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Falcon SG5K-2TC manual

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Table of contents for the manual

  • Page 1

    OWNER'S OPERATING MANUAL SG Series UPS Plus ® Uninterruptible Power Supply Models: SG5K-1TX, SG5K-1TXC, SG5K-2T. SG5K-2TC SG5K-2TX, SG5K-2TXC SG6K-1TX SG6K-2T, SG6K-2TC Detailed SG Series product specifications are available in PDF format at www.falconups.com FALCON ® Electric Inc., 5106 Azusa Canyon Rd., Irwindale, California 91706, (626) 9[...]

  • Page 2

    SG UPS Features. ...... 1 SG Series Online UPS Block Diagram. ..... 1 Important Safety Instructions (READ FIRST) .... 2 Chapter 1. SG Series UPS Overview ..... . 3 True Regenerative On-line Design .... . 3 Input Power Factor Correction .... . 3 Microprocessor Control ..... . 3 SNMP/HTTP Remote Management .... . 3 Extended Battery Bank Option .... .[...]

  • Page 3

    SG SERIES UPS FEATURES SG SERIES ON-LINE UPS SYSTEM BLOCK DIAGRAM Models available with either 120V or 208-240Vac Input True Double Conversion On-Line Design Input Power Factor Correction Dual Output Models Available with 120 & 208-240Vac Wide Input Voltage Window Pure Sinewave Output Precision Output Voltage Regulation Superior Brownout, Surge[...]

  • Page 4

    IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions which must be followed during the installation, operation and maintenance of this UPS and its batteries. Please read all instructions before operating this equipment and save this manual for future reference. All of the models presented herein are desi[...]

  • Page 5

    CHAPTER 1 CHAPTER 1 SG Series UPS - Overview True Regenerative On-Line Design As new and innovative technologies have become the backbone of today's businesses, maxi - mum system availability is critical and downtime is more expensive than ever. Increasingly, busi - nesses need a UPS that not only protects against blackouts, but also virtually[...]

  • Page 6

    CHAPTER 2 CHAPTER 2 INSTALLATION INSTRUCTIONS General - Common for all models 1. Verify the following is included in the UPS shipping carton: (1) UPS, (1) Software Diskette(s) & Manual, (1) Owners Manual & (1) UPS/Computer Cable. 2. Verify the UPS unit is configured for the proper input/output voltage and frequency. This information is stat[...]

  • Page 7

    DIP SWITCHES SELECTION TABLE ON = 1 OFF = 0 SW2 SW1 OUTPUT VOLTAGE 1 (All models) OUTPUT VOLTAGE 2 (- TX & - TXC models only) Down Down 208 Vac 115 Vac Down Up 220 Vac (default) 120 Vac Up Down 230 Vac 125 Vac Up Up 240 Vac 130 Vac SW3 FUNCTION Down GREEN MODE ON Up GREEN MODE OFF SWITCH SETTINGS FOR ALL MODELS GREEN MODE SWITCH SETTINGS FOR AL[...]

  • Page 8

    6. Select a suitable location for the UPS. VERIFY THE FLOOR OR SURFACE SUPPORTING THE UPS WILL SUPPORT THE WEIGHT OF THE UPS AND ANY OPTIONAL EXTENDED BATTERY BANKS. SG5K-2T & SG6K-2T UPS MODELS = 216 lbs. (98 kg) SG5K-2TC & SG6K-2TC UPS MODELS = 239 lbs. (108 kg) SG5K-1TX, SG5K-2TX, SG6K-1TX, SG6K-2TX UPS MODELS = 299 lbs. (136 kg) SG5K-1T[...]

  • Page 9

    Installation Instructions For Hardwire Models (see model numbers referenced below) 1.0 UPS Input & Output Requirements. Note: All SG Series hardwire UPS models must be installed by a licensed electrician, in accordance with the National Electrical Code (NEC) ANSI/NFPA70 and all local regulations. It is further required that the input of SG Seri[...]

  • Page 10

    2.0. UPS Output Requirements Note: The outputs of SG 5 & 6kVA models are not configured for 208 or 240Vac split-phase operation. Please reference the output configuration diagrams on pages 9-10 prior to making any wiring connections to the UPS. Should a 208 or 240Vac split-phase output configuration be required, please contact the factory. MODE[...]

