SP-1000

User & Service

Manual
SP SERIES
CONTINUOUS POWER SYSTEM
MODELS COVERED:
SP1000SR
SP1000SN
SP1250SR PLUS
SP1250SN PLUS
Included with:
PIM30 & PIM60

CLARY CORPORATION
150 E. Huntington Dr.
Monrovia, California 91016
Telephone
626-359-4486

800-44 CLARY
Fax.  626-305-0254
World Wide Web  HTTP: // WWW.CLARY.COM
E-Mail  SALES @ CLARY.COM

Information contained herein is the property of Clary Corporation, is proprietary,

confidential, and not to be disclosed, disseminated or used except for the purpose
provided by
CLARY CORPORATION

P/N 510-13481-REV. E Date 06/29/10

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TABLE OF CONTENTS

Section 1 General Description

1.1 Introduction....................................................................................................... 5
1.2 Operating Modes .............................................................................................. 5
1.3 Physical Description ......................................................................................... 8

Section 2 General Characteristics

2.1 General Characteristics .................................................................................. 13
2.2 Specification ................................................................................................... 16

Section 3 Installation and Operations

3.1 Installation ...................................................................................................... 19
3.2 Preparation ..................................................................................................... 19
3.3 Procedure ....................................................................................................... 21
3.4 PIM-Summary of Connectors.......................................................................... 22
3.5 Operation Configuration and Setup................................................................. 24
3.6 Operation........................................................................................................ 26
3.7 Optional Communication Procedure ............................................................... 27

Section 4 Adjustments
4.1 Adjustment Overview for DOS Programs ........................................................ 29
4.2 Adjustment Overview for Windows Programs ................................................. 34

Section 5 Care and Maintenance

5.1 Safety ............................................................................................................. 41
5.2 Preventive Maintenance ................................................................................. 42
5.3 Trouble Analysis ............................................................................................. 43
5.4 Service and Repair ......................................................................................... 44

Warranty ................................................................................................................. 45

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LIST OF FIGURES
Figure 1 Front Panel View ............................................................................................ 8
Figure 2 Rear Panel View .......................................................................................... 10
Figure 3 PIM30 & PIM60 Front View .......................................................................... 22
Figure 4 PIM To Cabinet Interconnections …………. ……………………………………24
Figure 5 PIM30 Simplified Schematic Diagram ......................................................... 25
Figure 6 PIM60 Simplified Schematic Diagram ......................................................... 25
Figure 7 Signal/RS232 Pin Assignments ................................................................... 28

LIST OF TABLES
Table 1 Front Panel View ............................................................................................. 9
Table 2 Rear Panel View............................................................................................ 10
Table 3 Electrical Specifications ................................................................................. 16
Table 4 Physical Specifications, UPS Electronics Module .......................................... 17
Table 5 Physical Specification, PIM Module ............................................................... 17
Table 6 Environmental Specifications ........................................................................ 17
Table 7 Battery Specifications .................................................................................... 17
Table 8 Clary OutPostTM Batteries* ............................................................................ 18
Table 9 Recommended Installation Equipment .......................................................... 20
Table 10 Installation Procedure For Traffic UPS .......................................................... 21
Table 11 Preventive Maintenance Schedule ................................................................ 43

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“IMPORTANT SAFETY INSTRUCTIONS”

“SAVE THESE INSTRUCTIONS”
This manual contains important safety instructions that should be followed during installation
and maintenance of the UPS and batteries. The instructions should be followed during installation
and maintenance of the UPS and batteries. Be aware of the following symbols and their meaning
as they appear throughout the manual:

This symbol indicates that This symbol indicates that

dangerous voltage there are important CAUTION
constituting a risk of
electrical shock is present
within the unit.
! operating and
maintenance instructions
in the literature
RISK OF ELECTRIC
SHOCK DO NOT OPEN
!
accompanying this unit.

Earth Ground Symbol:

On / Off Symbol:

Internal Battery Voltage is 72 VDC.

Maximum Ambient Temperature 74°° C.

This unit intended for installation in a controlled environment (temperature controlled, indoor area
free of conductive contaminants).

CAUTION – Do not dispose of batteries in a fire. The batteries may explode.

CAUTION - Do not open or mutilate the batteries. Released electrolyte is harmful to the skin and
eyes. It may be toxic.

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.
1. Remove watches, rings, or other metal objects.
2. Use tools with insulated handles.

FCC-Rules
This equipment generates and uses radio frequency energy and if not installed and used properly in strict accordance with the
manufacturer's instructions, may cause interference to radio and television reception. All units in this manual have been tested and
found to comply with the limits for a Class A computing device in accordance with the specifications in Subpart J of Part 15 of FCC
Rules, which are designed to provide reasonable protection against such interference in a commercial installation. However, there is
no guarantee that interference will not occur in a particular installation. If this equipment does cause interference to radio and
television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:
 Reorient the receiving antenna.
 Relocate the UPS with respect to the receiver.
 Move the UPS away from the receiver.
 Plug the UPS into a different outlet so that the UPS and receiver are on different branch circuits.
If necessary, the user should consult the dealer or an experienced radio/television technician for additional suggestions. The user may
find the following booklet prepared by the Federal Communications Commission helpful:
"How To Identify and Resolve Radio-TV Interference Problems"
This booklet is available from the U.S. Government Printing Office, Washington, DC 20402, Stock No. 004000003454.

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Section 1
GENERAL DESCRIPTION
1.1 INTRODUCTION
You have selected the highest quality power protection system available for your traffic control
devices. You now own a SP Series Traffic UPS (Uninterruptible Power System). The SP Series
is an all Digital Technology UPS product designed and manufactured by Clary Corporation, the
first name in UPS reliability. Clary UPS can be found on naval warships and submarines, hospital
operating rooms, labs, water treatment plants and traffic intersections. The SP (Signal Power)
Series offers a rugged, compact package with superior features and performance you can depend
on.

When power problems occur, there can be no compromising the operations and reliability of your
traffic control devices - - and no compromising public safety. With fully conditioned, regenerative,
sine wave power and military-quality battery backup, the SP Series Traffic UPS is your complete
power solution.

This Owner’s Operating Manual is provided with your new SP Series Traffic UPS. It will enhance
your understanding of the product and its functions.

WE STRONGLY URGE YOU TO READ THIS MANUAL COMPLETELY, PRIOR TO

BEGINNING INSTALLATION OR ATTEMPTING OPERATION.
Studying this manual will save you time and effort in your installation and application, and it will
assure a trouble free installation and startup session, thus enhancing public safety and the image
of your agency.
The illustrations provided will familiarize you with this product’s operating modes and components.
Always operate the unit within the guidelines and specifications provided to maximize safety and
the lifetime of the unit. Your understanding of the product is a key element in assuring the proper
use and effectiveness of the SP Series Traffic UPS.

