - COMPONENT LOCATION DIAGRAMS” FOR BOARD LOCATION. OPERATION OF CONTROLS I/O FUNCTION AND CAPABILITIES (SEE BOARD LAYOUT ON NEXT PAGE)
  • Page 24 OPTIONAL TIMED OFF BUS SET UP CONTINUED OPTIONAL TIMED OFF BUS SETUP CONTINUED TIMED OFF BUS CONTROL BOARD LAYOUT ONLY APPLICABLE WITH STANDARD MONITOR SEE “APPENDIX A - COMPONENT LOCATION DIAGRAMS” FOR BOARD LOCATION. OFF BUSS ON DELAY FACTORY PRESET AT 1 SECONDS OFF BUSS RETURN DELAY FACTORY PRESET AT 15 MINUTES ON = CLOSED OFF = OPEN...

  • Page 25: Optional External Bypass Installation

    OPTIONAL EXTERNAL BYPASS INSTALLATION The Model ELU is available with an external, make-before-break (MBB) or break-before-make (BBM), wrap-around maintenance bypass switch option. Either bypass option is available on inverter systems where the nominal input and output voltages are the same and output distribution breakers are external from the Inverter enclosure. When in bypass mode, the switch will bypass the Inverter system and feed the load power directly from the AC input power source.
  • Page 26 OPTIONAL EXTERNAL BYPASS CONTINUED ***CAUTION*** TO REDUCE THE RISK OF FIRE, CONNECT ONLY TO A CIRCUIT PROVIDED WITH (+) AMPERES MAXIMUM BRANCH CIRCUIT OVERCURRENT PROTECTION IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE, ANSI/NFPA 70.” BREAKER MINIMUM BREAKER MINIMUM BREAKER MINIMUM BREAKER MINIMUM SIZE...

  • Page 27: Break Before Make, 1.5-10Kva

    11.905 GROUND TERMINALS: 12 AWG - 1 AWG AUXILIARY CONTACT TERMINALS: 22 AWG - 8 AWG FRONT VIEW SIDE VIEW CONTROLLED POWER COMPANY 1955 STEPHENSON HWY. TROY,MI 48083 ELU & ESV WALL MOUNT BYPASS CABINET OUTLINE C32/50A BREAK-BEFORE MAKE BYPASS WEIGHT: 50# 7.CORRECTED AUXILARY N.O.

  • Page 28: Break Before Make, 1.5-10Kva - System Wiring

    OPTIONAL EXTERNAL BYPASS CONTINUED BREAK BEFORE MAKE, 1.5-10KVA - SYSTEM WIRING...

  • Page 29: Break Before Make, Llx And Ggx, 12.5Kva And 14 Kva

    POWER TERMINALS: 8 AWG - 2/0 AWG GROUND TERMINALS: 14 AWG - 2/0 AWG AUXILIARY CONTACT TERMINALS: 22 AWG - 8 AWG 14.060 24.000 16.828 CONTROLLED POWER COMPANY 1955 STEPHENSON HWY. TROY,MI 48083 FRONT VIEW SIDE VIEW ELU & ESV WALL MOUNT BYPASS CABINET OUTLINE C80/100A...

  • Page 30: Break Before Make, Llx And Ggx, 12.5Kva And 14 Kva - System Wiring

    OPTIONAL EXTERNAL BYPASS CONTINUED BREAK BEFORE MAKE, LLX AND GGX, 12.5KVA AND 14 KVA - SYSTEM WIRING...

  • Page 31: Make Before Break, 1.5-10Kva

    GROUND TERMINALS: 12 AWG - 1 AWG 12.313 AUXILIARY CONTACT TERMINALS: 22 AWG - 8 AWG FRONT VIEW SIDE VIEW CONTROLLED POWER COMPANY 1955 STEPHENSON HWY. TROY,MI 48083 ELU & ESV WALL MOUNT BYPASS CABINET OUTLINE C32/50A MAKE-BEFORE-BREAK BYPASS 6.CORRECTED AUXILARY N.O. CONTACT NUMBERS. 11/13/2018 T.SZ WEIGHT: 50# 5.

