Ametek Surgex ups-17602-52r User manual

Online Battery Backup

UPS-17602-52R –6000 VA UPS

User Manual

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User Manual

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Table of Contents

1. Introduction 1

1-1. FCC Compliance 1

1-2. Safety 1

1-2-1. Safety Intended Use 1

1-2-2. Safety Notices 2

1-3. Emergency 3

1-4. Leakage Currents 3

1-5. Radio Interference 3

1-6. Batteries 3

1-7. Repackaging 4

1-8 About the Operating Instructions 4

1-9. Symbols 5

1-10. Documentation Structure 5

1-11. Preparation for Use 5

1-11-1. Delivery 5

1-11-2. Storage 5

1-12. Unpacking and Inspection 5

1-13. Handling 6

1-14. Environmental Conditions 6

1-15. Access to Area 6

1-16. Rack Loading 6

2. Rack/TowerInstallation 7

2-1. Tower Installation 7

2-2. Rack Installation 8

2-2-1. Attaching the mounting ears 8

2-2-2. Mechanical Fixing of 19-inch Units 8

2-2-3. Assembly Steps 9

2.3. Electrical Preparations for UPS Installation 11

2.3.1. External Protection and Isolating Devices 11

2.3.2. Installation Data 11

2.3.3. Cable sizes and Current 12

2.3.4. Connection Warnings 12

2.4 Connecting Mains and Load Cables 14

2.4.1 Prepare input and output cables 14

2.4.2 Connect the input and output cables to the terminal block 14

3. Operations 16

3-1. Operating Mode / Status Description 16

3-2. Button Operation 17

3-3. LED Indicators 18

3-4. Audible Alarm 18

3-5. Single UPS Operation 18

3-5-1. Turn on the UPS with utility power supply (to Line mode) 18

3-5-2. Turn on the UPS without utility power supply ( to Battery mode) 19

3-5-3. Connect devices to the UPS 19

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3-5-4. Charge the batteries

3-5-5. Battery mode operation

3-5-6. Test the batteries

3-5-7. Turn off the UPS with utility power supply in Line mode

3-5-8. Turn off the UPS without utility power supply in Battery mode

3.6. LCD Operation

3-6-1. Main Interface (Home Page)

3-6-2. Operation Menu

4. Interfaces

4-1. Serial Interface COM3

4-2. Interface Slot COM

5. Emergency Power Off (EPO)

6. Maintenance

6-1. Maintenance Warnings

6-2. Test, Replacement and Disposal of Batteries

6-2-1. Battery Replacement

………………………………………………………………………………….

6-3. Storage

6-4. Cleaning

7. Troubleshooting

7-1. Warning status

7-2. Fault Mode

………………………………………………………………………………………………

7-3. Troubleshooting Table

………………………………………………………………………………...

9. Appendix A : Specifications

……………………………………………………………………….

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1. Introduction

Thank you for selecting this uninterruptible power supply (UPS). SURGEX’s Rackmount UPS offers the most

reliable protection from the harmful effects of electrical line disturbances for your computing and communications

equipment. SURGEX’s ISO 9001 certification represents our commitment to building world-class products. We take

pride in every unit that leaves our facility.

1-1. FCC Compliance

ATTENTION: Changes or modifications to this unit not expressly approved by the party responsible or in

FCC compliance could void the user’s authority to operate the equipment.

This equipment was tested and complies with the limits for a Class A digital device, pursuant to Part 15

of FCC Rules. These limits are designed to provide reasonable protection against harmful Interference

when the UPS is operating in a commercial environment. The UPS generates, uses, and can radiate radio

frequency energy. If installation and use is not in accordance with the instruction manual, it may cause

harmful interference to radio communications.

ATTENTION: Operation of this equipment in a residential area may cause harmful radio communications

interference. The user is responsible for correcting the interference.