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1.2 OPERATING MODES

Clary’s SP Series Uninterruptible Power Systems (UPS) are designed for powering low power
(i.e., LED & NEON) traffic & pedestrian indications, plus critical traffic control devices (i.e.,
controllers, modems, CMU’s, etc.). The power system consists of three elements, which work
together to provide critical loads with continuous, conditioned, regulated, sinusoidal waveform
power that is free from disturbances such as spikes, surges, brownouts or blackouts. These
elements are the:
1. UPS Module – (UPS)
2. Power Interface Module - (PIM)
3. Battery Module
Backup power is achieved with a set of rechargeable, SVRLA (sealed valve-regulated lead-acid),
maintenance-free, AGM (absorbed glass mat), batteries. The complete UPS system is controlled
by an onboard digital microprocessor at all times.
There are two basic modes of operation:
• Standby Operating Mode
• Continuous Operating Mode
In both modes, the UPS continuously generates 120V AC power. The selected mode determines
when and how the UPS generated power is applied to the loads in the traffic cabinet.

Standby Operating Mode:

During Standby operation, utility (AC) power enters the PIM and passes through a normally
closed, contactor then directly out to the cabinet power bus, PDA, etc. This utility power is used
to power the intersection until a power disturbance occurs at which time, the contactor is
switched, routing the UPS generated AC power to the cabinet power bus. Typically, the UPS will
then be drawing its power from the battery pack. This operation continues until good utility power
is restored, after which, the contactors switch back to route the utility power to the loads.

With Standby operation, 0.5 seconds (user programmable from 30ms to 2.5sec) after an outage is
detected, standby power is connected to the system and if desired, the Flash Command is
initiated, forcing the cabinet into Flash Mode operation. Depending on the size of the battery
system being used and the loading on the power system, backup power can continue for several
hours. NOTE: If the flash mode operation is not desired, make sure intersection load is not over
875 watts.

When utility power returns, (or upon application of generator power) the SP Series UPS waits 30
seconds to be sure that the utility power has stabilized. After this built-in safety delay utility power
is restored to the cabinet. The battery charger then recharges the batteries in typically 10 to 20

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times (depending on the load) the duration of the outage or battery discharge time (whichever is
shorter).

The UPS can be set to force a break in power of 2.5 seconds after utility power returns. This is
optional (not the default) and is used in intersections when a hard-restart needs to be applied to
various devices when returning from flash.

With Standby operation, the ONLY required change to cabinet wiring occurs by the introduction of
the PIM. Removal and Replacement (R&R) of the UPS module is quick and easy even with traffic
control devices (TCD’s) connected to the UPS. If no TCD’s are plugged into the UPS module (i.e.
being used for LED flash backup only), R&R of the UPS module (for upgrades or in the rare event
of UPS failure) can be done without powering down the cabinet or otherwise affecting cabinet
operation in any way.
Continuous Operating Mode:
Continuous operation is used for low power applications such as full LED intersections, power to
the intersection is continuously conditioned and backed up by the UPS. Within the limitation of
the battery capacity, virtually all brownout and power outages are eliminated.
SP1250 PLUS OPTIONAL
The SP1250 PLUS has an extended load option that will allow 1400watts peak load for ten
seconds. This option allows for support of intersections that have not yet replaced the yellow
incandescent traffic lamps.
Additional Notes on Operating Modes:
• A generator can also be connected up and fed through the PIM to provide indefinite
auxiliary backup of the intersection.
• The SP Series Traffic UPS is designed for compatibility with, and complete transparency
to, all traffic signal cabinet functions including police panel operation.

Flash Operating Modes:( For PIM 30 Model only)

The PIM includes three (3) sets of normally-open (NO) and normally-closed (NC) relay style
contacts. The contacts are intended to connect to the Flash controllers or other devices in the
traffic cabinet. The contacts are actuated at various times as a means of signaling these devices
of important aspects of current operation. These three relay contact sets are labeled and switched
as follows:

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Labeled Usage / Indication Notes

On-Batt UPS is operating from battery power. When unit is in standby
operation.
Timer UPS has been on battery longer than programmable Default time period is 2 hours.
threshold. Used as notice of shutdown coming from Programmable from 1 to 255
low-battery cutoff. minutes.
Low-Batt UPS is operating from battery and the battery voltage Default voltage is 69V (about
has fallen below a programmable threshold. Used as 40% capacity.) Programmable
notice of shutdown coming from low-battery cutoff. from 60 – 80 volts.

1.3 PHYSICAL DESCRIPTION

This section will point out and illustrate the various indicators, functions and controls of the SP
Series UPS. The important attributes of the SP Series unit are numbered to assist you in locating
them on your machine and also to fully explain its function and how it relates to system operation.
Numbers on the drawing will correspond to the operating component’s name at the bottom with a
brief identification. In the next section, a complete explanation of all numbered items will be
enhanced to ensure you have a full understanding of the operation of this system.
Visual indicators used on the front panel are long lasting, very efficient, light emitting diodes
(LED). When operating the push-button switches, always hold the switch in for at least two
seconds to insure function confirmation. This feature has been implemented into the system
design to avoid inadvertent operation of any of the user-available functions.
Figure 1 is the front view of the model SP1000SN. Model SP1000SR is identical in operation;
however, items 17 through 22 have been repositioned to the rear panel.
Table 1 describes items 1 – 22.

7 8 3 4 9 5 13 19 21 22

11

10

1 2 6 15 14 12 16 17 20 18
Figure 1: FRONT PANEL VIEW

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Table 1: FRONT PANEL VIEW

FRONT PANEL VIEW

HOUR METER – Battery runtime meter in

1 SYSTEM POWER SWITCH 12
hours
EVENT COUNTER– Counts power
2 INPUT AC LINE FUSE 13
interruptions
INVERTER – Inverter operating RESET – Clears Event Counter back to
3 14
indicator zero
UPS OUTPUT PRESENT – Output
4 AC IN – Input line indicator 15
indicator
LOAD LEVEL – Output capacity DC INPUT– Protection circuit breaker for
5 16
indicators battery
BATTERY LEVEL -- BYPASS – Protection circuit breaker for
6 17
Charge/discharge indicators bypass
7 COLD START – DC start switch 18 RS232 – Computer communications signals
COLD START ACKNOWLEDGE UPS OUTPUT – Continuous power
8 19
INDICATOR receptacle
9 ALARM – Fault indicator 20 SIGNAL – Open-collector signal contacts
ALARM SILENT/TEST – Dual AC IN / OUT – Input receptacle for all AC
10 21
function switch power (to PIM)
ALARM SILENT/TEST DC IN – Input receptacle for all DC power
11 22
ACKNOWLEDGE INDICATOR (to Batteries)

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26 24 25 19 21 22

Figure 2: REAR PANEL VIEW 17

15 16 23

Table 2: REAR PANEL VIEW

REAR PANEL VIEW

23 SYSTEM GROUNDING STUD

24 SNMP – (optional) Slot for sophisticated Network monitoring
25 FAST CHARGER MODULE (optional) Slot for extra charging module
IDENTIFICATION LABEL – The system Model number and Serial number
26
are identified here

SUMMARY OF INDICATORS AND CONTROLS

SYSTEM POWER SWITCH - The main control switch that engages utility power to the
entire unit. By activating this switch it initializes normal operation.

NOTE – The DC INPUT circuit breaker must be on before activating the System
! On/Off switch.

