AMETEK Electronic Systems SURGEX UPS-32020-80 User manual

© 2018 AMETEK Electronic Systems Protection / Technical Support: 1-800-645-9721 / espsurgex.com / UM-UPS-32020-80-Rev-A
Uninterruptible Power Supply
UPS-32020-80
User Manual

© 2018 AMETEK Electronic Systems Protection / Technical Support: 1-800-645-9721 / espsurgex.com 2
Table of Contents
1. Introduction and Safety
Important Safety
Instructions 4
Note to
Users 6
2. Installation
UPS Unpacking
Instructions 8
UPS
Installation 10
Clearance
Guide 11
Wiring
Guide 12
UPS Connector Terminals and Lug
locations 13
3. Product Specifications
UPS-32020-80 Product
Specifications 17
4. Operation
UPS Operational
Overview 19
UPS Operation: Normal
Mode 19
UPS Operation: Battery
Mode 20
UPS Operation: Bypass
Mode 21
UPS Operation: Emergency
Bypass 22
UPS Operation: Manual Maintenance Bypass
Mode 23
Touch Screen Description, Calibration, Using the Touch
Screen 24
Touch Screen Descriptions
(Monitoring) 25
UPS Startup
Sequence 26
UPS Shutdown
Sequence 31
UPS Maintenance Bypass
Sequence 33
Monitor
Functions 41

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Control Functions 43
Touch Screen Menu’s 57
5. Maintenance
UPS Maintenance 75
Battery Maintenance 76
Battery Replacement 77
6. Service and Troubleshooting
Alarm Severity Definitions 85
Alarms Messages 86
7. Drawings
UPS Outline Drawings 90
Block Diagram (UPS + External Battery Cabinet) 91
Block Diagram (UPS + Input Transformer Cabinet) 92
Block Diagram (UPS + Output Transformer Cabinet) 93
Block Diagram (UPS + Input/Output Transformer) 94
Block Diagram (UPS + 3 Breaker MBS) 95
Block Diagram (UPS + 3 Breaker MBS + Input Step-Down Transformer) 96
Block Diagram (UPS + 3 Breaker MBS + Output Isolation Transformer) 97
Block Diagram (UPS + 3 Breaker MBS + Input/Output Transformers) 98
Facility Data Planning Guide 100

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1. Introduction and Safety
****IMPORTANTSAFETY
INSTRUCTIONS****
****SAVE THESE
INSTRUCTIONS****
This manual contains important instructions to be followed during installation and maintenance of the
UPS and batteries.
Please read all instructions before installing or operating the described equipment and
PLEASE SAVE THIS MANUAL FOR FUTURE REFERENCE!
SPECIAL SYMBOLS: The following are examples of symbols used on the UPS, or within this manual to
alert you to important information. Please familiarize yourself with these symbols.
Risk of Electric Shock- observe the warnings associated with the risk of electrical
shock.
CAUTION: HOT SURFACE –Do not touch! Risk of burn hazard.
CAUTION: REFER TO OPERATOR’S MANUAL—refer to operator’s
manual for additional information, such as specific
operating and/or maintenance instructions.

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Do Not Discard--this equipment utilizes components that contain lead and must be
disposed of properly. For more information, contact your local recycling/refuse or hazardous waste
center.
Do Not Discard-- never discard Waste Electrical or Electronic Equipment
(WEEE) in the trash. For proper disposal contact your local recycling/refuse or hazardous waste center.
Information of Special Note--Specific handling or operational instructions may
apply.
Phase--This is the electrical symbol for the word “phase”.
Recycle—equipment or components are made of recyclable material, please
contact your local recycling center for proper disposal.

© 2018 AMETEK Electronic Systems Protection / Technical Support: 1-800-645-9721 / espsurgex.com 6
NOTE TO USERS
To ensure correct operation of the UPS, please read this instruction manual carefully. Please
keep this manual handy for future reference.
This UPS has dangerouslyhigh voltageson both its Input and output
connections. Contact with these voltages may
be life threatening. Please follow the operating instructions
carefully. Please give close attention to the warnings in this manual and those
posted on the UPS. There are no user serviceable parts inside the UPS.
Disassembly and/or
maintenance should only be done by authorizedpersonnel.
IMPORTANT INFORMATION FOR USERS OF THIS
UNINTERRUPTIBLE POWER SUPPLY
1. Before operating the UPS or connecting any load equipment, please ensure the UPS
is connected to a properly grounded electrical supply.
2. This UPS has dangerouslyhigh voltages on both its input and output connections.
Contact with these voltages may be life threatening.
3. Please do not disassemble the covers. There is a risk of electric shock.
4. In an emergency, immediately turn off the circuit breaker for the circuit supplying power to the UPS.
Also immediately turn off the battery circuit breaker.
5. This UPS has two power sources. One is the circuit supplying the UPS with input power. The other is the
UPS battery. Prior to any maintenance, both of these power sources must be disconnected to ensure that
the UPS is de-energized. If only the input power is disconnected, the UPS can still operate from the
battery, and hazardous voltages may still exist.
6. To prevent damage or a safety hazard, keep the UPS away from open flame and any other devices that
may cause sparks.
7. Do not open or damage individual battery cases as spillage of caustic electrolyte may occur resulting
in danger to life, safety, and the environment.
8. The charging characteristicsof UPS batteries vary by both brand and type. For this reason, replacement
batteries should be of the same brand and type as those specified by the manufacturer. Using batteries
other than the brand and type specified by the manufacturermay affect the performance of the UPS.
Before installing batteries of different brand or type, please consult with the manufacturer.
9. The UPS has an internal EMI filter for purposes of enhancing electromagnetic compatibility with the
input mains supply. This filter produces leakage current to earth on the input mains. When selecting a
circuit breaker for the branch circuit

