Synthesis Zone Inverter 300-600 Watt Models
Contents
1. 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 5 Phone 855 486 2216 Phone 800 668 9008 www philips com luminaires www philips com luminaires 104 5 Cabinet Mounting Models ZI300 and Z1400 Single Cabinet Units All models are designed for wall mounting The cabinets have 4 keyhole slots for easy mounting and removal make sure that the surface the system 1s fastened to and the fasteners used are capable of safely supporting the weight of the unit 1 Select area for unit mounting When installed cabinet must have a minimum of 8 20 3 cm of clearance on both the right and left hand side of the cabinet to assure proper ventilation Conduit entry should be from the top left or left hand side of cabinet 2 Carefully locate and mark mounting holes on the wall surface using the dimensions shown in Fig 2 below taking care to assure installed cabinet will be level when hung on mounting hardware Fig 2 ST 20 18 0 5 08 cm 45 7 cm 1 0 2 54 cm Na p 0 625 1 6 cm Keyhole K O TYP 4 13 5 Back of Cabinet 34 3 cm 3 Drill mounting holes in the wall surface Partially install mounting hardware such that the heads of mounting screws or bolts project approximately 1 2 1 3 cm from wall surface Hang system cabinet on partially installed hardware and tighten cabinet securely to the wall surface 4 Once the cabinet is securely fastened2. Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 18 Phone 855 486 2216 Phone 800 668 9008 www philips com luminaires www philips com luminaires
3. Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 253 Phone 855 486 2216 Phone 800 668 9008 www philips com luminaires www philips com luminaires Section 100 System Installation Instructions 101 Specifications Input e Input voltage 120 or 277VAC Input frequency 60HZ 2 e Operating temperature 20 C to 30 C 68 F to 86 F e Synchronizing slew rate 1 Hz per second nominal e Input surge protection Meets UL 924 Output e Output voltage 120 or 277V AC 60HZ Other voltages available upon request e Output regulation static 5 based on a 0 100 resistive load e Minimum loading none required e Output distortion Less than 3 THD linear load e Load power factor 5 lag to 5 lead e Output frequency Normally Synchronized to utility 2 Hz during emergency e Overload 150 for five seconds e Time to transfer to inverter after a utility power failure x1 ms Battery e Battery type Maintenance free sealed lead calcium e Battery charger Fully automatic with temperature compensation e Recharge time Meets UL requirements 72 Hours e Battery protection Automatic low battery voltage disconnect and reverse polarity protection Automatic restart upon utility return e Battery switch Also used as battery isolator e Standard battery Sealed lead calcium 10 year life e Battery voltage 36 or 72 system dependent e Runtimes
4. cable lug will not contact any part of the cabinet even if the battery is moved Keep the cable away from any sharp metal edges 5 Install the battery cables so they cannot be pinched by the battery cabinet or the Synthesis Zone Inverter system cover doors 6 Where conductors may be exposed to physical damage protect conductors in accordance with NEC requirements 7 1f replacing batteries or repairing battery connections follow the procedure in this manual to shutdown the Synthesis Zone Inverter system and remove both AC and DC input power 8 Full voltage and current are always present at the battery terminals The batteries used in this system can produce dangerous voltages extremely high currents and possible risk of electric shock Batteries may cause severe injury if the terminals are shorted together or to ground earth Be extremely careful to avoid electric shock and burns caused by contacting battery terminals or shorting terminals during battery installation Do not touch un insulated battery terminals 9 A qualified electrician who is familiar with battery systems and required precautions must install and service the batteries Any battery used with this unit shall comply with the applicable requirements for batteries in the standard for emergency lighting and power equipment UL 924 Cabinets are designed to be used with and batteries must be replaced by identical cells or a Chloride approved equivalent If using substitute batteries
5. disconnecting AC to the Synthesis Zone Inverter system Only authorized persons shall be able to disconnect AC to the unit See NEC 700 20 and 700 21 CAUTION To prevent electrical shock or equipment damage for all units the Main AC Switch the Main DC Switch all output circuit breakers and the AC input at the service panel are all off before making AC connections to the Synthesis Zone Inverter system 4 If not previously done remove knockouts for AC Input and AC Output in the top or left side of the Synthesis Zone Inverter system See Fig 1 in Section 104 4 CAUTION Do not drill the cabinet drill filings may damage the unit and prevent it from operating If larger knockouts are needed use a chassis punch to enlarge the appropriate knockout Do not add additional or unnecessary knockouts 5 Install the input and output conduits 6 Run the AC Input service conductors and AC Output conductors through separate conduits Synthesis Zone Inverter system emergency output circuits shall be installed in dedicated conduit systems and not shared with other electrical circuits as described in NEC 700 9 b KI LI ps Philips Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 253 Page 12 Phone 855 486 2216 Phone 800 668 9008 www philips com luminaires www philips com luminaires 106 2 AC Input and AC Output Connections Make all AC input and out