  • Page 11

    Terminal #10 Terminal #1 PFC INPUT RECTIFIER PWM INVERTER Output 2 - 120Vac Line (Black Wire) Output 2 - 120Vac Neutral (White WIre ) Chassis Ground (Output 1 & 2) Chassis Ground (Input) 120 Vac Input Neutral (White WIre ) 120 Vac Input Line (Black Wire) 208- 240Vac Output Output Auto-transformer Battery Charger Internal UPS Batteries ( 240Vdc [...]

  • Page 12

    INTERNAL UPS DIAGRAM SG5K-2TX(C) & SG6K-2TX(C) Terminal #10 Terminal #1 PFC INPUT RECTIFIER PWM INVERTER Output 2 - 120Vac Line (Black Wire) Output 2 - 120Vac Neutral (White WIre ) Chassis Ground (Output 1 & 2) Chassis Ground (Input) 208- 240Vac Input L2 or Neutral 208- 240Vac Input L1 208- 240Vac Output Isolated 120Vac Output New Derived 1[...]

  • Page 13

    3. Select a suitable location for the the extended battery bank, preferably close to the UPS to minimize the risk of DC voltage drop due to excessive long wiring runs. Use 10 Awg, 600V insulated wire for all hardwired DC connections between the UPS and battery bank(s). See Wire Guage Chart of page 7. VERIFY THE FLOOR OR SURFACE SUPPORTING THE UPS W[...]

  • Page 14

    12 G N D L 1 L 1 L 2 L 2 240 Vdc + UTILITY INPUT OUTPUT TO NEXT BANK BATTERY Battery Disconnect & Circuit Breaker Input/Battery Termi n a l Block CAUTION Reference the torque specifications in this manual prior to making terminal block conn ections. COOLING FAN DO NOT BLOCK Reference the Leveling Feet adjustment procedure USE ONLY THE WIRE G A [...]

  • Page 15

    Installation Instructions for All Models Except Hardwire 1.0 UPS Input & Output Requirements. Note: All SG Series UPS models, except Hardwire models, may be installed by anyone providing the specified outlet, circuit and circuit protections are available. Other plug and receptacle configurations are available, please reference page 14 or contac[...]

  • Page 16

    2.1 Output Power Distribution Center All models referenced on the previous page come equipped with a (4) bay power distribution center mounted on the rear of the UPS. The Power Distribution center is shown in the “standard” or “base” configuration. Custom configurations are available; see the table below or contact the factory. BAY 1 (full [...]

  • Page 17

    15 Typical SG5 & 6kVA Rear Panel Layout (Shown with Power Distribution Center ) Output Voltage & Green Mode Select Switches RS-232 Computer Interface Connector Communications Option Slot Cover Plate COOLING FANS DO NOT BLOCK AIR FLOW INPUT AC CIRCUIT BREAKER ALWAYS TURN ON AFTER THE BATTERY CIRCUIT BREAKER HAS BEEN TURNED ON BATTERY CIRCUIT[...]

  • Page 18

    16 INSTALLATION PROCEDURE 1. Verify the battery disconnect circuit breaker on the UPS and all external battery banks to be connected are in the off position. 2. Locate the battery interconnect cable(s). 3. Connect one end of the battery interconnect cable to the the UPS battery connector located on the power distribution center (see page 14). Conne[...]

  • Page 19

    17 CHAPTER 3 CHAPTER 3 OPERATION 1 2 3 4 5 6 7 8 9 10 11 UPS FRONT PANEL INDICATOR AND FUNCTION KEYS 1. LOAD LEVEL INDICATOR LEDs *The first or bottom LED is lit when the output load is greater than 25% of the ` rated output of the UPS. *The second LED is lit when the output load is greater than 50% of the rated output of the UPS. *The third LED is[...]

  • Page 20

    5. BYPASS INDICATOR LED When this led is lit, the UPS bypass is active. Should the Alarm led be lit at the same time, the UPS detected an internal failure and the UPS must be serviced. 6. INVERTER INDICATOR LED When this led is lit, the UPS inverter is operating and powering the connected load. 7. GREEN MODE LED INDICATOR This led is lit when the c[...]

