Users Manual Cobra Plus Stand-By Lighting Inverter Technical Manual #018-0110-01 Revision B Phone: 1.877.DSPM.POWER 1.877.377.6769 Fax: 909.930.3335 Website: www.dspmanufacturing.com E-Mail: techsupport@dspmanufacturing.com
TABLE OF CONTENTS Introduction Important Safety Instructions General Unit Information Front Panel Description Bypass Switch Description System Component Layout Installation Inspection Placement Connections Interface Internal Battery Pack Connection to Utility Charging of the Batteries Connection of the s System Ratings Operation Start Up Turning System Off Manual Bypass Battery Run Audible Alarm Low Battery (Rapid Alarm) Direct Communications Maintenance Technical Support Battery Connections Environmental Control Module Trouble Shooting Notes 3 4 6 6 7 9 10 12 12 12 13 13 14 14 14 14 15 17 17 17 18 18 18 18 19 19 19 20 24 25
Introduction Save these instructions Please read and save this manual! Thank you for selecting this Lighting Inverter System. It provides you with perfect protection for connected loads and equipment. The manual is a guide to install and use the Lighting Inverter System. It includes important safety instructions for operation and correct installation of the Lighting Inverter System. If you should have any problems with the Lighting Inverter System, please refer to this manual or call technical support at 1.877.377.6769 Please save or recycle the packaging materials! The Lighting Inverter System shipping materials are designed with great care to provide protection within delivery. These materials are invaluable if you have to return the Lighting Inverter System for service. Damage happening during transit not covered under the warranty; please call the freight carrier immediately or DSPM customer service to report any damage. Intelligent Microprocessor Control The product is an advanced Lighting Inverter System based on microprocessor control. The Lighting Inverter System is an intelligent protector and provides pure, reliable AC power to the emergency loads protecting them from utility power blackouts, swells, sags, surges and interference. All types of lamps are supported by our lighting inverter. There will be a 16-60msec transfer time. Under normal power conditions, the design enables the system to adjust and filter power fluctuations continuously and automatically. In the event of power failure, it can immediately provide back-up power from the batteries without any interruption. When the utility power is connected, the charger will automatically recharge the batteries. Advanced Battery Management The visual and audible indications of the Lighting Inverter System present the battery s status, including capacity and battery conditions. The self-test function lets the Lighting Inverter System detect a weak battery. The Lighting Inverter System performs a self-test at power up. Self-test function can be conducted manually with the ON/TEST switch at any time.
Important Safety Instructions Transportation and/or Moving Unit Please transport the Inverter with care to ensure the unit is protected against shock and impact. Set-up Ensure the unit is completely dry before being installed. Moving the unit directly from a cold to warm environment may cause condensation to form on electronic/electrical parts. Please allow an acclimatization time adequate for all condensation/water to evaporate. Do not install the Inverter near water or in damp environments. Do not install the Inverter where it could be exposed to direct sunlight or near heat. Do not block off ventilation openings in the Inverter cabinet. WARNING: Intended for installation in a controlled environment. Installation Connect conduit in such a way that no one can step on or trip over the conduit. Batteries CAUTION: Risk of electrical shock Hazardous live parts inside unit are energized from the internal battery supply even when the input AC power is disconnected. CAUTION: Risk of electrical shock, non-isolated battery circuit. Hazardous voltage may exist between battery terminals and ground. CAUTION: Do Not dispose of batteries in a fire, the battery may explode. CAUTION: Do Not open or break apart the battery, released electrolyte is harmful to the skin and eyes. 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: Remove watches, rings and/or other metal objects. Use tools with insulated handles. Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions. DO NOT Dismantle the Lighting Inverter System.