6. install the system batteries Socket Set Philips Screwdriver Electrical Tape Digital Volt Ohm Meter Safety Glasses with Side Shields CAUTION Always use insulated tools for battery installation KI i LI ps Philips Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 9 Phone 855 486 2216 Phone 800 668 9008 www philips com luminaires www philips com luminaires 105 2 Installation Considerations This section explains how to install the Synthesis Zone Inverter system s batteries fuses and cables A qualified electrician who is familiar with battery installations and applicable building and electrical codes should install the batteries MAKE SURE THE DC BREAKER IS IN THE OFF POSITION BEFORE PROCEEDING The DC fuse F1 is shipped installed from the factory and is located in the fuse block holder in the front of the unit 105 3 Battery Installation Procedure Battery Voltage Select which wiring diagram to use from this table System Model Z1300 Z1400 _ System DC Voltage 386 72 O 72 Battery Part Number 1000010241 1000010228 ie S 3 6 Number of Batteries Wig Degen s IMPORTANT Be careful to observe correct polarity on the battery terminals Illustrations are given as a guide only polarity markings may vary from battery to battery 105 3A Wiring Diagram 1 ZI300 6 Volt Battery Connection Diagram Red
7. side of the electronics module cabinet Lower Tier Batteries Located in the Bottom of the Battery Cabinet 2 LI DS Philips Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 11 Phone 855 486 2216 Phone 800 668 9008 www philios com luminaires www philips com luminaires IMPORTANT Use only Chloride supplied batteries to assure proper operation and maintain system warranty DO NOT TURN ON THE DC BREAKER AT THIS TIME AS SIGNIFICANT DAMAGE TO THESYSTEM MAY OCCUR See Section 108 for proper system start up procedure 105 4 Flectronics Cabinet Voltage Check Using a digital volt ohm meter check for correct nominal battery voltage between electronics cabinet DC Input NEG and POS wires Refer to table in section 105 3 for proper system DC voltage Voltage reading should be 10 of system DC voltage 106 AC Connections CAUTION a All Synthesis Zone Inverter system units contain hazardous AC and DC voltages Because of these voltages a qualified electrician must install the Synthesis Zone Inverter system AC line service and batteries The electrician must install the AC line service according to local state and NEC codes and must be familiar with batteries and battery installation b Before installing maintaining or servicing the unit always remove or shut off all sources of AC and DC power and shut off the Sy
8. the batteries properly For assistance contact Chloride Technical Support at 800 451 9423 during normal business hours EST 301 Warranty Information IMPORTANT Lengthy storage of batteries will cause irreversible damage to the cells Failure to connect Synthesis Zone Inverter system batteries to an energized charging circuit within 90 days from the date of shipment will void the battery warranty KI LI DS Philips Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 253 Page 17 Phone 855 486 2216 Phone 800 668 9008 www philips com luminaires www philips com luminaires WARRANTY The system is guaranteed under normal and proper use against defects in workmanship and materials for a period of 3 years from the date of shipment Batteries supplied as part of the system are covered under a separate pro rata warranty as described below Batteries year plus 9 years pro rata period 302 Technical Service and Support During or after installation Chloride Technical Support is available to provide expert assistance Our service representatives are available to answer customers questions or solve their problems Toll Free Number A toll free phone has been set up for Synthesis Zone Inverter technical assistance The number 1s 800 451 9423 Service representatives are available during normal working hours EST KI LI ps Philips