DC INPUT - A two pole, 20A (25A for SP1250 PLUS) circuit breaker used to connect the
battery to the internal UPS electronics. It also protects against over-current situations in the
battery circuit.

INPUT AC LINE FUSE - The input line protection device to limit excessive current draw to
the system.

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INVERTER - This indicator identifies the status of the regenerated, conditioned protected
output power. This indicator will stay ON as long as protected power is available from the
power inverter generator.

AC IN - The utility input indicator that identifies status of the line voltage. If the line voltage
is within the specified range, it will remain lit. If the AC input is out of range, but present,
the indicator will slowly blink.

LOAD LEVEL - This is the system output capacity status bar. The number of LEDS
illuminated indicates an approximate percentage of system load. All green LEDS
illuminated would indicate full load. The top red LED illuminates on over-loads.

BATTERY LEVEL - This is the battery status bar graph. During normal operation, this bar
graph will show the charging of the battery; all indicators lit will represent a fully charged
battery. During battery operation, this bar graph represents a discharge meter indicating
less battery time available as each light goes OFF. If Battery status LEDs are blinking, the
unit has failed a battery self test. See Trouble Analysis section on page 43 for more
information.

COLD START - A momentary push-button switch to activate the system in the event no
utility power is available. The system will be allowed to start up by using power from the
battery. Depress this switch, the indicator above it will light, and hold it in until the audible
alarm beeps once. The system will maintain a load for a period of time depending upon the
condition of the battery. DC INPUT breaker must be ON.

ALARM - This is a fault indicator that will light in the event that the inverter generator is non-
operable. This could be due to an over-temperature situation or an inverter malfunction.

NOTE - Cold Start and Alarm Silent switches must be held in for at least two
! seconds to engage their function. This is to prevent any inadvertent switch
operation.
HOUR METER - A cumulative run time meter that shows the total battery run time for the life
of the unit.

EVENT COUNTER - A meter that counts the number of times the system has gone into
battery operation. The Event Counter also increments each time the unit is turned off and
on by the SYSTEM POWER SWITCH.

RESET- A momentary pushbutton switch that resets the Event Counter to zero.

UPS OUTPUT PRESENT - A green LED that is illuminated to indicate fully conditioned and
continuous output AC power is present at the output receptacle.

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RS232 - A DB-9 subminiature, female connector that outputs true RS232 communications
signals.

UPS OUTPUT - A NEMA type duplex, 5-15R output connector that provides continuous
power. This receptacle is connected to the bypass line when the inverter is not running.
NOTE: This output provides continuous UPS power even when UPS is in the offline mode.
Do not load more than the rated output of the UPS(including what is already loaded through
the PIM).

BYPASS - A 15A protective circuit breaker in the bypass line of the continuous output
circuit. Protects the UPS OUTPUT 5-15R connector noted above.

SIGNAL - A DB-9 subminiature, female connector that outputs the open-collector signal
contacts that generate a low state during utility interrupt, low battery and inverter off
conditions.

AC INPUT - A circular locking connector provided for AC power to and from the UPS to PIM.
DC INPUT - A circular locking connector provided for battery power to the UPS.

NOTE – For safety purposes, these AC INPUT and DC INPUT connectors are
! tied into an interlock system which ensures that if either connector is
disconnected, the unit will discontinue operation.

SYSTEM GROUNDING STUD - A 10-32 x 3/4 threaded stud for system grounding
termination.

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Section 2
GENERAL CHARACTERISTICS
2.1 CHARACTERISTICS

Overview
The Clary SP Series Traffic UPS is a turnkey, true on-line, power conditioner and battery backup
or uninterruptible power system (UPS) designed for the extreme environments found in traffic
cabinets (-40 to + 74 deg C).

The Clary SP Series, with its standard 41Ahr battery pack, is capable of operating, a full LED
intersection for over 2 hours at 700W (watts) output. A typical intersection consuming 450W can
be powered for approximately 4 hours. In Red-Flash operation, which consume only about 300W,
over 6 hours of backup is possible. These times assume fully charged batteries at the ambient
temperature of 25C.

Operation
The Traffic UPS is capable of producing – simultaneously -- full regenerated and regulated, true
sine wave power, with standby and continuous AC outputs. The Power Interface Module (PIM) is
the link between the utility power, the UPS power, and the loads.

When utility power is adequate, the PIM routes that power to the loads. Upon loss of utility power
the Traffic UPS routes UPS generated power to the loads. In the event of UPS failure and/or
battery depletion, the PIM will ensure that the UPS will drop out and, return to utility power when
available. The traffic control system will then default to normal operational mode.

The Power Interface Module (PIM) enables removal and replacement of the Traffic UPS without
shutting down the traffic control system (i.e. “hot swap” capability). Connectors are equipped with
a “safety interlock” feature.

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For 170 type cabinets, upon loss of power the Traffic UPS can actuate the existing Flash Transfer
Relays (FTRs), Mercury Contactor (MC) or Railroad Preemption to allow the traffic control system
to put the cabinet into Flash Mode operation.

Existing Flasher Modules and Flash Transfer Relays are utilized. The Traffic UPS does not
duplicate or take over flash operation or flash transfer relay functions.

The Traffic UPS is capable of providing continuous, fully regenerated, conditioned, regulated,
sinusoidal (AC) power to selected devices such as signal controllers, counters, modems,
communications hubs, NTCIP adapters, video equipment, etc.

To facilitate emergency crews and police activities, the Traffic UPS is compatible with police panel
functions (i.e. “Signals OFF” switch must kill power to the field wiring even when on UPS/Battery
power).

Utility Voltage Windows and Battery Operation

The UPS operates from utility if the utility voltage is between 85 and 135 vac. When the utility
falls below 85 vac or climbs above 135 vac the UPS operates from the batteries. In the Standby
modes of operation, the PIM is activated when the utility is below 100 +/- 2 VAC or above 130 +/-2
VAC.

There is a programmable noise rejection window, which specifies how the UPS system treats
small time-duration power glitches. Power disturbances must last at least 40ms to trigger change
in operation. Small disturbances on this order occur frequently due to many different conditions.
These disturbances, however, are not detrimental to traffic controllers. To minimize nuisance
switching this noise rejection window is implemented. See page 38 to program.

After operating in Standby mode, the UPS monitors the utility voltage. When this voltage is
restored to adequate conditions for 30 seconds, the UPS returns utility power to the cabinet.

Description

The Traffic UPS consists of three major components, the UPS Power Module, the Power Interface
Module, and the Battery System.

The UPS Power Module consists of the following:

• True on line, double conversion, pure sine wave, high frequency inverter utilizing IGBT
technology.
• Local individual indicators for battery status, load levels, battery run-time, and event counter.
• Two separate DB9F connectors for remote signal alarms and true RS232 monitoring and
remote communications.
• Multi-stage, temperature compensated battery charger.