  • Page 32: Make Before Break, 1.5-10Kva - System Wiring

    OPTIONAL EXTERNAL BYPASS CONTINUED MAKE BEFORE BREAK, 1.5-10KVA - SYSTEM WIRING AUTHORIZED PERSONNEL ONLY ***** WARNING ***** POTENTIAL FOR BACK FEED EXISTS WHILE OPERATING THIS MAKE BEFORE BREAK SWITCH. KEEP SWITCH LOCKED-OUT AT ALL TIMES TO PREVENT UNAUTHORIZED ACCESS / OPERATION. USE PROPER LOCK-OUT / TAG-OUT PROCEDURE BEFORE OPERATING THIS SWITCH.

  • Page 33: Make Before Break, Llx And Ggx, 12.5Kva And 14 Kva

    POWER TERMINALS: 8 AWG - 2/0 AWG GROUND TERMINALS: 14 AWG - 2/0 AWG AUXILIARY CONTACT TERMINALS: 22 AWG - 8 AWG 14.060 24.000 16.875 CONTROLLED POWER COMPANY 1955 STEPHENSON HWY. TROY,MI 48083 SIDE VIEW FRONT VIEW ELU & ESV WALL MOUNT BYPASS CABINET OUTLINE C80/100A...

  • Page 34: Make Before Break, Llx And Ggx, 12.5Kva And 14 Kva - System Wiring

    OPTIONAL EXTERNAL BYPASS CONTINUED MAKE BEFORE BREAK, LLX AND GGX, 12.5KVA AND 14 KVA - SYSTEM WIRING AUTHORIZED PERSONNEL ONLY ***** WARNING ***** POTENTIAL FOR BACK FEED EXISTS WHILE OPERATING THIS MAKE BEFORE BREAK SWITCH. KEEP SWITCH LOCKED-OUT AT ALL TIMES TO PREVENT UNAUTHORIZED ACCESS / OPERATION. USE PROPER LOCK-OUT / TAG-OUT PROCEDURE BEFORE OPERATING THIS SWITCH.

  • Page 35: Optional Zonesaver 2 Installation

    OPTIONAL ZONESAVER 2 INSTALLATION Specifications Voltages ........... 277VAC 50/60Hz Max Load Requirements LED Lighting..........18A @277VAC Ballast............. 20A @277VAC Incandescent...........10A @120VAC OPTIONAL ZONESAVER-2, “LOCAL CONTROL OVERRIDE” INSTALLATION 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 36: Optional Zonesaver-2, "Zone Sensing" Installation

    OPTIONAL ZONESAVER 2 INSTALLATION CONT. OPTIONAL ZONESAVER-2, “ZONE SENSING” INSTALLATION 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 37: Multiple Zonesaver-2 Units Connected To One Inverter - Wiring Diagram

    OPTIONAL ZONESAVER 2 INSTALLATION CONT. MULTIPLE ZONESAVER-2 UNITS CONNECTED TO ONE 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 38: 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 39 OPTIONAL REMOTE ANNUNCIATOR CONTINUED ALARM TERMINALS - TO REMOTE 120VAC POWER, 50/60Hz LOCATED ON THE ANNUNCIATOR CABLE. 2 WIRE W/ GROUND CONTROL MODULE TERMINAL SUPPLIED BY OTHER L1 - 120V - BLACK TO INVERTER N - WHITE OUTPUT - 120V GROUND - GREEN (BARE) UPS ON (ORANGE) WHITE...
  • Page 40 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 41: 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 42: Optional Multifunction Communications Modem

    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 43: Optional Remote Communications

    OPTIONAL REMOTE COMMUNICATIONS NETMINDER AND INTELLISTAT TS NETWORK COMMUNICATIONS Optional Network Communications The NetMinder’s series of adapters integrate the UltraLITE with Standard Monitor into an Ethernet TCP/IP, MODBUS TCP, or MODBUS RS485 network with a specific IP address for Ethernet connected systems. See NetMinder Setup Guide.

