Okay, let's break down this large UPS requirement and explore solutions tailored for your dynamic sign application. You're right, off-the-shelf IT-centric UPS units often fall short when dealing with higher current, hardwired connections like you need.

Challenges and Considerations



High Current Output

A 10kVA load at 208V draws a significant amount of current. You're looking at close to 50 amps. A standard L6-30R or L5-20R outlet won't cut it.

Hardwired Connection

Screw terminals for direct connection is essential for a robust, code-compliant installation.

2-Hour Backup

This is a substantial runtime requirement and will significantly impact the battery size and cost.

Department of Transportation Requirements

DOTs are very strict on safety and reliability. The solution needs to be robust, code-compliant, and designed for continuous operation.

Environmental Considerations

Highway environments can be harsh (temperature swings, vibration, etc.). The UPS needs to be rated for the environment.

Potential Solutions


Industrial/Commercial Grade UPS



Advantages

Designed for heavy-duty applications. Available with higher current output ratings and hardwired connections (screw terminals). Built for harsher environments. May have enhanced monitoring and control features.

Manufacturers to Research



Eaton

Eaton makes a wide range of 9PX and 93E Industrial series with options for higher power output with hard-wired terminals. These may be overkill for 10KVA, so look at spec sheets carefully.

Schneider Electric (APC)

While their IT UPS units are common, they also have industrial and commercial models (e.g., Easy UPS series). Review their catalog carefully to find models with hardwired outputs.

Vertiv (Liebert)

Vertiv specializes in critical infrastructure solutions, including UPS systems for various industries. Look at the Liebert PSI5 UPS and similar models.

Toshiba

Toshiba's UPS systems are well-regarded for their reliability and robust design.

Mitsubishi Electric

Mitsubishi offers a variety of UPS systems, including models suitable for industrial applications.

Key Features to Look For



Output Voltage and Current

MUST match your 208V, 60-70A requirement.

Hardwired Output

Screw terminals or a similar robust connection.

Double Conversion/Online Topology

Provides the cleanest and most reliable power to the sign.

Scalability

Can the unit be expanded if needed?

Remote Monitoring

SNMP, Modbus, or other protocols for remote status monitoring.

Warranty and Support

Critical for long-term reliability.

Operating Temperature Range

Ensure it matches the ambient temperature range at the installation location.

Seismic Rating

If the area is prone to earthquakes, this may be a requirement.2.

Inverter/Charger + Battery Bank



How it Works

A large battery bank is constantly charged by a high-power charger. An inverter converts the DC battery power to AC power for the sign.

Advantages

Potentially more flexibility in battery sizing to achieve the 2-hour runtime. Components (charger, inverter, batteries) can sometimes be sourced separately for greater customization.

Disadvantages

More complex to design and integrate. Requires a knowledgeable integrator. Coordination of components to ensure compatibility and performance. May require more space than a packaged UPS.

Manufacturers to Research (Inverters)



Magnum Energy

Offers inverters and inverter/chargers suitable for off-grid and backup power applications.

OutBack Power

Known for their robust and reliable inverters for renewable energy and backup power.

SMA

Although primarily known for solar inverters, they also have battery inverters.

Manufacturers to Research (Battery Chargers)



EnerSys

Industrial-grade battery chargers.

Mean Well

A wide range of power supplies and battery chargers.

Important Considerations



Battery Type

Consider AGM (Absorbent Glass Mat) or Lithium-ion batteries. Lithium-ion offers better energy density and lifespan but are more expensive. Flooded lead-acid batteries are generally not suitable due to maintenance requirements and safety concerns in this type of application.

Battery Sizing

A crucial calculation to meet the 2-hour runtime. Account for inverter efficiency and battery derating over time. Consult with a battery specialist.

Safety

Proper fusing, disconnects, and battery management are critical.

Steps to Take


Detailed Load Analysis

Confirm the exact power requirements of the sign (including inrush current) with the manufacturer. Get the sign's power factor. This is critical for proper UPS sizing.2.

Contact Manufacturers Directly

Don't rely solely on websites. Talk to applications engineers at Eaton, Schneider Electric, Vertiv, and other manufacturers. Explain your requirements in detail (208V, 60-70A hardwired output, 2-hour runtime, DOT requirements).3.

Engage a Qualified Electrical Contractor

This project REQUIRES a licensed electrical contractor experienced in industrial/commercial power systems and UPS installations. They can help with: System design Code compliance Installation Permitting Coordination with the Department of Transportation4.

Request Detailed Specifications and Drawings

Get complete specifications, wiring diagrams, and installation manuals for any UPS or inverter/charger system you are considering.5.

Get References

Ask the manufacturers for references of similar installations.6.

Consider Maintenance and Monitoring

Factor in ongoing maintenance costs (battery replacement, etc.). Remote monitoring is essential for early detection of problems.7.

DOT Approval

Ensure the chosen solution meets ALL DOT requirements. This may involve submitting plans and specifications for review.

Important Notes



Safety

Working with high-voltage power is dangerous. Only qualified personnel should perform installations and maintenance.

Codes

The installation must comply with the National Electrical Code (NEC) and any local codes.

Cost

Be prepared for a significant investment. A 10kVA UPS with a 2-hour runtime and hardwired output is not a cheap solution.

Recommendation:

Start by contacting Eaton, Schneider Electric (APC), and Vertiv and discussing your requirements with their applications engineers. They can help you determine the most suitable UPS model for your application. Given the complexity and criticality of the project, working with a reputable electrical contractor is essential.Good luck! Flag for review