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The Power Interface Module 30 contains a magnetic contactor for back feed protection and to
facilitate hot swapping of the electronics module. It is the primary interface between the UPS and
the cabinet.
The PIM houses the relays connected to the Flash controllers. These electro-mechanical relays
are controlled by signals carried to the PIM from the UPS’s SIGNAL port. These logic signals are
converted through optical switches into 120VAC levels, which are then used to switch the electro-
mechanical relays.
The Power Interface Module 60 contains two mercury contactors for back feed protection and to
facilitate hot swapping of the electronics module. The PIM 60 does not include the electro-
mechanical relays for the Low Battery and Timer function.
The Battery Module. The battery is comprised of one or more strings of 6 individual 12V batteries
connected in series for a total string voltage of 72V DC nominal.
The batteries are extreme temperature, deep cycle, AGM/VRLA (Absorbed Glass Mat/ Valve
Regulated Lead Acid) batteries that have been field proven and tested by the U.S. military. The
OutPostTM batteries supplied by Clary Corporation are certified to operate at extreme
temperatures from –40°C to +74°C.
The batteries are provided with appropriate interconnect wiring harness. Optional battery
mounting trays and brackets are available.
The interconnect cable connects to the base module via a quick-release circular connector.
The UPS module includes a charger that replenishes the Battery Pack whenever possible and
required. This charger operates with a maximum charging current of 0.6A at 72V. An optional
“Fast Charger” module plugs into the UPS module to increase the charging current to over 3.5A at
72V.

Mounting/ Configuration
NEMA Style: mounting method is shelf-mount or wall-mount.170 Style: Mounting method is 19”
rack-mount. Shelf angles or rails, typically supplied by others, are available as optional
accessories.
For purposes of safety and proper operation, the circular battery connector has interlocking pins
to prevent turn-on if battery system is not connected, and to shut off the UPS should the battery
system be disconnected.
Battery construction includes heavy-duty, inter-cell connections for low-impedance between cells,
and heavy-duty plates to withstand shock and vibration.

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2.2 SPECIFICATIONS
The various specifications of the UPS system are provided in the following tables.
Table 3: ELECTRICAL SPECIFICATIONS

Electrical Specifications
Input Specification
Nominal Input Voltage 120 VAC, Single Phase
Input Voltage Range 85 VAC to 135 VAC
Input Frequency 45 to 65 Hz (+/- 5%)
Input Configuration 3 Wire (Hot, Neutral & Ground)
Input Current (Max. draw) 8.8 amps, Power-Factor Corrected
Input Protection Input Fuse 15 amps (20 amps SP1250 PLUS)
Output Specification
Nominal Output Voltage 120 VAC, Single Phase
Power Rating 1.25 kVA (1250VA/875W)
Output Voltage Regulation +/- 2% for 100% step load change and from
High battery to Low battery condition

Output Frequency 50 or 60 Hz (+/- .5%) unit not in sync.

Output Configuration Keyed, circular connectors and duplex Receptacle.
Output Wave Form True Sine wave
Overload capability 110% for 10 minutes 200% for 50 milliseconds
2k PLUS 160% for 10 seconds
Fault clearing Current limit and automatic shutdown
Short circuit protection Current limit and automatic shutdown
Efficiency 90% at full load (on utility)
Load Power Factor .7 lagging through unity to .7 leading

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Table 4: PHYSICAL SPECIFICATIONS, UPS ELECTRONICS MODULE

Physical Specifications, UPS Electronics Module

Dimensions:
Rack-mount units:
Width = 19”, Depth = 13”, Height = 3.5” (2U)

Shelf-mount units:
Width = 19”, Depth = 13”, Height = 3.5”

Wall-mount: / Unistrut Rail mount units:

Width = 19”, Depth = 13”, Height= 3.5”

Weight: UPS: 20 lbs., Shipping weight: 25 lbs.

Table 5: PHYSICAL SPECIFICATIONS, PIM MODULE

Physical Specifications, PIM Module

Dimensions:
Width = 6”, Depth = 2.8”, Height = 9”

Weight: PIM: 5 lbs., Shipping weight: 5 lbs.

Table 6: ENVIRONMENTAL SPECIFICATIONS

Environmental Specifications
Temperature: - 40°C to +74°C.

Table 7: BATTERY SPECIFICATIONS

Battery Specifications
Temperature: – 40°C to +74°C.
Ampere-Hour ratings: see Table 8
Hydrogen gas emissions: meets Mil-Spec #MIL-B-8565J

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Table 8: CLARY OutPostTM BATTERIES*

Estimated Runtime
(Per set @ 77°F / 25°C) Unit Overall Dimensions
(New Batteries, fully Weight Per Battery Inches (cm.)
charged)
Clary Volts/ 300 500 700 875 Lbs. Length Width Height
Watts Watts Watts Watts
Part. No.* A-hrs. (Kg.) L W H
OP72C 12 6.5 4.0 2.5 1.8 29 7.68 5.15 7.9
(Set of VDC/
Hrs.** Hrs.** Hrs.** Hrs.** (13.2) (19.6) (13.1) (20.1)
Six
41 AH
Batteries)

*OP72X battery sets include six (6) batteries per set. Wired in series, each set provides 72 VDC.
** Actual times may vary, runtimes are dependent on many factors.
Lower/Higher AH capacity batteries, allowing less or more runtime, are available on special order.
Contact factory for more information.
Communications, Controls & Diagnostics
Alarm Function Monitoring: The traffic UPS comes standard with a DB-9F connector with open
collectors (40 V @ 20 mA) indicating On-Battery, Low-Battery, Timeout on-battery and Alarm.
A separate RS232 Interface is provided via a DB-9F connector allowing full, interactive, remote
computer monitoring and control of the UPS functions via standard UPS protocols.
Optional TCPIP/Ethernet available, contact factory for more information.
Front Panel controls: Power ON, Cold (DC) Start, Alarm Silence, Battery Test, Bypass Circuit
Breaker, and DC/Battery Circuit Breaker.
Options
Battery Tray to hold three (3) OP72C batteries is 19” wide for use in 170 type cabinets and
mounts on standard RETMA rails.
Swing-out Battery Box, mounts on right rail inside back door of 170 type cabinets. Box is designed
to hold tree (3) OP72C batteries
Fast Battery Module, optional module provides extra charging current to the batteries when
required, reducing charging time.

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Section 3
INSTALLATION AND OPERATIONS
3.1 INSTALLATION
The UPS system is typically rack or shelf mounted in standard traffic cabinets. When determining
how to position the UPS system inside your cabinet, the following requirements MUST be met.
• The installation site MUST maintain an ambient air temperature of less than 165oF (74oC).
• The air inlets, vents and fan MUST NOT be obstructed or blocked in any way. There MUST
BE clearance around each air-inlet and vent.
• The air should remain free from excessive dust and chemical fumes.
• Total power requirements to be drawn from the UPS must not exceed the rated power of the
UPS.

Please note these items when designing the UPS system’s mounting hardware:
• The front panel is designed to fit in a standard 19" rack. This panel fills a 3.5-inch slot.

3.2 PREPARATION
Installation of the SP Series Traffic UPS must be preceded by careful preparation. The following
steps are typical:
• Ensure that the Installation Requirements will be met. (See previous section).
• Read this manual thoroughly.
• Assemble wiring diagrams.