  • Page 44: Dip Switch Set Up

    DIP SWITCH SET UP SETTING THE DIP SWITCHES Dip Switch Settings (located on the top or side of the Control Module - see below or “Appendix A - Dip Switch and Alarm Terminal Locations”). Switch #1 For restart options, set these dip switches to one of the following positions. NOTE: Both switches must be set the same.

  • Page 45: Communications Description

    COMMUNICATIONS DESCRIPTION STANDARD MONITOR COMMUNICATIONS FOR USE WITH STANDARD MONITOR ONLY See “Appendix A - Dip Switch and Alarm Terminal Location Diagram” for Terminal Location. *** Caution *** Be sure that no power is applied to the Inverter while wiring internal configuration of Control Module.
  • Page 46 COMMUNICATIONS DESCRIPTION CONTINUED INTELLISTAT TS MONITOR COMMUNICATIONS FOR USE WITH INTELLISTAT TS MONITOR ONLY See “Appendix A - Component Location Diagram” for Interface Board location. *** Caution *** Be sure that no power is applied to the Inverter while wiring internal configuration of Control Module.

  • Page 47: Communications

    COMMUNICATIONS FOR SERVICE USE ONLY THIS TYPE OF COMMUNICATION SETUP IS TEMPORARY AND ONLY USED FOR SERVICING OF THE SYSTEM. If a permanent method of communications is desired, there are multiple ways of accompishing this. Information can be obtained remotely with the use of optional devices such as the MCM Device the Auto Dialer and other optional software as well as by use of the alarm terminals provided.

  • Page 48: Communications Procedures

    COMMUNICATIONS PROCEDURES COMMUNICATIONS PROCEDURES 1. Connect the DB9 to USB Null Modem Conversion cable from K7A (DB9) on the Control Board (For units with the Intellistat Monitor the existing connection plugged into K7A on control board will have to be removed - must be reconnected when done) to the USB port on a computer.

  • Page 49: Communications Commands

    COMMUNICATIONS COMMANDS SYSTEM PARAMETERS To access system parameters, send a lower case “ss” to the Inverter from the terminal. Sample Display Description Explanation AC Volts input measured from Line 1 to Input Voltage(L1-L2) = 240 The input voltage the Inverter is receiving Line 2 AC Volts output measured from Line 1 to The output voltage the Inverter is sending to...
  • Page 50 COMMUNICATIONS COMMANDS CONTINUED SYSTEM SETPOINTS 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 = 3.0 AC volt-amps output of the unit apparent power...
  • Page 51 COMMUNICATIONS COMMANDS CONTINUED LOG FUNCTIONS To access a log of the outages and overloads, send a lower case “ll” (L) 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 52: Start Up Procedure

    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 53 START UP PROCEDURE CONTINUED 9. Check for correct output voltage at the output terminal (X1, X2, X1A, X2A, XN). OUTPUT 120/208V X1-XN=120V X2-XN=120V X1-X2=208V 120/240V X1-XN=120V X2-XN=120V X1-X2=240V 120/277V X1-XN=120V X2-XN=277V 120/347V X1-XN=120V X2-XN=347V OFF BUS OUTPUT 120/208V X1A-XN=120V X2A-XN=120V X1A-X2A=208V 120/240V X1A-XN=120V X2A-XN=120V X1A-X2A=240V 120/277V X1A-XN=120V X2A-XN=277V 120/347V X1A-XN=120V X2A-XN=347V...