9. 90 minutes standard e Operating temperature 20 C to 30 C 68 F to 86 F e Relative humidity 95 non condensing Note Battery performance rated at 25 C 77 F Table 1 Input QOutput Input Current Output Capacity Battery Weight TE a Maximum Rating 90 Min Voltage WxDxH Lbs Ke oo 300 Watts 330 VA 36VDC 22x8x16 113 51 3 21300277 a aoe 300 Watts 330 VA 36VDC 22x8x 16 113 51 3 21400120 400 Watis 660VA 72VDC 22x8x16 132 60 0 21400277 400 Watts 660 VA 72VDC 22x8x16 132 60 0 21600120 600 Watts 660 VA 72VDC 22x8x23 188 85 4 ZI600277 600 Watts 660 VA 72VDC 22x8x23 188 85 4 fA LI DS Philips Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 3 Phone 855 486 2216 Phone 800 668 9008 www philips com luminaires www philips com luminaires 102 Receiving Moving and Storing Systems and Batteries 102 1 Shipping Damage Synthesis Zone Inverter systems and batteries are shipped separately Carefully inspect all cartons upon receipt for evidence of shipping damage Notify carrier immediately of leaking or damaged cartons for possible concealed damage 102 2 Temporary Storage of Units and Batteries For temporary storage of Synthesis Zone Inverter systems and batteries prior to installation select a clean cool dry location with normal ventilation for human habitation and level floors St
10. Battery Lead Black Battery Lead Intercell Connectors IMPORTANT Use only Chloride supplied batteries to assure proper operation and maintain system warranty DO NOT TURN ON THE DC BREAKER AT THIS TIME AS SIGNIFICANT DAMAGE TO THESYSTEM MAY OCCUR See Section 108 for proper system start up procedure 2 LI DS Philips Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 10 Phone 855 486 2216 Phone 800 668 9008 www philios com luminaires www philips com luminaires 105 3B Wiring Diagram 2 Z1400 72 Volt Battery Connection Diagram For ease of assembly install the rear intercell connectors between battery sets outside of the unit enclosure Place each of the three interconnected sets of batteries into the enclosure separately Do not attempt to place all six batteries into enclosure at once ik V Ho A Black Battery Lead NOTE Top of Red Battery Lead Batteries Shown Intercell Connectors Uk J F 105 3C Wiring Diagram 3 Z1600 72 Volt Battery Connection Diagram Red Battery Lead Intercell ea Connectors Bi E Upper Tier Batteries Located in the Bottom of the Electronics Cabinet Black Battery Lead q P NOTE Route the red Intercell Ma Connectors Nia battery lead and the rat m inter tier connection CI lead through the insulating bushing on the right hand
11. PHILIPS Synthesis Zone Inverter 300 600 Watt Models IMPORTANT SAFEGUARDS When using electrical equipment basic safety precautions should always be followed including the following READ AND FOLLOW ALL SAFETY INSTRUCTIONS All servicing should be performed by qualified personnel only Equipment should be mounted in locations and at heights where it will not be readily subjected to tampering by unauthorized personnel The use of accessory equipment not recommended by the manufacturer may cause an unsafe condition Do not use this equipment for other than intended use Do not use outdoors Do not let supply cords touch hot surfaces Do not mount near gas or electric heaters KI LI DS Philips Lighting Company 200 Franklin Square Drive Somerset NJ 08873 Phone 855 486 2216 www philips com luminaires INSTALLATION AND OPERATING INSTRUCTIONS Use caution when servicing batteries Battery acid can cause burns to skin and eyes If acid is spilled on skin or eyes flush acid with fresh water and contact a physician immediately CAUTION To avoid electrical overload total connected lamp load factory and field installed should not exceed output rating SAVE THESE INSTRUCTIONS WARNING Shut off AC power to branch circuits to which units will be connected All wiring should be per N E C Articles 501 4 b and local codes To maintain warranty equipment with batteries must be installed or placed on ch
12. arge within prescribed period after shipment Philips Lighting Company 9140053315 JULY 2013 281 Hillmount Road Markham ON Canada L6C 2S3 Page 1 Phone 800 668 9008 www philips com luminaires Table of Contents Section 100 System Installation Instructions Description Page 101 Unit Specifications 2a 3 102 Receiving Moving and Storing Systems and Batteries 0 4 102 1 Shipping DAMAGE 2 2na ma KABLE vane tedav an dkieeve hate DAWA D DRE AKA 4 102 2 Temporary Storage of Units and Batteries 20 0 0 ccc ees 4 103 Installation Requirements 2a 4 103 1 Operating Environment 0 20 0 0 cc eee eee eens 4 103 2 High Altitude Operation go5 552 AAKALA NA eee tbedeenth ded LYR ede wae 4 104 Cabinet Mounting 2 a 5 104 1 LOCO Req ed senene BAN PRADO KET eae ARENA ALONE MAL eens eakeeeues 5 104 2 Mounting Hardware AA AA 5 104 3 Cabinet Clearance 2 select het ar is ded het ee MA an Reiser BA nA AA 5 104 4 Knockout Locations aaa NG NAGA KAG se AB PR BRA WANG NADAAN ed KAAGAW NG 3 104 5 Cabinet Mounting Models ZI300 and Z1400 Single Cabinet Units b 104 6 Cabinet Mounting Models Z1600 Two Cabinet Unit 008 7 105 Battery Installation and Connection 0 0 0 0 00 00 a 9 VODA LOO anan shen ATAKE NIDMDE NA ATABALA NATAWA AAATABTIBANEAADE HANDA 9 105 2 Installation Considerations n n a 10 105 3 Battery Install