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• Unpack and ensure that all UPS System components are on-hand and operative:
o UPS System Module
o Power Interface Module (PIM) w/mounting bracket
o Battery Module (6 batteries w/cabling)
• Collect appropriate mounting hardware for the particular installation.
o For 170/332 cabinets only, one or two battery trays (per shipping documents, depends
on version purchased)
• Assemble your tools and inventory your equipment. Table 9 is a checklist of items that have
proved useful during previous installations.
• Contact the responsible agencies to schedule a brief power down (10 to 15 minutes) at the
intersection(s) affected.
• Allot 2 hours of time for the installation.

Table 9: RECOMMENDED INSTALLATION EQUIPMENT

Armored sheathing (cable protector) Connectors (butt type and
insulated)
Cordless drill w/ bits and a spare Crimpers (for insulated and non-
battery pack insulated connectors)
Dikes DVM w/ probes
Electrical Tape Flat Head screwdriver
Hardware in spill-proof carrying case Hold-downs (adhesive back)
Nut Driver Set #2 Phillips head screwdriver
Phillips head drill bit Propane torch (miniature) or
cigarette lighter
Shrink tubing Socket Set
Socket Wrench Current clamp meter
Wire cutters Wire strippers

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3.3 PROCEDURE
The recommended installation procedure is presented in Table 10 . The Table refers to, which
presents a schematic wiring diagram.

Read through the entire procedure before beginning. If any steps are unclear, do not begin the
installation process – please contact Clary Corporation for assistance.

Finish each step completely before continuing to the next.

Table 10: INSTALLATION PROCEDURE FOR TRAFFIC UPS

1. Mount Power Interface Module (PIM) in Vertical Position. The PIM mounting bracket can be
removed and repositioned in a number of different directions to accommodate most
applications. The PIM may be mounted near the bottom of the cabinet perpendicular to the
sidewall.

IMPORTANT! PIM 60 MUST BE MOUNTED IN A VERTICAL POSITION.

2. Disconnect utility input from input terminal block (cabinet side) and connect to Out H terminal
of PIM.
3. Connect Common N terminal of PIM to neutral bus using AWG #8 wire.
4. Connect Common G terminal of PIM to ground bus using AWG #8 wire.
5. Connect Flash connections in the PIM.
a. If immediate Flash on battery is desired, connect to “On Batt” terminals. (“FLASH” for
PIM 60)
b. If delayed Flash on battery is desired, connect to either “Timer” or “Low-Batt”,
depending on installation needs. (Only on PIM 30)
c. Use either NO or NC contacts as required.
d. “Timer” and “Low-Batt” connections can be paralleled if desired to produce Flash if
either condition is present. (Only on PIM 30)
6. Connect utility input cabinet side to input H of PIM.
7. Mount UPS in cabinet.
8. Mount batteries and connect interconnect cables.
9. Connect PIM to UPS:
a. Power cable (circular connector and cable)
b. Signal port (db9 style connector and cable) (Only on PIM 30) NOTE: Green LED on
bottom of PIM30 must be illuminated for delays to work properly.
10. Connect batteries to UPS. Make sure six batteries are wired in series (+ to -) with 72VDC full
potential across complete string.
11. Test installation for proper operation.
12. Document installation.

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3.4 PIM: SUMMARY OF CONNECTORS

Figure 3: PIM30 & PIM60-FRONT VIEW

PIM30 PIM60

 
  


4 5 7 4 9
6

2 3
1
1

PIM30 & PIM60

NO AND NC RELAY CONTACTS
1 AC IN/OUT CABLE TO UPS 6
FOR “LOW BATTERY”
NO AND NC RELAY CONTACTS
2 SIGNAL CONNECTION TO UPS 7
FOR “TIMER”
LED INDICATING SIGNAL
3 OPEN COLLECTOR 8
CONNECTION TO UPS
MAIN POWER TERMINAL BLOCK NO AND NC RELAY CONTACT FOR
4 9
(HIGH VOLTAGE) “FOR FLASH AND STOP TIME”
NO AND NC RELAY CONTACTS
5
FOR “ON BATTERY”

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3.4 PIM: SUMMARY OF CONNECTORS

Figure 3: PIM30GR-FRONT VIEW

PIM30

1 (800) 44-CLARY

GENERATOR
INPUT

POWER INTERFACE
MODULE

GFCI
OUTLET

10 OUTLET
CIRCUIT BREAKER

11

5 7
4
6

1 2 3 8

PIM30 & PIM60

NO AND NC RELAY CONTACTS
1 AC IN/OUT CABLE TO UPS 6
FOR “LOW BATTERY”
NO AND NC RELAY CONTACTS
2 SIGNAL CONNECTION TO UPS 7
FOR “TIMER”
LED INDICATING SIGNAL
3 OPEN COLLECTOR 8
CONNECTION TO UPS
MAIN POWER TERMINAL BLOCK NO AND NC RELAY CONTACT FOR
4 9
(HIGH VOLTAGE) “FOR FLASH AND STOP TIME”
NO AND NC RELAY CONTACTS
5
FOR “ON BATTERY”

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3.5 OPERATING CONFIGURATION AND SETUP:

Illustration shows how the PIM is connected to the traffic cabinet. This schematic diagram
illustrates the interconnections.

Figure 4: PIM TO CABINET INTERRCONNECTIONS

OPTIONAL
1 (800) 44-CLARY

GENERATOR
INPUT

POWER INTERFACE
MODULE

GFCI
OUTLET

OUTLET
CIRCUIT BREAKER

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Figure 5: Power Interface Module (PIM30)– Simplified Schematic Diagram

K1
A
B

AC+ IN NC
1
NEUTRAL
2 NO
C
GROUND
3
AC+ OUT
4
ON BATTERY C
5 NC 4 2
1
6 NO
7
TIMER C 3 5
8
NC
9 6 7
NO
10
LOW BATTERY C
11
NC
12
NO
13

RELAYS ON
NC

NC

NC
NO

NO

NO
PCB1
B

A
C

C
RLY1 RLY2 RLY3

7 2

BATTERY

11 13
12
9 SIGNAL COMMON
5 LOW BATTERY

2 UTILITY FAIL
6 +10VDC
1
4
8

7
3

Figure 6: Power Interface Module (PIM60) – Simplified Schematic Diagram

K1

TB1 MC1 MC2

NC NO
AC+ IN
H 1
NEUTRAL
N 2
GROUND
G 3
AC+ OUT
H 4
C 5 4 2
K1A 1
NO 6
NC 7 3 5

C 8 7
6
NO 9
K1B

NC 10

7 2

BATTERIES

11 13
12
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3.6 OPERATION
Once the system has been properly installed, it is ready to operate. The following procedures
will explain how to start-up the system while wired into rated electrical power and also how to
start-up with no AC power available.