  • Page 54: Operation

    OPERATION STANDARD MONITOR OPERATION INVERTER SYSTEM LINE VOLTAGE HIGH NORMAL ON STATIC BYPASS LOAD BATTERY IN USE CHECK BATTERY FULL BATTERY ON/OFF ALARM OFF Previous Version 1. LED indicates that high input voltage is present (+10%). 9. LED indicates that the system alarm is “ON”. 2.
  • Page 55 OPERATION CONTINUED STANDARD 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 56: Intellistat Ts Monitor Operation

    With this in mind, Controlled Power Company designed the model “ELU” with state of the art monitoring features to provide complete system diagnostics and testing with access to all electrical system parameters.
  • Page 57 OPERATION CONTINUED INTELLISTAT TS MONITOR OPERATION MONITOR TREE *** CAUTION *** IT IS RECOMMENDED THAT ALL PAREMETERS BE LEFT AT FACTORY PRESET LEVELS. IF MODIFICATION OF SYSTEM PARAMETERS AND ALARM LEVELS IS REQUIRED PLEASE CONTACT THE FACTORY PRIOR TO MODIFICATION. IMPROPERLY SETTING ALARM LEVELS MAY RESULT IN NUISANCE ALARMS.
  • Page 58 OPERATION CONTINUED INTELLISTAT TS MONITOR OPERATION PARAMETER DEFINITIONS TIME: 07:58:17 AM SYSTEM NORMAL DATE: 03/31/10 MANUAL BYPASS STATIC BYPASS LOAD % INVERTER LINK INPUT OUTPUT BATTERY BATTERY STATUS CHARGE PARAM ALARMS SETUP TEST ON/OFF PARAMETERS MENU SUB MENU MEANS TERM PARAMETERS INPUT INPUT VOLTAGE FROM L1 TO L2...
  • Page 59 OPERATION CONTINUED INTELLISTAT TS MONITOR OPERATION PARAMETER DEFINITIONS PARAMETERS MENU SUB MENU MEANS TERM SETUP HIGH HIGH OUTPUT VOLTAGE X1 TO N ALARM LEVEL AC VOLTS X1-N HIGH OUTPUT VOLTAGE X2 TO N ALARM LEVEL AC VOLTS X2-N HIGH VA X1 TO N ALARM LEVEL VA X1-N HIGH VA X2 TO N ALARM LEVEL VA X2-N...
  • Page 60 OPERATION CONTINUED INTELLISTAT TS MONITOR OPERATION This section will give you a basic understanding of the Intellistat TS Monitor, its menu items and functions. All parameters are preset at the factory. GENERAL The system is pre-programmed at the factory specific to your unit. There should be no need to change any system parameters.
  • Page 61 OPERATION CONTINUED INTELLISTAT TS MONITOR OPERATION COMMON SCREENS PASSWORD SCREENS Passwords are required to access certain screens. A typical password screen is shown below. Enter the desired number using the key pad. The number selected will appear next to the “Enter Password” area. When the numbers desired are fully entered, select “ENT”...
  • Page 62 OPERATION CONTINUED INTELLISTAT TS MONITOR OPERATION MAIN SCREEN Typical “System Normal” Main Screen showing TIME: 07:58:17 AM SYSTEM NORMAL the percentage load for each output and the DATE: 03/31/10 battery charge level. The Low Battery and output overload indicators will change to red if the levels MANUAL BYPASS reach the programmed low set points (factory STATIC BYPASS...
