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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) 962-7770, Fax 626-962-7720, Email: sales@falconups.com
®
2004 Falcon Electric Inc. All rights reserved.
All other brand names and trademarks are the property
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TABLE OF CONTENTS 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 . . . . . 3 Frequency Converter Option . . . . . 3 Chapter 2. Installation Instructions (Common for all mode
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SG SERIES UPS FEATURES 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 and Transient Protection Internal System Bypass Eliminates Generator Frequency & Voltage Drift Microprocessor Control & RS-232 Communications ® UPSILON Monitoring & Shutdown Software Optional F
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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. CAUTION All of the models presented herein are designed for installation and use in a temperature controlled environment, free of contamination. CAUTION This UPS utilizes voltage that may be
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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 eliminates more frequent and subtle power disturbances. Surges, sags, line noise and brownouts can disrupt proper operation of sensitive equipment. These
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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 stated on the nameplate label located on the rear or the side panel of the unit. If any special input plug and output receptacle configurations were specified
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VIEW OF OUTPUT VOLTAGE & GREEN MODE SELECT SWITCHES (LOCATED ON THE UPS REAR PANEL) OFF = 0 Disregard “ON” Designation DIP SWITCHES ON = 1 SELECTION TABLE SWITCH SETTINGS FOR ALL MODELS SW2 SW1 OUTPUT VOLTAGE 1 OUTPUT VOLTAGE 2 (All models) (-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 GREEN MODE SWITCH SETTINGS FOR ALL MODELS SW3 FUNCTION Down GREEN MODE ON Up GREEN MODE OFF 5
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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-1TXC, SG5K-2TXC, SG6K-2TXC UPS MODELS = 322 lbs. (146 kg) FLOOR STANDING EXTENDED BATTERY BANKS = 363 lbs. (165 kg) MAX. (EACH BANK) 7. If extended battery ban
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Installation Instructions For Hardwire Models (see model numbers referenced below) 1.0 UPS Input & Output Requirements. IMPORTANT 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 Series hardwire UPS be wired to a building service panel incorporating a dedicated “branch rated” circuit breaker of the proper rating. INPUT R
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2.0. UPS Output Requirements IMPORTANT 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. OUTPUT REQUIREMENTS MODEL RECOMMENDED OUTPUT CIRCUIT BREAKER SG5K-1TX: Output 1: 208, 220, 230 or 240Vac selectable, 1 phase, 2 wire 30A Output 2
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Chassis Ground (Output 1 & 2) Chassis Ground (Output 1 & 2) Output 1 - 208-240Vac L2 or Neutral NOT USED Output 1 - 208-240Vac L1 NOT USED Output 2 - 120Vac Neutral (White WIre) Output 1 - 208-240Vac L2 or Neutral Output 2 -120Vac Line (Black Wire) Output 1 - 208-240Vac L1 - External Battery (- 240Vdc) - External Battery (- 240Vdc) + External Battery (+240Vdc) + External Battery (+240Vdc) 120Vac Input Neutral (White WIre) 208-240Vac Input L2 or Neutral 120Vac Input Line (Black Wire) 208-240Vac I
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Chassis Ground (Output 1 & 2) Output 1 - 208-240Vac L2 or Neutral Output 1 - 208-240Vac L1 Output 2 - 120Vac Neutral (White WIre) Output 2 -120Vac Line (Black Wire) - External Battery (- 240Vdc) + External Battery (+240Vdc) 208-240Vac Input L2 or Neutral 208-240Vac Input L1 Chassis Ground (Input) INTERNAL UPS DIAGRAM SG5K-2TX(C) & SG6K-2TX(C) PWM PFC INVERTER Isolated 120Vac 208-240Vac Output Output Internal UPS INPUT Batteries (240Vdc) RECTIFIER New Derived 120Vac Neutral + Battery Charger T
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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 WILL SUPPORT THE WEIGHT OF THE UPS AND ANY OPTIONAL EXTENDED BATTERY BANKS. FLOOR STANDING EXTENDED BATTERY BANKS = 363 lbs. (165 kg) MAX. (EACH BA
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SG5 & 6kVA Extended Battery Bank Rear Panel Details (Hardwire Model Shown) COOLING FAN DO NOT BLOCK For all Input/Output wiring USE COPPER CONDUCTORS ONLY Battery Disconnect & Circuit Breaker USE ONLY THE WIRE GAUGE & TYPE REFERENCED IN THE AC Input Voltage --- 208-240 Vac AC Input Current --- 4.5A max PRECEEDING WIRING Charger Current --- 3.9A TABLE DC Output Voltage --- 240 Vdc DC Output Current --- 30A Input/Battery Terminal Block CAUTION Reference the torque speci
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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 contact the factory should an unlisted configuration e required.. MODEL REQUIRED REQUIRED INPUT RECEPTACLE CIRCUIT BREAKER SG5K-1TXC - 120Vac, 50/50Hz
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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. TYPICAL POWER DISTRIBUTION CENTER CONFIGURATION BAY 1 (full size) 120V FUSES 120V OUTPUT BAY 2 RECEPTACLES (full size) 208-240V FUSES BAY 3 (full size) CAUTION 208-2
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Typical SG5 & 6kVA Rear Panel Layout (Shown with Power Distribution Center ) Communications Option Slot Output Voltage & Green Mode Cover Plate Select Switches MAINTENANCE BYPASS RS-232 Computer Interface SWITCH Connector REFER TO PAGE 20 FOR OPERATING INSTRUCTIONS COOLING FANS DO NOT BLOCK AIR FLOW WARNING NEVER TURN THIS SWITCH TO THE ON POSITION UNLESS THE UPS HAS BEEN PLACED INTO MANUAL BYPASS, OR THE UPS INPUT AC CIRCUIT BREAKER HAS BEEN TURNED OFF ALWAYS TURN ON AFTER THE BATTERY CIRCUIT B
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Please refer to the battery bank selection guide on page 11 for more model details. EXTENDED BATTERY BANK DC INTERCONNECTION (All models except hardwire) 2nd Extended Battery 1st Extended Battery Bank Bank Connections Connections (Rear Panel View) (Rear Panel View) To the Battery Connector Detailed To UPS Battery Connector To the Battery Connector on on the second Battery Bank View (See Step 3 below) the next Battery Bank RED PIN IS +240Vdc RED KEY PIN GREEN PIN IS Chassis Ground BLACK PIN IS
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CHAPTER 3 CHAPTER 3 OPERATION UPS FRONT PANEL INDICATOR AND FUNCTION KEYS 9 1 10 2 8 3 11 4 5 6 7 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 lit when the output load is greater than 75% of the rated output of the UPS. 2. BATTERY LEVEL INDICATOR LEDs *The third or top LED is lit w
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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 connected output load of the UPS drops to under 10% of the full rated output of the UPS, providing SW3 is in the "down" position (Green Mode Enable