Normal Operation on AC Start-Up:

• Verify that the unit is wired into properly rated electrical power through the Power Interface
Module (PIM).
• The AC IN and DC IN cables must be fully connected to the unit. There is an interlock
system that will not allow the SP unit to operate if either of these connectors are open.
• Position the DC breaker to the ON position. Must be turned on before turning on System
Switch. If not done in this order, you may see the Battery LEDs flashing.
• Position the System Power Switch to the ON position.
The system will proceed through about a three-second diagnostic where all the lights will
sequence ON then OFF. The AC IN light will flash several times and the audible alarm will
give a short burst. The AC IN light will then stay ON once it acknowledges acceptable input
voltage and frequency. The battery level meter will light to indicate battery charge. The
INVERTER light will come ON and power will be available at the output receptacles.
Continuous power is available at the output receptacles from the inverter. If the inverter is
powered down or should malfunction, a bypass circuit will maintain power at this receptacle.
This bypass line is protected through the Bypass breaker.

Battery Operation after AC Start-Up:

• Remove AC power from the system.
The AC ON light will flash. In stand-by mode, inverter power will be supplied to the PIM in two
timing steps to control the traffic equipment wired to the SP system, now powering the cabinet
in flash mode. In continuous mode, the cabinet operation will continue without interruption. A
small hourglass will be in motion within the HOUR METER.
If operation were to continue in this mode, the BATTERY LEVEL meter would start to turn
OFF, one light at a time. If the unit is allowed to operate further, it will time out and shut off
completely. If power were to return, the unit will automatically restart and return to the
condition it was in at the moment it went into Battery Mode.
Once power is returned, if in standby mode, inverter power to the traffic equipment will be
discontinued through the PIM in a sequenced timing operation. In continuous mode, the
cabinet operation will continue to operate without interruption. The EVENT COUNTER
METER will increment. The EVENT COUNTER METER can be reset by momentarily pushing
the RESET button located between the meters.
Total battery operation is recorded on the HOUR METER.

DC Start Operation (Cold Start)

If no utility power is available at the time backup power is required, the unit may be started to
accomplish abbreviated tasks. The limitations of the battery prevent extended operations at
full load.
• Position the DC Input Breaker to the ON position.
• Position the System Power Switch to the ON position.

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• Push and hold in the COLD START switch until the audible alarm beeps.
The unit will start up similarly to normal AC start-up except the AC IN LED will continue to
flash. It will now operate as described above in battery operation.
Loading the System
The system can be loaded up to full rated load. As load is applied, the LOAD METER will
start to turn ON. Once full load is achieved, the full LOAD METER should be lit. As additional
load is applied, the top red OVERLOAD LED will come ON. If too much overload is applied,
the audible alarm will sound. If this increased load is not removed within five seconds, the unit
will discontinue output operation and latch into an alarm condition. The audible alarm will
continue to sound and the ALARM LED will light. Reducing the load and cycling the System
Power Switch OFF then ON can reset the system.
Battery Self Test
Periodically the unit will perform a battery self test. The test is set to run every 160 hours. If
unit fails battery self test, the battery status indicators will be flashing. If this happens, see
Page 43 for troubleshooting help. Note: This test does not replace the need for regular
battery maintenance checks.

3.7 Optional Communication Procedure

The UPS system includes additional interfaces for communications to host computers or other
similar devices. Their use is optional, but allows for remote monitoring and control of the
power system. Effective utilization of these capabilities will enhance the reliability of the traffic
power system.

There are two DB-9, subminiature, female connectors. These are provided for
communications links to a computer or sophisticated monitoring device. These two
connectors are labeled and used as:

o SIGNAL provides open collector type contact closures that signal Utility Interrupt, Low
Battery and Timer conditions to the PIM. These in turn, activate the respective relays
named ‘On-Batt’, ‘Low-Batt’, and ‘Timer’. The SIGNAL port cables to the PIM. The
PIM provides a pass-through port to make these signals available to the user.
o RS232 is a true communications signal port. This port connects to standard PC-type
serial ports.

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SIGNAL PORT
2- UTILITY INTERRUPTED SIGNAL
3- INVERTER ACTIVE SIGNAL
4- COMMON SIGNAL RETURN
5- LOW BATTERY SIGNAL
6- + UPS SHUTDOWN
7- - UPS SHUTDOWN

RS232 PORT
2- TRANSMITTING DATA (TX)
3- RECEIVING DATA (RX)
6 & 8- DATA SET READY
5- SIGNAL GROUND

GN RX
LOW BATTERY
TX
INVERTER ACTIVE

5 3 2
UTILITY INTERRUPTED
5 1
DB-9F (Programmable: DB-9F
6 8
9 6 0 to 4Hr 15 Min.)

-
SYSTEM
SHUTDOWN +

SIGNAL: OPEN-COLLECTOR DSR

CONNECTOR

RS232: COMPUTER
CONNECTOR
Figure 7: SIGNAL/RS232 PIN ASSIGNMENTS

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Section 4
ADJUSTMENTS
4.1 Adjustment Overview for DOS Programs

CAUTION: The UPS has no required nor recommended field adjustments.

There are programmable features and calibrations used by the UPS. These are always preset
in the factory and fall into these categories:

• Identification: An assigned Factory ID Number and a User-programmable ID String.

• Statistical Information: Count and Timings of various modes. Reset to all zeros at the
factory.
• Option and Configuration Settings: Used to specify certain operations such as
Continuous or Standby Operation. Delay Flash indications (voltage trip points and
time-out periods) can also be specified.
• Calibration: Used to compensate for small offsets in reading internal voltages.

A factory supplied PC computer program SP1000.EXE is used to change these values.

Information is provided on how SP1000.EXE can be used to monitor and configure the UPS.

CAUTION: NEVER CHANGE ANY CALIBRATION PARAMETERS. Calibration

Parameters are calculated by special purpose factory instruments and the settings
are particular to each UPS. Changing these parameters can cause the UPS to mal-
function. The factory keeps records of the settings of each machine.

USING SP1000.EXE

SP1000.exe is distributed on a diskette. It requires a Laptop with serial port COM1 available.
The program runs under DOS and/or Windows. Copy all files to any directory on the hard-
drive.

Connect the UPS’s RS232 port to the Laptop’s COM1 port using a straight-thru 9 pin cable.
The UPS is ready for communications whenever it is powered on.

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Initiate the program by opening a MS-DOS command window or restarting in MS-DOS mode.
Then issue the command:

C:> SP1000
A window is presented giving various options. Submenus are available.

Clary Digital SP1000 Command Program Access: DEBUG

Version 12 of March 19, 2001

Command Choices:

?> Menu
Q> Quit

G> Control UPS Operation...

R> Reset UPS Oper/Stats...
S> Set Configuration...

A> Alarm Status

B> Battery Status
C> Configuration Status
I> Input Status
O> Output Status
U> User Status
Z> UPS Statistics

X> Diagnositics & Test ...

Command [?=Menu, Q=Quit] >

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CONFIGURING OPERATING CHARACTERISTICS

The UPS can be configured to operate either in Continuous or Standby Mode. The
parameters associated with Flash operation can also be set.