  • Page 63 OPERATION CONTINUED INTELLISTAT TS MONITOR OPERATION ON INVERTER SCREENS MAIN SCREEN - OFF BUS CONNECT TIME: 07:58:17 AM OFFBUS CONN 00:00:40 DATE: 03/31/10 (L) Indicates a low line condition caused the MANUAL BYPASS inverter to switch to STATIC BYPASS LOAD % battery.
  • Page 64 OPERATION CONTINUED INTELLISTAT TS MONITOR OPERATION MANUAL BATTERY TESTING Default customer password = 05151 Press the “TEST” button to invoke a TIME: 07:57:20 AM SYSTEM NORMAL DATE: 04/16/10 battery test * (Duration is dependant on battery option purchased). The MANUAL BATTERY TEST duration is preset at the factory and is not user accessible.
  • Page 65 OPERATION CONTINUED INTELLISTAT TS MONITOR OPERATION AUTOMATIC PERIODIC BATTERY TESTING Default customer password = 05151 Push to enable the test. P r e s s t h e “ T E S T ” Factory preset enabled. b u t t o n t o i n v o k e a TIME: 07:57:20 AM The test will auto run SYSTEM NORMAL...
  • Page 66 OPERATION CONTINUED INTELLISTAT TS MONITOR OPERATION AUTOMATIC ANNUAL BATTERY TESTING Default customer password = 05151 Push to enable the test on P r e s s t h e “ T E S T ” a yearly basis. Factory b u t t o n t o i n v o k e a TIME: 07:57:20 AM SYSTEM NORMAL preset disabled.
  • Page 67 OPERATION CONTINUED EGRESS LIGHTING INTEGRITY TEST (OUTPUT VOLT AMPS ON BATTERY - FACTORY DEFAULT = 0) Default customer password = 05151 To satisfy NFPA-mandated periodic and annual requirements, the Intellistat TS automatically initiates the testing of all life safety circuits, regardless of egress lighting design (“always on” or “normally off”). This automatic test checks the inverter system and batteries, as well as the individual circuits leading to the emergency fixtures.
  • Page 68 OPERATION CONTINUED INTELLISTAT TS MONITOR OPERATION ALARMS, ALARM LOGS AND TEST LOGS TYPICAL ALARM SCREEN PUSH TO PUSH TO PUSH TO TIME: 07:58:17 AM TOTAL ALARM: 01 SILENCE DATE: 04/16/10 SILENCE ! SILENCE ! AC OUTPUT VOLTS X1 - N HIGH = 129.9 ALARMS CLEAR AUTOMATICALLY AFTER EVENT IS...
  • Page 69 OPERATION CONTINUED INTELLISTAT TS MONITOR OPERATION ALARM MESSAGES AND DEFINITIONS LOG / CURRENT / RS232 ALARM BANNER THE OUTPUT VOLTAGE ON LINE 1 IS ABOVE AC OUTPUT VOLTS X1-N HIGH = 121.3 TOTAL ALARM: 01 THE OUTPUT VOLTAGE HIGH SETPOINT. THE OUTPUT VOLTAGE ON LINE 2 IS ABOVE AC OUTPUT VOLTS X2-N HIGH = 121.3 TOTAL ALARM: 01...
  • Page 70 OPERATION CONTINUED INTELLISTAT TS MONITOR OPERATION ALARM MESSAGES AND DEFINITIONS LOG / CURRENT / RS232 ALARM BANNER OVERTEMPERATURE WARNING THERE IS AN OVER TEMPERATURE WARNING TOTAL ALARM: 01 LAST POWER OFF: DC BUS VOLTAGE SYSTEM SHUTDOWN DUE TO AN TOTAL ALARM: 01 HIGH OVERVOLTAGE ON THE DC BUS.