13. ation Procedure 1 0 0 a 10 105 3A Wiring Diagram 1 ZI300 0 0 aa 10 105 3B Wiring Diagram 2 ZI1400 ee nes 11 105 3C Wiring Diagram 3 ZI600 ees 11 105 4 Electronics Cabinet Voltage Check 0 0 0 0 a 12 106 AC Connections 245 eugene uwe ew amen ey edu woe eu ewe dao ee ie PAA PLAY 12 106 1 AC Wiring Preparations 0 0 20 00 e ee nee 12 106 2 AC Input and AC Output Connections 0 0 0 eee a 13 107 Final Installation Checklist 0 0 00 0000 0c ee eens 13 108 System Start Up Procedure 0 0 0 000 e 14 109 System Verification 0 00 00 a 14 Section 200 User Manual Description Page 200 Status Indicators 0 0 0 0000 a 14 Section 300 Maintenance Warranty and Technical Support Description Page 300 Maintenance 0 0 eee o 15 300 1 Safe Shut Down Procedure 0 0 0 0 ce eens 15 300 2 Routine System Maintenance 0 0 aaa 15 300 3 Manual Routine Inverter Tests 0 0 0 0 aaa 16 300 4 Battery Maintenance and Replacement 2 00 cee eens 16 300 5 Routine Battery Inspection and Maintenance 0 eee eee 17 300 6 Battery Replacement Procedure 0 20 0 0 cc eee eens sd 300 7 Battery DIS pOsda naa wk waaa DENG KABAN Os oo KAKA HaibaAN DING BANA NMN BAiDJA MOL 17 301 Warranty Information a 17 302 Technical Service and Support a 18 H LI ps Philips Lighting Company
14. ecommends that the smaller auxiliary battery cabinet be installed first to act as a shelf for mounting the larger heavier electronics module Hang auxiliary battery cabinet in position on mounting hardware and tighten securely against the wall surface making sure the cabinet is level 6 Hang the electronics module on its mounting hardware on top of auxiliary battery cabinet and align K O s between the top and bottom cabinets Do not tighten electronics module mounting hardware at this point 7 Install the 7 8 plastic insulating bushings into both large K O s to align cabinets then bolt the two cabinets together through the four small K O locations using the 1 4 20 bolts and hardware provided Refer to Fig 5 below Fig 5 Hardware 1 4 20 Detail Assembly 8g Flat Washer ape ee _ Flat Washer TYP 4 LI o Nut O 7 8 Insulating Alignment Bushings AQ Bottom of Electronics Module Shown Lock Washer 8 Tighten the electronics module cabinet securely to wall surface 9 Once the cabinets are securely fastened to the wall run and attach conduit using the provided knock outs on the top or left hand side of the unit See Fig 1 Additional entry points if required can be added using a 2 LI DS Philips Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 8 Phone 855 486 2216 Phone 800 668 9008 ww
15. eps to assure the unit will operate properly 300 2 Routine System Maintenance The Synthesis Zone Inverter unit is designed to provide years of trouble free operation The unit does require some routine attention to assure peak performance Chloride recommends a Preventative Maintenance check be performed by a qualified service technician at least every six months The technician must observe important safety precautions while performing the following recommended tasks e Inspect and clean the unit interiors e Inspect all batteries for leaks case swelling or terminal corrosion e Perform an emergency operation test to check operation of all critical connected loads KI LI DS PnUps Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 15 Phone 855 486 2216 Phone 800 668 9008 www philips com luminaires www philips com luminaires 300 3 Manual Routine Inverter Tests NFPA 101 requires that Emergency Lighting Equipment be tested on a monthly basis for a period of at least 5 seconds and a minimum of 90 minutes once a year We strongly recommend these guide lines be followed to insure system readiness and to prolong battery life The Synthesis Zone Inverter system was designed with a front panel test switch to facilitate monthly testing Simply depress the button and hold to test the inverter at anytime Once released the Synthesis Zone Inv
16. erter will revert back to standby operation this may take a few seconds to allow the unit to synchronize back to the line For annual 90 minute discharge or other prolonged tests simply turn off the AC Input breaker 300 4 Battery Maintenance and Replacement This section provides precautions for qualified service personnel working with unit batteries Important Safety Precautions The service technician must take these precautions 1 Wear protective clothing eye wear rubber gloves and boots Batteries contain corrosive acids or caustic alkalis and toxic materials and can rupture or leak if mistreated Remove rings and metal wristwatches or other metal objects and jewelry Don t carry metal objects in pockets where the objects can fall onto the batteries or into the Synthesis Zone Inverter system or battery cabinet 2 Tools must have insulated handles so that they will not short battery terminals Do not allow a tool to short a battery terminal to another battery terminal or to the cabinet at any time Do not lay tools or metal parts on top of the batteries and do not lay any objects where they could fall onto the batteries or into the cabinet 3 Install the batteries as shown on the battery wiring diagram provided in this manual or with the battery cable kit When connecting cables never allow a cable to short across a battery s terminals the string of batteries or to the cabinet 4 Align the cables on the battery terminals so that the