Start SP1000.exe. Enter ‘V’ to select Options Programming. The following menu is presented:

Option Settings:

1> OPT_STARTUP = 0F (hex)

2> OPT_RPANEL = 00 (hex)
3> OPT_FPANEL = FF (hex)
4> OPT_TRAFFIC = 20 (hex)
5> OPT_MISC = 06 (hex)
6> OPT_ALARM = 01 (hex)
7> BACKUP DELAY (x10 msec) = 4
8> OPT_DEBUG = 00 (hex)

A> FLASH TRIGGER (Min.s) = 120

B> FLASH TRIGGER (Volts) = 69
C> BACKUP STANDBY TIMEOUT = 0
D> BAT. TEST PERIOD (HRS) = 0
E> INTERFACE DELAY (x10 msec) = 0

Set Option Number: [q=quit,r=re-read] >

Enter the appropriate menu selection (1-8,A-E) to change a parameter.

Selections 1-8 represent numbers 0-255 and are entered in HEX format but without the ‘H’
indicator. For example, the number 47 is represented as 2F in HEX, ‘2F’ would be entered.
These values are stored in one byte (8 bits) in the UPS and interpreted bit-by-bit by the UPS
firmware. Each of the 8 bits potentially can be used to carry information, however, only a few
bits in each byte are used.

The options of relevance to the SP-1000 UPS system are described below.
For these options: the bit-mapping, default, and notes are given.

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OPT_TRAFFIC: (Enter Hex value)

OPT_TRAFFIC =1 =0
Bit 7 (MSB) Long return always Short return
6 Long return if Flash volt or Short return
minute triggers occurred.
5 SIGNAL port pin 2 carries SIGNAL port pin 2 carries
Flash Timeout Trigger. Utility Fail indication.
4 Brownout Protection Brownout Protection
Disabled Enabled
3 Reserved Fixed 0
2 Reserved Fixed 0
1 Bypass Disabled Bypass Enabled
0 Bypass Overloads Don’t Bypass Overloads

Default: 30H
Notes:
• Long returns insert 2.5 second power breaks upon return from Standby
operation. Short returns add no breaks.

OPT_MISC: (Enter Hex value)

OPT_MISC =1 =0
Bit 7 (MSB) Reserved Fixed 0
6 Sets Continuous Operating Sets Standby Operating
Mode Mode
5 Reserved Fixed 0
4 Reserved Fixed 0
3 Reserved Fixed 0
2 Battery Test enabled Battery Test disabled
1 UPS output synched to Un-synched output
utility.
0 Fixed 1 Reserved.

Default: 06H
Notes:
• Standby operating mode is default.

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BACKUP DELAY (x10 msec)

This value sets the time period of the utility AC noise rejection window. Utility
disturbances of duration less than this setting are ignored. Units are in 10msec. For
example, 40 millisecond delay is specified by 4.

Default: 4
Range: 1 – 100
Notes: Feature cannot be disabled.

FLASH TRIGGER (Volts)

Enter this value in decimal units of volts. This is the voltage specifies the trip point that
activates the Flash operation via the “LOW-BATT” relay contacts in the PIM.

Default: 69
Range: 0 – 90V
Notes: 0 Disables feature

FLASH TRIGGER (Minutes)

Enter this value in decimal units of minutes. This is the voltage specifies the trip point
that activates the Flash operation via the “TIMER” relay contacts in the PIM.

Default: 120
Range: 0 – 255 minutes
Notes: 0 Disables feature

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4.2 Adjustment Overview for Windows Program

Open the Traffic UPS Program for Windows. Connect a straight through 9-pin RS232 cable from the computer
serial port to the UPS RS232 port. Make sure UPS is turned on. Click OK. Select comport being used. Typically
“Com1”.

Once connected, you should see this screen. The Information screen gives you the model and firmware of the
UPS.

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Click on the “UPS Status” tab. This screen shows the current UPS Input status, Output status and Battery Status.

Click on the “Performance” tab. This screen shows the UPS Performance Data. The only two changeable features
on this screen is the “Battery Install Date” and the “Audible Alarm”.

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Click on the “Alarm Status” tab. This screen shows the type of alarm the unit is in.

Click on the “Options” tab. From this screen you can change many of the options.

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From the “Options” menu, click on the “Set value” tab for “4> Opt_Traffic.

1) This option used in the “Standby Mode”.

a. The “Long return always” is used to force a break in power for 2.5 seconds after the utility power returns.
This is used in intersections when a hard-restart needs to be applied to various devices.
b. The “Short return”(which is the default) is used when no break in the power is needed.

2) This option is used in the “Continuous Operating Mode”.

a. The “Long return if flash volt or minutes trigger occurred” is used to force a break in power for 2.5 seconds
after the utility power returns if “Flash trigger” in minutes or volts occurs.
b. The “Short return” (which is the default) is used when no break in the power is needed.

3) a. The “Signal port pin 2 carries Flash Timeout Trigger” enables the “Timed Delayed Flash” feature. This
feature enables you to activate the Timer NO\NC contacts.
b. The “Signal port pin 2 carries Utility Fail indication” disables the “Timer Delayed
Flash” feature. The Timer NO\NC contacts become active when utility
Power is lost.

From the “Options” menu, click on the “Set value” tab for 5> Opt_Misc.

1) a. The “Sets CONTINUOUS (online) Operating Mode” is to set the UPS into Continuous operation.
b. The “Sets STANDBY Operating Mode” is to set the UPS into Standby operation.

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From the “Options” menu, click on the “Set Value” tab for 7> Backup Delay.
The Backup Delay allows you to set the time period of the utility AC noise rejection window.
Utility disturbances of duration less than this setting are ignored. Units are in 10msec.

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From the “Options” menu, click on the “Set Value” tab for A> Flash Trigger (Min.s).
This is the time that specifies the trip point that activates the Flash operation via the “TIMER” relay contacts after
Utility power is lost.

From the “Options” menu, click on the “Set Value” tab for B> Flash Trigger (Volts)
This is the Battery Voltage that specifies the trip point that activates the Flash operation via the “TIMER” relay
contacts.

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This is the Calibration Settings for the UPS. DO NOT CHANGE ANY OF THESE
UNLESS INSTRUCTED TO DO SO BY THE

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Section 5
CARE AND MAINTENANCE
5.1 SAFETY
There are hazardous high voltages and materials present in the UPS system which present safety
risks. You MUST follow basic safety procedures when maintaining the UPS. In addition please note the
following:
ELECTRICAL SAFETY
• Hazardous high voltages are present in this product, which can cause electrical shock.
• Do not work alone under hazardous conditions.
• Always wear eye-protection when servicing energized power electronics.
• Connect equipment only to three wire AC outlets (two poles plus ground). The receptacle must
be connected to an appropriate protected branch circuit (fuse or circuit breaker).
• Connecting this equipment in a manner other than specified may result in a shock hazard and
may violate local electrical codes.
DE-ENERGIZING SAFETY
• To de-energize the UPS, BOTH the AC Power connector and the DC Power connectors must
be disconnected.
• There is internal energy storage in the UPS Power Module. This energy is stored in Capacitors,
which require at least 2 minutes of discharge time after power is disconnected.