  • Page 71: Bypass Switch - Standard Monitor

    BYPASS SWITCH - STANDARD MONITOR The purpose of the bypass switch is to connect the loads to utility power in case of inverter failure. The bypass function is a push to turn mechanical switch. *** CAUTION *** DO NOT switch to bypass mode if the Inverter is on battery or the “On Bypass”...

  • Page 72: Bypass Switch - Intellistat Monitor

    BYPASS SWITCH - INTELLISTAT MONITOR BYPASS SWITCH OPERATION - The purpose of the bypass switch is to connect the loads to utility power in case of inverter failure. The bypass function is a push to turn mechanical switch. *** CAUTION *** DO NOT switch to bypass mode if the Inverter is on battery or the “On Static Bypass”...

  • Page 73: Maintenance Procedures

    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 74: 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 75: Automatic Periodic Battery Test - Standard Monitor

    MAINTENANCE PROCEDURES CONTINUED BATTERY TESTING - STANDARD MONITOR CONTINUED AUTOMATIC PERIODIC BATTERY TEST - STANDARD MONITOR GENERAL - The inverter is preset at the factory for automatic monthly testing enabled and takes place on the programmed calendar date. Starting with the 15th day of the following month from the actual ship date at 10 P.M. See “Battery Test Durations”...
  • Page 76 MAINTENANCE PROCEDURES CONTINUED CHANGING BATTERY TEST PARAMETERS - STANDARD MONITOR CONTINUED Extreme caution should be taken when changing system parameters - contact the factory prior to doing so. Type in the value desired and the next set of parameters will be displayed. If no change is desired simply hit return to scroll to the next set of parameters.

  • Page 77: Battery Testing - Intellistat Ts Monitor

    MAINTENANCE PROCEDURES CONTINUED BATTERY TESTING - INTELLISTAT TS MONITOR CAUTION - DO NOT PLACE UNIT IN BYPASS WHILE BATTERY TESTING IS IN PROGRESS. PREPARATION - Proper precautions must be taken when performing battery testing. The lighting load(s) should be available to test on inverter, in a loss of power simulation. Be sure also to take precautions to have the lighting load in a mode that could tolerate a shut down.

  • Page 78: Automatic Annual Battery Test - Intellistat Ts Monitor

    MAINTENANCE PROCEDURES CONTINUED BATTERY TESTING - INTELLISTAT TS MONITOR CONTINUED AUTOMATIC PERIODIC BATTERY TEST - INTELLISTAT TS MONITOR CONTINUED NOTE : Invoking a test by pressing the “TEST” button will automatically change the date and time of the Periodic Test to the date and time that the test button is pushed. The auto test will commence exactly 30 days (depending on the period set) later on the same date and time the test button was initially pushed (if enabled).
  • Page 79 MAINTENANCE PROCEDURES CONTINUED AUTOMATIC ANNUAL BATTERY TEST - INTELLISTAT TS MONITOR CONTINUED To force an annual test: 1. On the Intellistat TS Monitor, select “Test” from the Main Menu. Enter the required password to continue. Select “ANNUAL” from the menu and when the next sreen appears push the green TEST button. This will force the inverter into battery mode for the programmed duration.

  • Page 80: 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 81: Customer Support

    CUSTOMER SUPPORT Contact Controlled Power Company. CONTROLLED POWER COMPANY NATIONWIDE CUSTOMER SUPPORT Controlled Power Company offers total customer support that assures your critical equipment is maintained properly for trouble free operation. WHAT A CUSTOMER SUPPORT PLAN OFFERS: HOT LINE: 24 hour toll free 1-800-521-4792.
  • Page 82 APPENDIX A APPENDIX A RELATIVE DRAWINGS & SCHEMATICS...

  • Page 83: Cabinet Outline

    CABINET OUTLINE 1.5KW - 3.5KW...

  • Page 84: Kw - 7Kw

    CABINET OUTLINE 4.2KW - 7KW...

  • Page 85: Kw - 10Kw With External Battery Cabinet

    CABINET OUTLINE 7.5KW - 10KW WITH EXTERNAL BATTERY CABINET...

  • Page 86: Kw - 14Kw With External Battery Cabinet

    CABINET OUTLINE 12.5KW - 14KW WITH EXTERNAL BATTERY CABINET...