17. ery bank e Once a year all battery connections should be checked for tightness and re tightened if necessary 300 6 Battery Replacement Procedure WARNING Always use the same quantity and type of battery as replacements Substituting batteries not supplied by Chloride will void the UL listing of the system and may cause equipment failure To ensure the superior performance of your Synthesis Zone Inverter system and to maintain proper charger operation replace spent batteries only with Chloride cells having the same part number voltage and ampere hour rating as the original batteries 1 Follow the proper shut down procedure as described in Section 300 1 2 Break down the battery bank beginning with the intercell connectors These cables tie the batteries installed on the same shelf together 3 Next remove the inter tier cables These cables connect the batteries located on different shelves together 4 Remove the batteries from the cabinet Batteries can be very heavy use proper lifting methods when removing battery 5 Install new batteries following the instructions outlined in Section 105 3 300 7 Battery Disposal WARNINGS Do not dispose of batteries in a fire the batteries could explode Do not open or mutilate batteries Released electrolyte is highly toxic and harmful to the skin and eyes CAUTION Batteries contain lead Many state and local governments have regulations about used battery disposal Please dispose of
18. fer to Section 105 3 for proper system DC voltage 6 Ensure that the DC Input and AC Input and any optional AC Output breakers are in the OFF position 7 Verify AC Input voltage to unit matches system voltage configuration BH LI DS Philips Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 13 Phone 855 486 2216 Phone 800 668 9008 www philios com luminaires www philips com luminaires 108 System Start Up Procedure IMPORTANT The Synthesis Zone Inverter system is a sophisticated electronic backup power supply Care must be taken to follow the steps below in their exact sequence Failure to do so will result in erroneous alarm messages and possible equipment failure CAUTION Familiarize yourself with the shut down procedure in section 300 1 before proceeding with the Start Up 1 Make sure the front cover door 1s installed and secured shut 2 Turn on the input circuit breaker in the building service panel serving as the AC disconnect to the Synthesis Zone Inverter system 3 Open the front access panel so that the input output circuit breakers within the Synthesis Zone Inverter unit are accessible 4 Hold the Pre charge Switch in the ON position for 30 seconds 5 Release the Pre charge Switch and immediately turn on the DC input breaker 6 Turn on the AC input breaker as well as any optional AC Output circui
19. for the unit to stabilize and return to standby mode 200 LED Status Indicators The Synthesis Zone Inverter system 1s equipped with 5 LED indicators showing the operating mode of the inverter and also to alert you of any possible abnormal conditions The ON OFF status of the LEDs will indicate a very specific condition The following table is used to illustrate as to what these conditions may be DH j LI ps Philips Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 14 Phone 855 486 2216 Phone 800 668 9008 www philips com luminaires www philips com luminaires OUTPUT OUTPUT INVERTER OVERLOAD AC ON VOLTAGE CURRENT ON SHUTDOWN LED1 Green LED2 Green LED3 Green LED4 Amber LED5 Red AC Input Power Load Connected Inverter Operating Overload Available To Unit Available and Operating Emergency Mode Condition OFE No AC Input Output Voltage Load Not Connected Inverter Off Normal Power To Unit Failure Or Switched Off Standby Mode Operation Should an abnormal condition be detected contact Chloride Technical Support at 800 451 9423 for assistance Do not attempt to make any repairs yourself the system is fed from more than one power source and extreme care must be taken before servicing 300 Maintenance 300 1 Safe Shut Down Procedure CAUTION To avoid possible equipment damage or personal injury assu
20. g hardware Fig 3 2 0 18 0 5 08 cm 45 7 cm p 1 0 2 54 cm 13 5 34 3 cm 0 625 1 6 cm Keyhole K O TYP 4 Back of Cabinet 16 0 40 6 cm 20 5 52 1 cm L 7 A 0 625 1 6 cm Keyhole K O TYP 4 fi 2 t 1 Back of Cabinet 1 5 1 3 81 cm 3 Drill mounting holes in the wall surface for both cabinets to be installed Partially install mounting hardware such that the heads of mounting screws or bolts project approximately 1 2 1 3 cm from wall surface KI LI DS Philips Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 7 Phone 855 486 2216 Phone 800 668 9008 www philips com luminaires www philips com luminaires 4 Remove the 4 small and 2 large K O s from the top of the auxiliary battery cabinet as shown in Fig 4 as well as the corresponding K O s in the bottom of the electronics module CAUTION Remove any K O slugs from the auxiliary battery and electronics module cabinets as loose metal inside either cabinet may produce an unsafe condition during operation Fig 4 N 0 313 0 79 cm K O TYP 4 Remove All 0 875 2 2 cm K O TYP 2 Remove Both IMPORTANT Remove corresponding K O s from the bottom of the electronics module cabinet before O attempting to assemble cabinets together 5 The factory r