1-2. Safety

1-2-1. Safety Intended Use

This device serves as an uninterruptible power supply for connected loads. The device is in compliance with all

relevant safety regulations concerning information technology equipment, including electronic machines for use in

an office environment.

Depending on the type and rating of UPS device, certain configurations of battery extensions must be connected.

These battery extensions may only be connected to the compatible basic UPS unit.

This system, henceforward the “unit”, serves as uninterruptible power supply for connected loads, available for use

in 19-inch racks. The 6kVA must be operated with at least one rack mounted battery extension. These battery ex-

tensions may only be connected electrically with the corresponding base UPS unit.

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WARNING: SURGEX considers the safety of personnel to be of paramount importance. For this

reason, it is essential that procedures relating to safety be studied before commencing work, and properly

adhered to thereafter.

· The User or Operator may intervene in the operation of the UPS provided that the instructions laid

out in “Batteries” on page 3 and “Button Operation” on page 17 are adhered to.

· The “Installation”of the UPS, described in “Electrical Preparations for UPS Installation” on page 11,

may only be carried out by qualified technical personnel.

· Even when all switches and interrupters are open, hazardous voltages are present within the UPS;

any operation that requires protection panels to be opened and/or removed must be carried out by

SURGEX authorized technical personnel only.

· The UPS listed in Table 1 on page 4, with a mounting height of 3 U (1 U = 1.75” (44.45 mm), is

designed for horizontal installation in 19-inch racks of Industrial strength.

1-2-2. Safety Notices

WARNING: Carefully read the following safety notices! Failure to observe the instructions may

endanger your life, your health, the reliability of your device or the security of your data.

· Transport the unit only in suitable packaging (protected against jolts and shocks).

· If the equipment is moved from a cold environment to the operating room, condensation may occur.

Before you switch on the equipment it must be absolutely dry. An acclimatization period of at least

two hours is required.

· The equipment must be installed in accordance with the environmental conditions specified in

“Environmental Conditions” on page 6 and in Table 4 on page 11 . Install the UPS indoors, and in a

structurally sound area.

· Even with all buttons in “OFF” (see “Button Operation”on page 17) the device

(UPS) is not isolated from the mains. To isolate completely from the mains, the power cables must be

disconnected.

· Lay all cables so that nobody can stand on them or trip over them. When connecting the device to the

power supply, follow instructions in the section “Electrical Preparations for UPS Installation”on

page 11.

· Make sure that no objects (e.g. pins, necklaces, paper clips, etc.) fall inside the device.

· In emergencies (e.g. damaged case, controls or power cables, penetration of liquids or foreign matter)

switch off the device and contact the appropriate customer service representative.

· Do not connect equipment that will overload the UPS (e.g. laser printers or vacuum cleaners) or

demand DC-current (e.g. half-wave rectifiers).

· When cleaning the unit, follow the instructions in the chapter “Maintenance” on page 35.

· The sum of the leakage currents (protective conductor current) of the UPS and the connected devices

may exceed 3.5 mA for ratings of the UPS. Earth connection is essential before connecting supply.

Connect your UPS power module’s grounding terminal to a grounding electrode conductor.

· Data transmission lines should not be connected or disconnected during a thunderstorm.

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· The UPS is connected to a DC energy source (battery). The output terminals may be live when the UPS is

not connected to an AC supply.

· Emergency Power Off (EPO) input is located on the rear of the unit (see Figure 11 on page 13). When this

connection is open, the logic circuit will immediately shut down the UPS output.

· When mounting the unit in a rack, it has to be hooked on both sides and the front plate of the unit has

to be fixed to the rack by screws. The unit has to be fixed in a horizontal position.

· Do not install the UPS near magnetic storage media, as this may result in data corruption.

· The vents for air intake and outlet at the front and rear side must not be obstructed. Leave adequate space

around all sides of the UPS for proper ventilation.