Operation CAUTION: The Inverter System features its own internal power source (batteries). The UPS/Inverter System output circuits may be electrically live, even if the Inverter System is not connected to the building wiring power source (utility). CAUTION: Ensure that no fluids or other foreign objects can enter the Inverter System. CAUTION: The Inverter System operates with hazardous voltages. Only qualified maintenance personnel may carry out service. Service CAUTION: Risk of electrical shock, do not remove cover. No user serviceable parts inside. Refer servicing to qualified service personnel. CAUTION: To reduce the risk of electrical shock; disconnect the Lighting Inverter System from the main supply before installing an interface signal cable. Reconnect the power only after signaling interconnections have been made. CAUTION: The Inverter System operates with hazardous voltages. Only qualified maintenance personnel may carry out repairs. CAUTION: Risk of electrical shock, non-isolated battery circuit. Hazardous voltage may exist between battery terminals and ground. Only TRAINED personnel familiar with batteries and with the required precautionary measures may replace batteries and supervise operations. Unauthorized persons must be kept well away from the batteries. CAUTION: A battery can present a risk of electrical shock and high short circuit current. The following precaution should be observed when working on batteries: Remove watches, rings and/or other metal objects. Use tools with insulated handles. Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. When replacing or charging batteries, install the same number and same type of batteries. Do not attempt to dispose of the batteries by burning them. This could cause batteries to explode. CAUTION: Do Not open or break apart the battery, released electrolyte is harmful to the skin and eyes.
General Unit Information The Cobra Plus is an Lighting Inverter System incorporating double-conversion technology. It provides perfect protection specifically for Egress Lighting for facilities. The inverter is a double-conversion principle eliminates all sources of power disturbances. A rectifier converts the alternating current from the building source to Direct Current (DC). This DC charges the batteries and powers the inverter. With the basic DC voltage, the inverter generates a sinusoidal alternating current (AC) voltage, which continuously supplies the load. The load is powered by the utility, which receives its power from the building source. In the event of the loss of the building source power the inverter will then derive it s power from the batteries. All units come standard with a 90-minute backup time.
Front Panel Description White Display 2 3 4 1 5-9 10 OFF Key Control Key On/Test/Mute Key Black Display or 10 OFF Key 5-9 ON Key 1 4 3 2
Both Display s 1 Line LED (Green): To indicate the AC Power is applied to the system input. In case this LED blinks, it means the main AC source is out of tolerance. 2 Bypass LED (Yellow): To indicate the load is powered via the bypass. 3 Battery LED (Yellow): To indicate the system is in battery backup mode when the building source power has failed. 4 Inverter LED (Green): To indicate the system is powered through the inverter 5-9 & Battery Capacity LED's: a. Number 5 and 8 LED s are green colored and Number 9 (used as a Warning LED for overload or battery low) is yellow. b. Number 5 to 8 LED s show the load % of the system if the main power is available (in normal operation). Each of the green LED s will indicate a % of the power level for the rating of the system. NOTE: Depending on unit size the LED s 5 to 9 may not indicate the actual load. c. In the battery operation, the LED s indicate the capacity (%) of the batteries run time remaining, As the batteries are depleted the LED s will extinguish from left to right. When LED number 9 is only lighted then there is 0-25% left on the battery run. 10 Fault LED (Red): To indicate that the Lighting Inverter System is in a fault condition because of inverter shutdown or over temperature condition. White Display (Only) OFF Key: This button should be pressed with the Control Key simultaneously to switch off the Lighting Inverter System. Control Key: This button should be pressed simultaneously with the Off Key, or On/Test/Mute Key to switch on or off the Lighting Inverter System, do auto-test and disable the buzzer. ON/Test/Mute Key: This button should be pressed with the Control Key simultaneously to switch on the Lighting Inverter System, and to do a system auto-test in normal AC mode. When in the battery mode pressing this button will silence the buzzer operation.
Black Display (Only) OFF Key: This button needs to be pushed to turn the emergency lighting inverter off. ON Key: This button needs to be pushed to turn the emergency lighting inverter on. Bypass Switch Description This switch is located inside the door of the system, and is protected by a cover that is held on by screws. (See system component diagram for exact location). The bypass switch is used in case of a failure of the lighting inverter. If the lighting inverter fails place the bypass switch in the BYPASS position. In this position the inverter section is bypassed allowing the load to be powered by the utility until the inverter can be repaired. Contact factory for service. WARNING: An Authorized Service Technician should only remove this cover. NOTE: Operation of the bypass switch will cause the inverter switch to static bypass and turn off the inverter if it was running. WARNING: The manual bypass switch should only operated by authorized personnel.