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supplying power to the UPS, ensure that the breaker selected is not an ELCB type circuit breaker that
detects earth leakage current.
10. Please contact the manufacturer or an authorized distributor for any assistance with troubleshooting.
11. The UPS should only be serviced or maintained by a factory authorized service technician.
12. This UPS meets FCC Class A electromagnetic compatibility requirements.
13. Depleted batteries must be disposed of in a proper manner. Contact your local recycling or
hazardous waste center or the UPS manufacturer for instructions concerning proper disposal.
LIFE CRITICAL APPLICATIONS
While SURGEX believes it designs and manufactures very reliable Products, many of the
vendors that SURGEX sources components from do not recommend or endorse the use of
their Products in life critical applications. By extension, SURGEX must adhere to the same
business policy and does not recommend the use of our Products in life critical applications.
Disclaimer
SURGEX Products are not designed, intended, authorized, tested, or UL Listed for use in
systems intended to support or sustain life, or for any other application in which the failure of a
SURGEX Product could create a situation where personal injury or death may occur. Should
Buyer purchase or use SURGEX Products for any such unintended or unauthorized application,
Buyer shall indemnify and hold SURGEX and its officers, employees, subsidiaries, affiliates
and distributors harmless against all claims, costs, damages and expenses, and reasonable
attorney fees arising out of, directly or indirectly, any claim or personal injury or death
associated with such unintended or unauthorized use, even if such claim alleges that SURGEX
was negligent regarding the design or manufacture of the part.

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2. Installation
UPS Unpacking Instructions
The SURGEX UPS-32020-80 comes packed in heavy cardboard with foam
dividers on a heavy wooden pallet. The unit is bolted to the skid with two metal brackets. A
wooden ramp is stored vertically in front of the UPS. This ramp is used to move the UPS off of
its shipping pallet.
Note: SURGEX encourages the end user to retain all shipping materials
until the UPS has been inspected, installed and verified for proper operation.
The SURGEX UPS-32020-80 UPS utilizes internal batteries which are pre-assembled in
individual trays and shipped separately from the UPS. These trays come completely wired and
ready for connection to the internal battery harness of the UPS. A quick visual inspection is
requested to determine if any connections were unseated during the shipping process.
Unpacking the UPS requires a 19mm wrench or socket. To remove the UPS from the packing
materials:
1. Visually inspect the unit for any signs of transit damage (Fig. 2-1). Remove and retain all
associated paperwork (packing list, user’s manual etc.) that is affixed to the top of the
unit. Remove the cardboard lid from the top of the container.
2. Remove any fasteners from the lower edge of the cardboard container.
3. With the help of an assistant, carefully lift the heavy cardboard container straight up until
it is clear of the UPS. (Fig. 2-2)
4. Remove the foam dividers. (Fig. 2-3)
5. Lift the ramp clear of the alignment pin, and place it sloping downward at the front of the
UPS, using the pin to hold the back of the ramp in place.
6. Remove the protective plastic cover from the UPS.
7. The UPS is attached to the shipping pallet with two shipping brackets—one on each side
of the UPS. Using an adjustable wrench or 19mm socket, remove the three bolts that
attach the bracket to the UPS. If your location has a Seismic requirement, please contact
factory for Seismic installation instructions. (Fig. 2-4)
8. The UPS has two leveling feet. Be sure to check that the levelers are up against the
bottom of the UPS to ensure it rolls freely on the ramp.

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9. With the help of an assistant, carefully roll the UPS off the pallet and down the ramp to
the floor of your facility. If the floor at your desired UPS location is uneven, the levelers
may be used to steady the UPS, once it is in place.
Please do not install batteries in the UPS. Batteries should be installed ONLY
by factory authorized personnel once the UPS is in its final location, and at the time of
initial startup.
Fig. 2-1 Fig. 2-2 Fig. 2-3
UPS
Leveler
Shipping
bracket
bolts (3
per side)
Fig. 2-4

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UPS Installation
The installation of this UPS should be performed only by
qualified personnel who are familiar with UPS and battery systems and
the required precautions necessary for safe and proper installation.
Unauthorized and /or unqualified personnel should not attempt to install
or service this equipment. Any damage resulting from installation or
service performed by unauthorized/unqualifiedpersonnel, or non-
compliance with any pertinent local codes will void the warranty of
this equipment.
Maximum operating ambient temperature is 40°C
Storage (non-operating) ambient temperature range is -20°C to 60°C
Please consult the Facility Data Planning Guide for floor loading and unit cooling characteristics.
The levelers are not designed to support the weight of the entire unit, they are to be used when
the floor is not entirely level.
CAUTION: Please confirm that the AC Input switch and the Battery Disconnect
switch are in the “Off”position, and the Manual Maintenance Bypass is in the “Normal”
position, before making any connections to this UPS.
The SURGEX UPS-32020-80 requires a 208V three phase, four wire (+ ground) input for
proper operation. Input over current protection and the output disconnect are to be
provided by the user. The Facility Data Planning Guide is available as a guideline to assist with
the installation of the UPS. This document however, is not intended as a substitute or to
supersede any regional or local electrical codes. In the event of questions or controversy
regarding the installation of this equipment, the local Authority Having Jurisdiction (AHJ)
should always be consulted and will have the ultimate final approval over the installation.