  • Page 21

    AUDIBLE ALARMS Audible alarm signals are divided into two different levels of alarm status. Category one alarms represent normal or correctable operational alarms. Category two alarms are sounded in the event of abnormal operation. 1. Category one alarms : a. Two short beeps followed by three short beeps. Notifies the user that the SG UPS is config[...]

  • Page 22

    Maintenance Bypass Operating Instructions Unless configured as a frequency converter, SG 5 & 6kVA models are equipped with an internal maintenance bypass switch. The switch is located on the rear panel of the UPS and is clearly identified, See page 15. The maintenance bypass switch is a manual second bypass primarily provided for service purpos[...]

  • Page 23

    CHAPTER 4 CHAPTER 4 COMMUNICATIONS INTERFACES RS-232 INTERFACE 21 Pin # Function explanation I/O 9 RS 232 Rx INPUT 6 RS 232 Tx OUTPUT 7 Ground Location: The RS-232 interface is standard on all SG series UPS models. The port is located on the UPS rear panel, via a DB-9 female connector. Supported Protocols UPSILON 2000 & SEC SmartMon BAUD RATE -[...]

  • Page 24

    22 DRY CONTACT & OPTO COUPLER INTERFACE BOARD OPTIONS JP1 JP2 JP3 J1 J2 J3 DB - 9 Typical Falcon Dry Contact Relay Board PIN DESCRIPTION 1 Low Battery ( When UPS reaches low battery, contact activates) (J1, 1 - 2 short = N.O) (J1, 2 - 3 short = N.C) 2 JP2 shorted = Low Battery common & all other shorted JP commons JP2 open = common for low [...]

  • Page 25

    23 PIN ASSIGNMENT FOR THE FALCON UA88373 OPTO-COUPLER OPTION BOARD (no-bypass signal) PIN DESCRIPTION 1 Not Used 2 Utility Loss (N.O.) (Closes upon utility loss) 3 Utility Loss (N.C.) (Opens upon utility loss) 4 Common for pins 2, 3 & 5 5 Low Battery (N.O.) (Closes at low battery) 6 Remote Shutdown Applying a +5 - +12Vdc voltage level f or >[...]

  • Page 26

    CHAPTER 5 CHAPTER 5 Maintenance & Technical Support 1. Care & Maintenance FALCON ® SG Series UPSs are designed to be maintenance-free. They can be cleaned with a damp cloth or non-abrasive cleanser, providing the UPS is turned off and the input plug is disconnected from the utility source. On a regular basis, check the vents to make sure t[...]

  • Page 27

    The following precautions should be observed by a qualified technician when working with 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. 4. Storing the UPS and Batteries Should you need to store the UPS for a lo[...]

  • Page 28

    6. Technical Support Your FALCON ® Electric SG Series UPS is backed by one of the finest customer service teams assembled. Write, call, fax or email should you require technical assistance or service. Falcon Electric, Inc. 5106 Azusa Canyon Road Irwindale, CA. 91706 Service 800.842.6940 Voice 626.962.7770 Fax 626.962.7720 Email: service@falconups.[...]

  • Page 29

    GENERAL PROVISIONS FALCON® ELECTRIC INC., hereby warrants product shipped under this agreement to be free from defective workmanship for a period of two years following date of shipment. This Limited New Product Warranty Agreement only applies to covered repairs to the product occurring within the United States and Canada. EXCLUSIONS: The followin[...]

  • Page 30

    SG Series TM UPS PLUS ® 5-6kVA MODELS 28 Electrical Input Nominal AC Voltage 120V 230V 230 V 120V 230 V 230 V AC Voltage Range 87 - 140V 170 - 275V 170 - 27 5V 87 - 140 V 170 - 275V 170 - 275V Current - Amps 38.7 20 .3 19.5 46.6 24 .3 23.4 Frequency 50/60 Hz ± 5% Efficiency (Typical) > 79% > 82% > 79% > 82% Power Factor Correction >[...]