System Component Layout The following layout will help you find the parts and components in your Lighting Inverter. If you need technical assistance, please contact DSPM. Do not attempt to service. Factory-trained personnel should perform maintenance only. 1 2 3 4 5 6 7 8 9 10 11 12 1 - Relay 13 2 - Input Terminal Blocks 3 - Input Transformer 4 - Input Circuit Breaker 5 - Battery Circuit Breaker 6 - Output Terminal Blocks 7 - Output Main Circuit Breaker 8 - Output Transformer 9 - ECM Test Terminal Blocks 10 - Branch Breaker Terminal Blocks 11 - Optional Branch Distribution Circuit Breaker 12 - TB/Circuit Breaker Label 13 - Manufacturers Label 14 - Batteries 14
Inside door layout: 1 2 3 4 5 1 - Manufacturers Label 2 - Bypass Switch 3 - Output Filter 4 - Display 5 - Charger Board 6 - Input Filter 7 - DC Caps 8 - Fan 9 - Main Power Board 10 - Interface Please see the Interface section of this manual for more detailed information 6 7 8 9 10
Installation Inspection Inspect the Lighting Inverter System upon receipt. If there was any damage during transportation; Do Not turn on the unit and notify the carrier and DSPM immediately. The packaging is recyclable; keep it for reuse or please disposed of it properly. Placement Install the Lighting Inverter System in a protected area with adequate airflow and free from excessive dust. Do not operate the Lighting Inverter System where the temperature and humidity is out of the specified limits. Top View 26 26 44 44 Front View 18 20 RAD Per code requirements please leave 3 on each side of the cabinet including the back, and a 3 foot clearance in front. Storage of the system should be in a cool and dry area with the unit being upright and covered. The unit cannot be stored for more then 3 months without charging the batteries. The warranty can be affected. Operating Temperature: 0º to 40ºC (32º to 104ºF) Storage Temperature: -20º to 60ºC (-4º to 140ºF)
Connections WARNING: Condensation of water may occur if the system is unpacked in a very low temperature environment. In this case it is necessary to wait until the system is fully dried inside out before proceeding with the connection of any power, otherwise there are hazards of electrical shock. Installation and wiring must be performed in accordance with the local electric code and the instructions of professional personnel. Interface (optional) Software interface kits can be used with this Lighting Inverter System. Contact the factory for kits supplied or approved by DSPM. If used, connect the interface cable to the 9-pin computer interface port (RS-232 Standard Interface Port) on the main control PCB in top of Lighting Inverter System. The RS-232 interface uses 9-pin female D-sub connector. This information consists of data about utility, load and the Lighting Inverter System. The interface port pins and their functions are identified in the following table. NOTE: Interface connection is optional. The Lighting Inverter System works properly without an optional interface connection. UPS FAIL 1 SUMMARY ALARM GND 2 3 6 7 8 BYPASS BATTERY LOW UPS ON REMOTE SHUTDOWN COMMON 4 5 9 LINE LOSS CAUTION: Use only factory supplied or authorized Lighting Inverter System monitoring cable!
Internal Battery Pack Before connecting, ensure that the batteries are connected according to the battery diagram (negative of first battery to positive of the second battery, negative of the second battery to positive of third battery, etc.). After connecting all the batteries connect the positive lead (Red) from the battery circuit breaker(s) (CB2) to the positive terminal. Connect the black to the negative side of the circuit breaker. WARNING: Make sure the proper polarity is observed. DC bus should be between 96 and 108 Vdc as tested at the top of the battery circuit breaker (CB2). Connection to Utility Ensure that the utility power to be connected is as listed on the system label, and the hots, neutral and grounds are correctly identified and wired to the input terminal blocks as designated. Charging of the Batteries The Lighting Inverter System charges it s battery whenever it is connected to utility power and the input circuit breakers (CB1) is turned on. For the best results, charge the battery for 24 hours in the initial use. Connection of the s Ensure that the loads to be connected are as listed on the system label, and the hots, neutral and grounds are correctly identified and are wired to the output terminal block as designated. CAUTION: Do not bond the output neutral to chassis ground! The system has been bonded as required by the manufacturer and NEC. s not powered by the system cannot use the neutral of the Lighting Inverter System. Any load powered by the Lighting Inverter System line and neutral outputs only.