  • Page 87: Component Location Diagram

    COMPONENT LOCATION DIAGRAM 1.5KW - 3.5KW OPTIONAL OPTIONAL OUTPUT INTELLISTAT NETWORK INPUT/OUTPUT BREAKER COMMUNICATIONS OR WIREWAY TRIPPED NETMINDER LOCATIONS INDICATOR ASSEMBLY (TYPICAL EACH SIDE) OPTIONAL INTELLISTAT OPTIONAL OPTIONAL INTERFACE OUTPUT INPUT ON/OFF BUS BOARD AND CONTACTOR REMOTE COMMAND ON TERMINALS OPTIONAL (INTELLISTAT REMOTE COMMAND...

  • Page 88: Control Module - 1.5Kw - 3.0Kw, Llx-3.5Kw And Ggx-3.5Kw

    COMPONENT LOCATION DIAGRAM CONTROL MODULE - 1.5KW - 3.0KW, LLX-3.5KW and GGX-3.5KW CONTROL DC SWITCH BATTERY BOARD BOARD CONNECTOR RELAY POWER BOARD BOARD...

  • Page 89: Kw - 14Kw

    COMPONENT LOCATION DIAGRAM 4.2KW - 14KW OPTIONAL INTELLISTAT NETWORK INPUT/OUTPUT COMMUNICATIONS OR NETMINDER WIREWAY ASSEMBLY LOCATIONS OPTIONAL INTELLISTAT INTERFACE BOARD AND OPTIONAL REMOTE COMMAND ON ON/OFF BUS TERMINALS (INTELLISTAT CONTACTOR MONITOR ONLY) REMOTE COMMAND SEE INTELLISTAT COMMUNICATIONS ON TERMINALS (STANDARD MONITOR ONLY) CONTROL INPUT TERMINAL MODULE...

  • Page 90: Control Module - 4.2Kw - 14Kw, Jjx-3.5Kw And Jyx-3.5Kw

    COMPONENT LOCATION DIAGRAM CONTROL MODULE - 4.2KW - 14KW, JJX-3.5KW and JYX-3.5KW CONTROL BOARD CONTROLLER BOARD POWER INTERFACE BOARD (NOT FOR COMMUNICATIONS USE) SWITCH POWER BOARD BATTERY CONNECTOR...

  • Page 91: Dip Switch And Alarm Terminal Locations

    DIP SWITCH AND ALARM TERMINAL LOCATIONS CLOSED OPEN MODULE POWER ALARM TERMINALS ON/OFF SWITCH DIP SWITCHES DB9 (K7A AND K7B) (K7A IS CLOSEST TO BOARD) INTELLISTAT MONITOR INTERFACE BOARD (WHERE APPLICABLE) 1.5KW - 3.0KW, LLX-3.0-3.5KW and GGX-3.0-3.5KW DB9 (K7A AND K7B) (K7A IS CLOSEST TO BOARD) CAUTION WARNING...

  • Page 92: Options Interconnection Diagram

    OPTIONS INTERCONNECTION DIAGRAM FOR USE WITH INTELLISTAT TS MONITOR ONLY TO CUSTOMER NETWORK (CUSTOMER SUPPLIED ETHERNET CABLE) OPTIONAL TO INVERTER INTELLISTAT NETWORK RECEPTACLE TO K9 TO K9 SEE NOTE COMMUNICATIONS OR ON INTELLISTAT ON INTELLISTAT BELOW INTERFACE BOARD INTERFACE BOARD NETMINDER ALARM TERMINALS - LOCATED ON THE CONTROL MODULE Ethernet...
  • Page 93 OPTIONS INTERCONNECTION DIAGRAM FOR USE WITH STANDARD MONITOR ONLY TO CUSTOMER NETWORK TO INVERTER (CUSTOMER SUPPLIED RECEPTACLE ETHERNET CABLE) TO ALARM TO ALARM SEE NOTE TERMINALS TERMINALS BELOW TO INVERTER RECEPTACLE NETMINDER SEE NOTE INTERNAL TO ALARM BELOW NETMINDER TERMINALS ASSEMBLY PHONE JACK...

  • Page 94: One Line Diagram

    ONE LINE DIAGRAM...

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