· Do not mount the unit with its front or rear panel facing down (at any angle). Mounting in this manner

will seriously inhibit the units internal cooling, eventually causing product damage not covered by

warranty.

1-3. Emergency

WARNING: The supply to the load may be operated by opening all the switches.

WARNING: DO NOT USE WATER to extinguish any fires that may occur in the area in which the UPS

is installed.

1-4. Leakage Currents

WARNING: Connect the earth ground [protection earth (PE)] safety conductor before any other cables

are connected.

1-5. Radio Interference

The SurgeX UPS is a class A product. The UPS device may cause radio interference. Do not place it near

devices which are especially susceptible to electromagnetic interference (e.g. transmitters/receivers, radar, metal

detectors, anti-theft devices).

1-6. Batteries

Battery maintenance must be carried out by authorized personnel.

· The batteries installed in external battery cabinets may contain electrolyte. Under normal conditions the

containers are dry. A damaged battery may leak electrolyte which can be dangerous in contact with skin

and cause irritation to the eyes. Should this happen, wash the affected part with copious amounts of?

water and seek immediate medical advice.

· Voltage is always present on the battery contacts.

· Even when discharged a battery has a capacity to supply a high short circuit current, which, in addition to

causing damage to the battery itself and to associated cables, may expose the operator to the risk of

burns.

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·The voltage of a single cell of a single battery block is not dangerous. However, a number of cells or

battery blocks, connected in series, can produce hazardous voltages.

· The battery is a “hermetic” type battery and must not be kept in storage or disuse for periods exceeding 6

months at 68°F (20°C) without being recharged (having been charged to 100% at the beginning of any

such period). If this period is exceeded it is essential that the batteries be recharged, which requires that the

UPS be switched on. If these conditions are not respected the performance of the battery can no l longer be

guaranteed. We advise recharging the batteries at least once every 4 months.

· Since new batteries often do not provide full capacity after an initial charge it may be necessary to carry

out a number of discharge/recharge cycles before optimum performance is achieved.

· In order to protect the environment batteries must be disposed of in accordance with the regulations

governing disposal of toxic and harmful waste.

1-7. Repackaging

To re-pack, proceed as follows:

1. Do not pack the equipment until at least six hours have elapsed since the last recharge.

2. Place the equipment in bags made of a material sufficiently porous to allow it to breath (e.g. 100µm

polyethylene).

3. Do not remove air from the packaging.

1-8. About the Operating Instructions

This manual contains information regarding the installation, operation and use of the Uninterruptible Power Supply

(UPS). It is advised that this instruction manual be consulted before installation of the equipment, which operation

shall only be carried out by qualified personnel. Thereafter, it shall be kept and referred to whenever it is necessary

to carry out work on the UPS.

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1-9. Symbols

The following symbols are used in this handbook:

WARNING: indicates instructions which, if not observed, may endanger your life, your

health, the reliability of your device or the security of your data.

NOTE: Indicates additional information and tips.

1-10. Documentation Structure

These instructions can be supplemented with additional sheets, describing, for example, specific extensions,

options or device status.

1-11. Preparationfor Use

1-11-1. Delivery

The goods have been checked thoroughly before dispatch. On receipt check the packaging and ensure that the con-

tents are undamaged.

1-11-2. Storage

If it is not intended that the UPS be used immediately upon delivery, attention shall be paid to the storage

conditions.

If the batteries or the equipment is to be stored, they must be kept clean, in a dry environment and away

from extremes of temperature.

Table 2: Storage Data

Temperature limits - Batteries ONLY

+32°F to +104°F (0°C to +40°C)

Temperature limits - UPS without batteries

-13°F to +131°F (-25°C to +55°C)

Relative humidity

from 10% to 90%

1-12. Unpacking and Inspection

The utmost care shall be taken when removing the packaging in order to avoid damaging the equipment.

Check all packaging materials to ensure that no items are discarded.

WARNING: A battery cabinet is very heavy. The unit weight of a battery cabinet is 142 lbs. (64.5kg).