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5.2 PREVENTIVE MAINTENANCE

CLEANING
This device is designed to be maintenance-free. It can be cleaned with a damp cloth or nonabrasive
cleanser.
WARNING: Do not use ACETONE-BASE cleaning solutions. Keep cleaning solutions out of the
electrical receptacles on this device.
Be sure filters, vents and fans are kept free from accumulation of dust, dirt or lint. Below (see Table 11)
is a simple maintenance schedule that will assist you in keeping the system at its peak level of
performance and also minimizing potential premature failures.
BATTERIES
Your system contains sealed maintenance-free batteries. When situated in the proper environment,
with the proper charging and limited cycling, these batteries can last many years.
Battery replacement should be performed or supervised by personnel familiar with the dangers of
batteries and the required precautions. DO NOT permit untrained or unauthorized personnel to replace
or service batteries.
WARNING: Never attempt to service batteries. 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 batteries, use the same number and type batteries.
CAUTION: Do not dispose of battery or batteries in a fire. The battery may explode.

! CAUTION: Do not open or mutilate the battery or batteries. Released electrolyte is harmful to the skin
and eyes. It may be toxic.
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:
1. Remove watches, rings, or other metal objects.
2. Use tools with insulated handles.
3. Wear rubber gloves and boots.
4. Do not lay tools or metal parts on top of batteries.
5. Disconnect the charging source prior to connecting or disconnecting battery terminals.
6. Determine if the battery is inadvertently grounded. If inadvertently grounded, remove source of
ground. Contact with any part of a grounded battery can result in electrical shock. The
likelihood of such shock will be reduced if such grounds are removed during installation and
maintenance.
7. The rechargeable battery is recyclable. At the end of its useful life, under various state and
local laws, it may be illegal to dispose of this battery into the municipal waste stream. Check
with the factory for details in your area for recycling options or proper disposal.

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BATTERY RECYCLING
• The batteries used in this equipment are recyclable. Proper disposal is required and mandated
by law. The batteries contain lead and pose a hazard to the environment and human health if
not dispose of properly.
• Refer to local codes for proper disposal requirements or return the batteries to the factory.
• ALWAYS contact the factory for information concerning shipment, disposal, or replacement of
batteries.

Table 11: PREVENTIVE MAINTENANCE SCHEDULE

Item Schedule Actions

Cleaning
6 Mos. Blow out unit with air.

Battery
6 Mos. Clean terminals and check for corrosion.

Fans
6 Mos. Check for proper operation.

5.3 TROUBLE ANALYSIS

Unit does not power up:
• Make sure AC & DC input connectors are connected and seated properly.
• Check front panel fuse(F1)
• Check PIM for proper installation and wiring.
Battery LED’s on front panel is flashing:
• Make sure when you power up the unit, turn DC breaker on first, then turn on the system switch.
• Possible Bad Battery
o Check each battery with a battery tester
• Possible faulty connection to Batteries
o Check all connectors for proper pin alignment and any corrosive build up.

No Backup when utility power is lost:

• Make sure DC breaker is in the “ON” position.
• If Bypass switch is installed, make sure it is in the “UPS” position.
• Check PIM for proper installation and wiring.
• Possible Bad PIM.
• Check Batteries.
Front Panel Fuse(F1) keeps going bad:
• Possible bad inverter.

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On turn on, Unit goes through startup sequence then goes into alarm and inverter does not turn on:
• Possible bad inverter.
• Load on unit may be over Max. rating.
Unit in Alarm, but is still operating OK:
• Possible over temp.
• Check fans in the unit to make sure they are running.
In On-line operation, intersection goes into flash when utility power is loss:
• Check PIM for proper installation and wiring.
• Options in the program may not be set properly.

5.4 SERVICE AND REPAIR

Your SP Series UPS is backed by one of the finest customer service teams available. Write or call
them at any time to obtain more information about your unit.
Clary Corporation
150 E. Huntington Dr.
Monrovia, CA 91016
1-800-551-6111
If a problem should occur, it is important that you obtain a Return Material Authorization (RMA)
number from the Service Department to process any unit returned to the factory. In consulting the
factory, always have the unit model number and serial number at hand. This information is located on
the identification label and is essential in retrieving your unit’s performance and history record.
The RMA number issued to you should appear on the outside of the carton, if the unit is returned, or
on any correspondence regarding your unit. When shipping a unit back to the factory, try to use the
original packing container and shipping materials. The Service Department cannot take responsibility
for any unit damaged in return shipment. All units must be returned prepaid to:
Clary Corporation
SP Service Center
150 E. Huntington Dr.
Monrovia, CA 91016

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WARRANTY
1. TIME AND SCOPE OF WARRANTY:
1.1. Clary Corporation hereby warrants parts shipped under this Agreement to be free from
defective workmanship for a period of 2 years following date of shipment. Accidental damage,
misuse or normal wear and tear shall not be construed as a defect.
1.2. The date of shipment as used herein will be the date on the Bill of Lading. If no Bill of Lading is
issued the date of shipment shall be shown on seller's shipping document.
1.3. No provision of this warranty shall cover equipment that has been altered or modified from the
original specifications to which it was manufactured unless authorized in writing.
1.4. No provision of this warranty shall cover batteries. However, battery manufacturer's warranties
will be passed through to the customer whenever applicable.
2. LIMITS OF "IN WARRANTY" SERVICE LIABILITY:
2.1. Clary is obligated during the in-warranty period to provide service and/or adjustments to
equipment returned to the factory at the expense of buyer (the term "factory" as used here-in
shall also include any field service centers which may be established by Clary) and to repair or
replace any part(s) thereof which in the opinion of authorized Clary personnel are found to
have been defective.
2.2. Equipment requiring in-warranty services must be returned to the factory with all transportation
charges prepaid, clearly tagged, and stating the nature of the trouble experienced, and the
disposition of the equipment after repair. The equipment will be returned collect by Clary to the
location specified via the best, least expensive carrier available or via customer's shipping
instructions.
2.3. The nature of certain equipment installations may be such that it would be impractical or
technically infeasible to remove the Clary portion of the equipment from the customer's
premises to the Clary factory. In such cases, and at the request of the buyer, Clary will
perform such service as can be satisfactorily rendered at buyer's location. The buyer will be
charged only for travel expenses incidental to the service call, provided that the warranty is
applicable.
2.4. During the in-warranty period, no service charges shall be payable by the buyer for service
performed other than for service necessitated by accident, misuse, theft, abnormal line or
source voltage fluctuations, abnormal conditions of operation, damage by the elements or
damage resulting from adjustments, repairs, modifications made by other than Clary
Authorized personnel, or the buyer's failure to reasonably maintain the equipment.
2.5. THE FOREGOING WARRANTY IS EXCLUSIVE AND IS GIVEN AND ACCEPTED IN LIEU
OF ANY AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING
WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE. THE REMEDIES OF BUYER SHALL BE
LIMITED TO THOSE PROVIDED HEREIN. IN NO EVENT WILL SELLER BE LIABLE FOR
COLLATERAL OR CONSEQUENTIAL DAMAGES. No person is authorized to assume in
behalf of Clary any obligation or liability in connection with the sale, warranty or service policy
of any products manufactured and/or marketed by Clary Corporation beyond the warranty
description on the face hereof.
3. Clary Corporation reserves the right to make changes, additions, and/or improvements in its
products without incurring any obligation to install them on its products previously sold.

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