System Current Ratings All circuit breakers provided by the end user that are connected to the inputs and outputs need to have a trip curve which is at least 10 times the rated current for.3 seconds. This is to prevent the breakers from tripping during startup of the unit or the loads, attached to the unit. Some manufacturers refer to these breakers as High Inrush breakers. KW Input Voltage Utility Feed Amps 120 35 Max Output Output Voltage Amps 120 20 277 8.7 480 5 KW Input Voltage Utility Feed Amps 120 37.9 Max Output Output Voltage Amps 120 21.7 277 9.4 480 5.4 120/240 20/10 120/240 21.7/10.8 208 20.2 120/277 20/8.7 120 20 277 8.7 480 5 120/240 20/10 208 21.8 120/277 21.7/9.4 120 21.7 277 9.4 480 5.4 120/240 21.7/10.8 2.4 240 17.5 120/277 20/8.7 120 20 277 8.7 480 5 120/240 20/10 2.6 240 19 120/277 21.7/9.4 120 21.7 277 9.4 480 5.4 120/240 21.7/10.8 277 15.2 120/277 20/8.7 120 20 277 8.7 480 5 120/240 20/10 277 16.4 120/277 21.7/9.4 120 21.7 277 9.4 480 5.4 120/240 21.7/10.8 480 8.8 120/277 20/8.7 120 20 277 8.7 480 5 120/240 20/10 480 9.5 120/277 21.7/9.4 120 21.7 277 9.4 480 5.4 120/240 21.7/10.8 120/277 20/8.7 12/277 21.7/9.4
KW Input Voltage Utility Feed Amps 120 43.8 Max Output Output Voltage Amps 120 25 277 10.8 480 6.3 KW Input Voltage Utility Feed Amps 120 55.4 Max Output Output Voltage Amps 120 31.7 277 13.7 480 7.9 120/240 25/12.5 120/240 31.7/15.8 208 25.2 120/277 25/10.8 120 25 277 10.8 480 6.3 120/240 25/12.5 208 32 120/277 31.7/13.7 120 31.7 277 13.7 480 7.9 120/240 31.7/15.8 3.0 240 21.9 120/277 25/10.8 120 25 277 10.8 480 6.3 120/240 25/12.5 3.8 240 27.7 120/277 31.7/13.7 120 31.7 277 13.7 480 7.9 120/240 31.7/15.8 277 19 120/277 25/10.8 120 25 277 10.8 480 6.3 120/240 25/12.5 277 24 120/277 31.7/13.7 120 31.7 277 13.7 480 7.9 120/240 31.7/15.8 480 10.9 120/277 25/10.8 120 25 277 10.8 480 6.3 120/240 25/12.5 480 13.9 120/277 31.7/13.7 120 31.7 277 13.7 480 7.9 120/240 31.7/15.8 120 49.6 120/277 25/10.8 120 28.3 277 12.3 480 7.1 120/240 28.3/14.2 120 61.3 120/277 31.7/13.7 120 35 277 15.2 480 8.8 120/240 35/17.5 208 28.6 120/277 28.3/12.3 120 28.3 277 12.3 480 7.1 120/240 28.3/14.2 208 35.3 120/277 35/15.2 120 35 277 15.2 480 8.8 120/240 35/17.5 3.4 240 24.8 120/277 28.3/12.3 120 28.3 277 12.3 480 7.1 120/240 28.3/14.2 4.2 240 30.6 120/277 35/15.2 120 35 277 15.2 480 8.8 120/240 35/17.5 277 21.5 120/277 28.3/12.3 120 28.3 277 12.3 480 7.1 120/240 28.3/14.2 277 26.5 120/277 35/15.2 120 35 277 15.2 480 8.8 120/240 35/17.5 480 12.4 120/277 28.3/12.3 120 28.3 277 12.3 480 7.1 120/240 28.3/14.2 480 15.3 120/277 35/15.2 120 35 277 15.2 480 8.8 120/240 35/17.5 120/277 28.3/12.3 120/277 35/15.2
Operation Start Up WARNING: Faliure to call for phone assistance for the initial start-up will void the warranty. With utility input power is present at the input terminal block of the Lighting Inverter System and the battery are connected to the DC circuit breaker; 1. Ensure that the bypass switch is in the BYPASS position. 2. Turn on the DC circuit breaker (CB2). 3. Turn on the input (utility) circuit breaker (CB1). 4. The display will then cycle through the LED s. 5. Turn on the output circuit breaker (CB3). If this is the first time the unit has been turned on, or the load has changed, verify that the output load does not exceed the rating of the system. 6. Turn off all CB s; open maintenance bypass switch (MBS) cover plate; rotate MBS to UPS position. Repeat steps 1-4 with MBS on UPS, continue to step 6. 7. After the cycling of the LED s press the Control Key and the On Key at the same time. WARNING: Do Not overload the Lighting Inverter System. Refer to the wattage rating of the unit to ensure no overloading. Turning System Off 1. Press and hold the Off Key and the Control Key simultaneously until the inverter LED turns off. 2. The system will now switch to bypass and turn off the inverter. 3. Turn off the input circuit breaker (CB1). 4. Turn off the battery circuit breaker (CB2). 5. Turn off the output circuit breaker (CB3).