21. hen selecting mounting hardware to assure that it 1s the proper type for the application and sized to safely support the systems full weight when installed assuring safe and secure attachment of system to wall surface For ease of installation the factory recommends that the head size of mounting screws or bolts be small enough to pass through the keyhole K O s provided for mounting This will allow the unit to be hung on partially installed mounting hardware and facilitate easy cabinet removal if ever necessary 104 3 Cabinet Clearance IMPORTANT When mounted the unit requires a minimum of 8 inches 20 3 cm of clearance on both the right and left hand sides of the cabinet to assure proper ventilation 104 4 Knockout Locations All models provide knockouts on the top and left hand side of the unit See Fig 1 Additional entry points if required can be added using a metal punch Do not drill into the cabinet as metal filings can cause short circuits and damage the equipment NOTE Consider unit knockout locations prior to mounting unit Allow room for easy routing of conduit to entry point Fig 1 i 1 25 ain 3 18 cm 45 3 8 cm 1 5 3 8 cm 0 875 2 2 cm Diameter K O TYP 4 Top of Cabinet Left Side of Cabinet NOTE Units are designed for left hand conduit entry only No K O s provided on right hand top or side of cabinet KI LI DS Pniups Lighting Compaly Philips Lighting Company 9140053315 JULY
22. me that there 1s AC voltage present inside the Synthesis Zone Inverter system unit any time AC input power or DC battery voltage is applied The inverter 1s capable of providing output voltage from the batteries even when there is no AC input line voltage When AC input voltage is present the unit can provide output voltage even when the batteries are disconnected Output Voltage AC AND DC VOLTAGES WILL BE PRESENT INSIDE THE UNIT UNTIL LINE AC ISDISCONNECTED AND ALL INTERNAL SWITCHES ARE TURNED OFF Do not touch components inside the unit DC voltage is always present at the batteries and battery cables Final Shut Down Procedure 1 Open the unit s front access panel 2 Turn off the DC Input breaker first and then the AC Input breaker Also turn off all optional AC Output circuit breakers if supplied CAUTION HAZARDOUS ENERGY IS STORED IN CAPACITORS INSIDE THE SYNTHESIS ZONE INVERTER UNIT AFTER TURNING OFF SWITCHES ALLOW 5 MINUTES FOR CAPACITORS TO DISCHARGE BEFORE ATTEMPTING ANY SERVICE PROCEDURES 3 If the service technician does not need to access the inside of the unit keep the unit s front cover door closed 4 If the unit will be shut off for an extended period of time recharge batteries every 60 to 90 days CAUTION The batteries will be damaged and the warranty voided if not routinely recharged NOTE To turn power back on follow the System Start up Procedure outlined in Section 108 Be sure to complete all of the st
23. moved Keep the cable away from any sharp metal edges 5 Install the battery cables so they cannot be pinched by the Synthesis Zone Inverter system cover door 6 Where conductors may be exposed to physical damage protect conductors in accordance with NEC requirements 7 Full voltage and current are always present at the battery terminals The batteries used in this system can produce dangerous voltages extremely high currents and possible risk of electric shock Batteries may cause severe injury if the terminals are shorted together or to ground earth Be extremely careful to avoid electric shock and burns caused by contacting battery terminals or shorting terminals during battery installation Do not touch un insulated battery terminals 8 A qualified electrician who is familiar with battery systems and required precautions must install and service the batteries Any battery used with this unit shall comply with the applicable requirements for batteries in the standard for emergency lighting and power equipment UL 924 Cabinets are designed to be used with and batteries must be replaced by identical cells or a Chloride approved equivalent If using substitute batteries not supplied by Chloride the unit s UL listing will be void and the equipment may fail to perform properly The installation must conform to national and local codes as well Keep unauthorized personnel away from batteries 105 1 Tools The following tools are required to
24. not supplied by Chloride the unit s UL listing will be void and the equipment may fail to perform properly The installation must conform to national and local codes as well Keep unauthorized personnel away from batteries KI LI ps Philips Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 16 Phone 855 486 2216 Phone 800 668 9008 www philips com luminaires www philips com luminaires CAUTION A battery can present a risk of electrical shock and high short circuit current Battery replacement should only be performed by qualified service personnel familiar with battery systems All safety precautions outlined at the beginning of this section must be observed when servicing maintaining or replacing batteries 300 5 Routine Battery Inspection and Maintenance Sealed Lead Calcium Batteries Lead Calcium cells are the most common type of battery used today in standby equipment By design it 1s as maintenance free as a battery can be It is recommended however that some simple steps be taken to increase system life and maximize reliability e A quarterly visual check of the batteries should be conducted to look for deformities in the cases and terminal corrosion Any defective batteries should be replaced All corroded terminals regard less how slight are to be cleaned and retightened at once to prevent failure of the entire batt