To prevent personal injury or damage to the battery cabinet suitable lifting equipment and multiple people

should be employed when lifting the battery cabinet.

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Unpack the package and check the package contents. The shipping package contains:

UPS Shipping Package

Battery Shipping Package

1. One UPS

2. One user manual

3. Rail kit

4. One USB cable

5. Two sets of tower stands consisting of two

feet, two short and four long extensions

6. One parallel cable and one current share cable

(units with parallel option only)

7. Two Mounting ears

8. Ferrules

1. One Battery cabinet

2. One Battery cable

3. Two Mounting ears

4. Rail kit

5. Two sets of tower stands consisting of two feet

and two short extensions

NOTE: Before installation, please inspect the unit. Be sure that the unit is not damaged during transportation.

Do not turn on the unit and notify the carrier and dealer immediately if there is any damage or lacking of some

parts. Please keep the original package in a safe place for future use.

1-13. Handling

The equipment must be kept upright at all times and handled with care, damage may be caused if dropped or

subjected to severe impact.

1-14. EnvironmentalConditions

The UPS must be installed in an area protected from extremes of temperature, water and humidity and the

presence of conductive powder or dust. (See Table 4 on page 11). Do not stack units and do not place any objects

on top of a unit.

The functional temperature range of the UPS is 32°F to 104°F (0°C to 40°C).

The ideal ambient temperature range is 59°F to 77°F (15°C to 25°C). The maximum ambient operating tempera-

ture is 104°F (40°C).

The battery life is defined at 68°F (20°C). Operation of the equipment above 77°F (25°C) reduces the service life

of the batteries dramatically.

1-15. Access to area

The area must have sufficient space for the installation operation to be carried out. Access doors must be suffi-

ciently large to permit passage of the unit .

1-16. Rack Loading

Taking into consideration the weight of the UPS/batteries as reported in the mechanical specifications for the

battery cabinet on page 48, it is necessary that the chosen cabinet be capable of supporting the weight of the

unit/batteries.

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2. Rack/Tower Installation

2-1. Tower Installation

The UPS system ships with two sets of feet and 6 extensions (2 short extensions plus 4 long extensions)

that can be used to install the UPS module in the Tower configuration.

A. Install Stand-a-lone. Refer to Figure 1.

Assemble two feet and one short extension as one tower stand as shown in Step 1.

Align the two stands approximately 35 cm apart as shown in Step 2.

Put the UPS module in the stands as shown in Step 3.

Figure 1

B. Install UPS module and one battery bank as shown in Figure 2 below.

Assemble two feet and two long extensions as one tower stand as shown in Step 1.

Align the two stands approximately 35 cm apart as shown in Step 2.

Put the UPS module and battery bank in the stands as shown in Step 3.

Figure 2

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2-2. Rack Installation

2-2-1. Attaching the Mounting Ears

Attach the mounting ears to the side mounting holes of UPS or the battery bank using the screws provided. The

ears should be oriented as shown in Figure 3 below.

2-2-2. Mechanical Fixing of 19-inch Units

Selection of the mounting location

Figure 3

NOTE: The UPS and its battery cabinets are designed to be mounted horizontally in 19-racks. When installing

the units, please consider the weight, especially of the battery extension. Preferably the units should be installed

in the lower section of the rack. UPS systems consisting of several units must be installed so that the battery

extensions are mounted in the lower section of the rack with the UPS directly above.

Included in each Rackmount carton is a rail kit. The Rail Kit consists of the following components (refer to

Figure 4):

Figure 4

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2-2-3. Assembly Steps

Step 1: Use 4 M6 screws to mount the right and left rail sliders to the two front posts of the four-post rack.

Refer to Figure 5 below.

Figure 5

Step 2. Use 4 M6 screws to mount the right and left rail sliders to the two back posts of the four-post rack.