Manual Bypass NOTE: Operation of the bypass switch will cause the inverter switch to static bypass and turn off the inverter if it was running. NOTE: If the cover over the manual bypass switch is not secured properly the inverter will not start and there will be an audible beep every one (1) to two (2) minutes. WARNING: The manual bypass switch should only operated by authorized personnel. Battery Run Audible Alarm When the system is running on Battery Backup mode, the system will emit an audible alarm. The alarm stops when the Lighting Inverter System returns to Normal mode operation. Pressing the On/Test/Mute key can silence the alarm during backup mode. In the backup mode the alarm occurs every 4 seconds until low battery. Low Battery (Rapid Alarm) In the Backup mode, when the energy of the battery is 5% - 10%, the system beeps rapidly until the system shuts down. NOTE: The Low Battery alarm condition cannot be silenced. Direct Communications The Lighting Inverter System has an interface allowing direct communication via RS232, the location of which can be found on the top shelf on the right hand side in the back. See the system component diagram exact location. Please see the interface section for more information.
Maintenance Factory-trained personnel should perform maintenance only. Factory training is available. Training can be done on-site, over the phone or at the factory. Do not attempt to service. Various maintenance contracts are available; please contact customer service for more details. Technical Support For technical support or help with any questions not covered in the manual, contract: DSPM Inc. 1921 S. Quaker Ridge Place Ontario, CA 91761 Work Hours: 8 a.m. 5 p.m. Pacific Standard Time Phone: 1.877.DSPM.POWER 1.877.377.6769 After Hours: 5 p.m. 1 a.m. Pacific Standard Time 951.840.0811 Fax: 909.930.3335 techsupport@dspmanufacturing.com Battery Connections Please see the inside door of your unit to see the battery layout. Battery interconnects are provided by factory. Cabinet interconnects provided by other (if applicable). If you have any further questions about battery connections please contact DSPM.
Environmental Control Module BLACK (Normally Closed) ECM Technical Drawing 0.10 1.28 BLUE (Normally Open) RED (Common) WHITE (Neutral) GREEN/YELLOW (120Vac) ORANGE (280-277Vac) 11.00 11.50 1.68 1.98 1.08 ECM Bypass Wall Switch Battery Pack(s) DSPM IN Hot Neutral Ground Utility ECM Interface ECM Interface Emg. Hot Emg. Neutral White GrnYel / Org (test) Wall Switch Black Red ECM Blue Hot Neutral Test Line = GreenYellow 120 VAC / Orange 277 VAC 20 Amps Maximum Hot Neutral Normal Normal ECM Interface ECM Stand-By Mode Battery Pack(s) DSPM IN Hot Neutral Ground Utility ECM Interface Emg. Hot Neutral White GrnYel / Org (test) Black (emg hot) Blue (other input) ECM Red To Other s Test Line = GreenYellow 120 VAC / Orange 277 VAC 20 Amps Maximum
ECM Standard Dimming Panel (DIM SECT) (NON-DIM SECT) 208V Line In NI Dimmer Panel DSPM Battery Pack(s) Black Prewired Pigtail GreenYel/Org (test line) Blue Non-Emg ECM White Red Emg Non-Emg Emg Test Line = GreenYellow 120 VAC / Orange 277 VAC ECM Emerg. Dimming Bypass Utility Dimmer Panel Hot Hot Ground Hot Neutral ECM Interface DSPM NI Battery Pack(s) ECM Interface Emg. Hot Emg. Neutral Blue Black White GrnYel / Org (test) ECM Red H N H N To Other s Test Line = GreenYellow 120 VAC / Orange 277 VAC 20 Amps Maximum ECM Override Wall Switch Battery Pack(s) Black (hot) DSPM Green (ground) NI White (neutral) Utility Test Line = GreenYellow 120 VAC / Orange 277 VAC 20 Amps Maximum GreenYellow / Orange (test) Black (Emg. Hot) White (neutral) Optional Panel White (neutral) White (neu.) Yellow (test line) Black (emg. hot) Blue (other input) ECM Lamp Red (hot out) To Other s