25. nthesis Zone Inverter system Disconnect AC line input at the service panel and turn off the Main DC Switch and the Main AC Switch to make sure the unit will not supply output voltage c Whenever AC and or DC voltage is applied there will be AC voltage inside the Synthesis Zone Inverter system unit the unit can supply power from AC line or from its batteries To avoid equipment damage or personal injury always assume that there may be voltage inside the Synthesis Zone Inverter system d Remove rings watches and other jewelry before installing the AC wiring Always wear protective clothing and eye protection and use insulated tools when working near batteries Whenever servicing an energized unit with the inside panel open electric shock is possible follow all local safety codes TEST BEFORE TOUCHING e To reduce the risk of fire or electric shock install the Synthesis Zone Inverter system and the batteries in a temperature controlled and humidity controlled indoor area free of conductive contaminants See Section 103 for operating environment specifications 106 1 AC Wiring Preparations 1 Remove the system s front cover Make sure all breakers are in the off position 2 Make sure the Synthesis Zone Inverter system input and output voltages are correct for the particular application Remember that the Synthesis Zone Inverter system provides single phase power only 3 The input circuit breaker in the input service panel provides the means for
26. orage Temperature Store all batteries at 0 to 40 C 32 to 104 F Batteries will have a longer shelf life if stored at15 C 60 F The PFT electronics and battery cabinets may be stored at 20 to 60 C 4 to 140 F IMPORTANT Lengthy storage of batteries will cause irreversible damage to the cells Failure to connect Synthesis Zone Inverter system batteries to an energized charging circuit within 90 days from the date of shipment will void the battery warranty DANGER Explosive Can Cause Blindness or Other Severe Injuries Every type of battery can produce hydrogen gas even sealed maintenance free batteries The gas is vented through the vent caps and into the air Do not allow smoking sparks or flames in battery storage location because hydrogen is concentrated under the vent cap of each cell of the battery Hydrogen is highly explosive and is hard to detect because it is colorless odorless and lighter than air 103 Installation Requirements 103 1 Operating Environment Install the Synthesis Zone Inverter system in a clean cool dry place with normal ventilation for human habitation and in such a location to hamper vandalism but allow easy access for testing and maintenance Operating Temperature Synthesis Zone Inverter systems are UL Listed for 20 to 30 C 68 to 86 F operation Battery performance and service life is maximized if the operating temperature is maintained at 25 C 77 F Temperature Effec
27. put connections to the Synthesis Zone Inverter system as indicated on the labels within the cabinet Fig 6A No Output Breakers Circuit Breaker Terminal Block 1 bog Access Door Installer Connections A Building Ground gt f Line In gt LED Status Neutral In _ Indicator Panel Neutral Out CT Fig 6C Two Output Breakers Terminal Block 1 Fig 6B One Output Breaker Terminal Block 1 Installer Connections Building Ground gt Installer Connections Building Ground Line In Neutral In Load 1 Neutral Out Load 1 Line Out AC Output Breaker 2 lt lt Load 2 Line Out AC Output Breaker 1 Load 1 Line Out 107 Final Installation Checklist IMPORTANT Before proceeding to the System Start Up Procedure Section 108 complete the Final Installation Checklist below 1 Insure the Synthesis Zone Inverter cabinet s is securely fastened to a wall or other structure 2 Insure that the input circuit breakers in the building service panel serving as the AC disconnect to the Synthesis Zone Inverter system is in the OFF position 3 Check for proper ground connections in the Synthesis Zone Inverter electronics module cabinet 4 Check for any loose wiring connections in the Synthesis Zone Inverter electronics module cabinet 5 Check that correct nominal battery voltage 36 or 72 VDC is present in the Synthesis Zone Inverter cabinet between the DC Input NEG and POS Re