Refer to Figure 6 below.

Figure 6

Step 3. Insert one M6 nut into the right and left front posts of the four-post rack for a 3U installation.

Refer to Figure 7 below.

Figure 7

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Step 4: Slide the UPS with its right and left ears attached onto the rail guide until the ears are in contact with

the front of the rail guide. Refer to Figure 8 below.

Figure 8

Step 5: Fasten each ear to the rack with the M6 screws. Refer to Figure 9 below.

Figure 9

Step 6: Assembly complete.

Figure 10

When the unit is securely in the rack continue with the electrical installation. See “Electrical Preparations for UPS

Installation” on page 11.

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2-3. Electrical Preparations for UPS Installation

Installation and wiring must be performed in accordance with the local electric laws/regulations by authorized

technical personnel only.

Make sure the mains wire and breakers in the building are enough for the rated capacity of UPS to avoid the haz-

ards of electric shock or fire.

NOTE: Do not use the wall receptacle as the input power source for the UPS, as its rated current is less than the

UPS’s maximum input current. Otherwise the receptacle may be burned and destroyed.

Switch off the mains switch in the building before installation.

Turn off all the connected devices before connecting to the UPS.

2-3-1. External Protection and Isolating Devices

WARNING: A disconnect switch shall be provided by others for the AC input circuit. To reduce the

risk of fire, connect only to a circuit provided with branch circuit over current protection for Table 3

Amperes rating in accordance with the National Electric Code, ANSINFPA 70.

The following table indicates the protection devices (circuit breakers and fuses) which must be installed

by the installing personnel for protection of both the cables and the equipment. One external branch

breaker on the UPS output side is strongly recommended for over-current protection and for easy

disconnecting the load device.

Table 3: Fuses or circuit breakers

UPS Part Number

UPS-17602-52R

INPUT

Fuse

50A

Circuit Breaker

50A

2-3-2. Installation Data

Table 4: Environment Data

Ambient temperature

+32°F to +104°F (0°C to +40°C)

Relative humidity (w/0 condensing at 20°C

90%

Max. altitude (w/o de-rating)

1000 m a.s.l

Cable inlet

Bottom at the rear side

Air inlet

front

Air outlet

rear

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2-3-3. Cable Sizes and Current

The following table indicates the recommended sizes of conductors in accordance with the NEC®.

(air temperature surrounding the conduits not greater than 104°F (40°C).)

NOTE: Cable sizes are suggested and based on standard configurations. Installed input/output wiring for the UPS

should be able to withstand over 40 amps of current. Installers should verify correct conductor sizes and

temperature ratings pursuant to NEC® and/or state or local codes. If the installation requires long conductor runs,

consult NEC® and/or state or local codes to account for electrical losses.

Table 5

Term ID

Description

UPS Part Number

UPS-17602-52R

Wire gauge

(awg)

Term torque

(in - lbs.)

min wire temp

(°C)

Input

Mains

Input Line

Input Neutral

GND

Input Ground

Output

Output Line

Output Neutral

GND

Output Ground

2-3-4. Connection Warnings

WARNING: Carefully read the following safety notices!

· There is feedback protection inside.

· The UPS should be connected with TN earthing system.

· The power supply for this unit must be single-phase rated in accordance with the equipment nameplate.

It must also be suitably grounded.

· Use of this equipment in life support applications where failure of this equipment can reasonably be

expected to cause failure of the life support equipment or to significantly affect its safety or effectiveness

is not recommended. Do not use this equipment in the presence of a flammable anesthetic mixture with

air, oxygen, or nitrous oxide.