ECM Interface ECM Normally OFF Wiring Battery Pack(s) DSPM NI Hot Neutral Ground Utility ECM Interface Emg. Hot Neutral Test Line = GreenYellow 120 VAC / Orange 277 VAC 20 Amps Maximum White GrnYel/Org (test) ECM Black Red Blue (other input) To Other s ECM Nitelite Override Mode Battery Pack(s) DSPM Test Line = GreenYellow 120 VAC / Orange 277 VAC 20 Amps Maximum NI Hot Neutral Ground Utility ECM Interface ECM Interface Emg. Hot Emg. Neutral Red Photo Sensor Red YelGrn/Org (test) White Black ECM Blue (Other Input) To Other s ECM Low Voltage Control Battery Pack(s) Line In Black (hot) IN DSPM IN Green (ground) White (neutral) Main Panel GreenYellow / Orange (test line) Black (emg. hot) White (neutral) White (neutral) Optional Panel Yellow (test line) Black (emg hot) Blue (other input) ECM Low Voltage Relay Red (hot out) To Other ECM s Low Voltage Control To Other s Test Line = GreenYellow 120 VAC / Orange 277 VAC 20 Amps Maximum
Emg. & Non Emg. Common Switch Battery Pack(s) Line In IN Black (hot) DSPM Green (ground) IN White (neutral) Main Panel GreenYellow / Orange (test line) Black (emg. hot) White (neutral) Optional Panel Blue (non-emg out) Non- GreenYellow (test) White (neutral) Black (emg. hot) ECM Test Line = GreenYellow 120 VAC / Orange 277 VAC 20 Amps Maximum Red (hot out) To Other s ECM Gen. Standby Wall Switch Generator (or other power source) Utility Hot Neutral Ground Emg. Neutral Emg. Hot Ground Test Line = GreenYellow 120 VAC / Orange 277 VAC 20 Amps Maximum GrnYel / Org (test) White GrnYel / Org (test) White Wall Switch Blue Red ECM Black Hot Neutral Blue Red ECM Black Hot Neutral Normal Normal Line In ECM Generator Panel GEN Yellow (test) Blue Black ECM Red EMG
Trouble Shooting Problem Possible Reasons Solutions Doesn t operate after pressing ON/OFF switches. No lights on, no warning sounds. Fault light is on. The alarm keeps beeping. Input power source not available. Main input circuit breaker open. Time of pressing the ON button may be too short. Output short circuit or overload on Lighting Inverter System. Lighting Inverter System is broken. Check the input power. Check Lighting Inverter System input circuit breaker is ON. Keep pressing ON button for 1 second. Turn off Lighting Inverter System, take off all load to make sure there are no problems on it or any internal short circuits. Contact DSPM Inc. for service or help. Alarm keeps beeping. Unit is overloaded. Reduce some of the load. Utility indicating light is blinking. Available time of batteries is too short. Battery s light is on when the power is supplied by utility. The voltage of utility is exceeding Lighting Inverter input range. Batteries haven t been charged. Lighting Inverter System is overloaded. Batteries are aged and need to be replaced. The charger is out of order. The voltage of batteries is too low or batteries haven t been connected. Verify input voltage. Keep Lighting Inverter System ON for over 20 hours to recharge the batteries. Check out batteries part of the Lighting Inverter System, make sure they are well connected. If there is any damage to batteries, contact DSPM immediately.
Notes