28. t On Battery Performance Batteries will be less efficient at temperatures below 18 C 65 F and high temperatures will reduce battery life Typically at 35 C 95 F battery life will be half of what it would be at normal temperature of 25 C 77 F At 45 113 battery life will be one fourth of normal Ventilation The air around the unit must be clean dust free and free of corrosive chemicals or other contaminants Do not place the Synthesis Zone Inverter system or batteries in a sealed room or container CAUTION Never Install Batteries in a Sealed Room or Enclosure 103 2 High Altitude Operation The maximum operating temperature drops 1 C per 300 meters 2 F per 1000 feet above sea level Maximum elevation is 3000 meters 10 000 feet KI LI DS Philips Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 4 Phone 855 486 2216 Phone 800 668 9008 www philips com luminaires www philips com luminaires 104 Cabinet Mounting 104 1 Tools Required The following tools are required to install the system Socket Set Philips Screwdriver Diagonal Wire Cutters Long Nose Pliers Electrical Tape Digital Volt Ohm Meter Safety Glasses with Side Shields Small Punch K O removal Hammer Electric Drill Wood or Masonry Bits Level 104 2 Mounting Hardware Mounting hardware is not provided Care should be taken w
29. t breaker s if supplied 7 After approximately five seconds the system should turn on the lighting loads should be energized the front panel s green AC ON and OUTPUT VOLTAGE LEDs should illuminate The OUTPUT CURRENT LED will illuminate only if the emergency lighting fixtures are connected and operable 109 System Verification At this point the connected load should be energized and LED 1 2 and 3 on the unit s status indicator panel should be lit Depending on the state of charge of the batteries the inverter may or may not come on when the test switch is depressed Allow a 24 hour charge period before testing the inverter system If you need assistance call Chloride Technical Support at 800 451 9423 S1 LED1 LED2 LED3 O a a CE a PUSH TO ACON OUTPUT OUTPUT INVERTER OUTPUT TEST VOLTAGE CURRENT ON OVERLOAD To simulate a power failure simply press and hold the test switch for a momentary test or open the AC input circuit breaker for a prolonged test The inverter will begin operating the AC ON LED will go off the OUTPUT VOLTAGE and OUTPUT CURRENT LEDs will remain lit and the INVERTER ON LED will illuminate All connected loads should be energized and operational HID fixtures should not wink out Allow the inverter to run for several minutes or until satisfied with its operation Close the AC input breaker to end the test and return the unit to standby mode Note It will take a few seconds
30. to the wall run and attach conduit using the provided K O s on the top or left hand side of the unit See Fig 1 Additional entry points if required can be added using a metal punch Do not drill into the cabinet as metal filings can cause short circuits and damage the equipment Be sure to follow all federal state and local codes as it pertains to emergency circuit raceways Refer to section 106 in this manual for AC wiring information KI LI DS Philips Lighting Company Philips Lighting Company 9140053315 JULY 2013 200 Franklin Square Drive 281 Hillmount Road Somerset NJ 08873 Markham ON Canada L6C 2S3 Page 6 Phone 855 486 2216 Phone 800 668 9008 www philips com luminaires www philips com luminaires 104 6 Cabinet Mounting Model Z1600 Two Cabinet Units NOTE The battery cabinet for use with Z1600 models is shipped inside the electronics module cabinet All models are designed for wall mounting Both Z1600 cabinets have 4 keyhole slots each for easy mounting and removal 1 Select area for unit mounting When installed both cabinets must have a minimum of 8 20 3cm of clearance on both the right and left hand side of the cabinet to assure proper ventilation Conduit entry should be from the top left or left hand side of cabinet 2 Carefully locate and mark mounting holes for both cabinets on the wall surface using the dimensions shown in Fig 3 below taking care to assure installed cabinet will be level when hung on mountin
31. w philips com luminaires www philips com luminaires metal punch Do not drill into the cabinet as metal filings can cause short circuits and damage the equipment Be sure to follow all federal state and local codes as it pertains to emergency circuit raceways 105 Battery Installation and Connection Important Safety Precautions The installer must take these precautions 1 Wear protective clothing eye wear rubber gloves and boots Batteries contain corrosive acids or caustic alkalis and toxic materials and can rupture or leak 1f mistreated Remove rings and metal wristwatches or other metal objects and jewelry Don t carry metal objects in pockets where the objects can fall onto the batteries or into the Synthesis Zone Inverter system 2 Tools must have insulated handles so that they will not short battery terminals Do not allow a tool to short a battery terminal to another battery terminal or to the cabinet at any time Do not lay tools or metal parts on top of the batteries and do not lay any objects where they could fall on to the batteries or into the cabinet 3 Install the batteries as shown on the battery wiring diagram provided in this manual or with the battery cable kit When connecting cables never allow a cable to short across a battery s terminals the string of batteries or to the cabinet 4 Align the cables on the battery terminals so that the cable lug will not contact any part of the cabinet even if the battery 1s
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