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Figure 11: UPS Rear Panel View

Figure 12: Battery Rear Panel

Legend

1. RS-232 communication port 11. Input/output terminal block

2. USB communication port 12. Input terminals

3. EPO (Emergency Power Off) connector 13. Input ground terminal

4. Share current port (for parallel function) 14. Output terminals

5. Parallel port (for parallel function) 15. Output ground terminal

6. Intelligent slot 16. IEC 320-C19 output receptacles

7. EMBS (External Maintain Bypass Switch) port 17. 16A Output circuit breakers

8. Cooling fan 18. Battery pack output circuit breaker

9. External battery connector 19. Part number and serial number label

10. Input circuit breaker

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2-4. Connecting Mains and Load Cables

Installation and wiring must be performed in accordance with the local electric laws/regulations and execute the

following instructions by professional personnel.

Make sure the mains wire and breakers in the building are enough for the rated capacity of UPS to avoid the haz-

ards of electric shock or fire.

NOTE: Do not use the wall receptacle as the input power source for the UPS, as its rated current is less than the

UPS’s maximum input current. Otherwise the receptacle may be burned and destroyed.

Switch off the mains switch in the building before installation.

Turn off all the connected devices before connecting to the UPS.

2-4-1 Prepare input and output cables

Prepare the input and output cables as described in Table 5 on page 12 and as shown in the figure below.

The selections for color of wires should be followed by the local electrical laws and regulations.

Remove 5/8” length of insulation from each of the conductors and terminate each conductor with a ferrule.

2-4-2 Connect the input and output cables to the terminal o k

Remove the cover from the terminal block housing located on the rear panel of UPS. Then connect the wires as

shown in figure 13 on page 15 (Refer to Table 5 on page 12 and to Figure 11 on page 13). It is suggested that the

input and output cables to the UPS be housed in earthed, metal conduits suitable for the wire box cover opening

(1.375 inches).

After connecting the wires and strain relief reattach the cover to the terminal block housing.

NOTE: Make sure that the wires are connected tightly to the terminals. Refer to Table 5 on page 12.

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Figure 13. Input, Output and Ground connections to the UPS (shown with strain relief)

Warning:

• Make sure the UPS is not turned on before installation. The UPS should not be turned on during wiring con-

nection.

• Do not try to modify the standard model to the long-run model. Particularly, do not try to connect the standard

battery cabinet to a non-standard external battery. The battery type and voltage may be different. If you con-

nect them together, it may lead to increased risk of electric shock or fire!

Warning:

• For standard battery pack, there is one DC breaker to disconnect the battery pack and the UPS. But for other

external battery pack, make sure a DC breaker or other protection device between UPS and external battery

pack is installed. If not, please install it carefully. Switch off the battery breaker before installation.

NOTE: Set the battery pack breaker in “OFF” position and then install the battery pack.

• Pay attention to the rated battery voltage marked on the rear panel. If you want to change the numbers of the

battery pack, please make sure you modify the setting simultaneously. The connection with wrong battery

voltage may cause permanent damage of the UPS. Make sure the voltage of the battery pack is correct.

• Pay attention to the polarity marking on external battery terminal block, and make sure the correct battery

polarity is connected. Wrong connection may cause permanent damage of the UPS.

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3. OPERATIONS

3-1. Operating Mode/Status Description

Mode/Status

Description

UPS Power On

When UPS is powered on, it will enter into this mode for a few seconds for initializing

the system.

AC Mode

When the input voltage is within acceptable range, and the UPS is turned on (the in-

verter is running), the UPS will provide pure and stable sine wave AC voltage. The

UPS will also charge the battery in AC mode.

Converter Mode

When input frequency is within 46 to 64Hz, the UPS can be set with a constant output

frequency (50 Hz or 60Hz) through the inverter. The UPS will still charge battery at

this mode. There is no bypass at this mode.

Battery Mode

When the input voltage is out of the acceptable range or power failure, and the UPS is

turned on (the inverter is running), the UPS will backup power from battery.

Bypass Mode

When input voltage is within acceptable range and the bypass is enabled, and the UPS

(inverter) is not turned on or the inverter can’t support the load, the UPS will supply

power to the load through bypass.

Battery Test Mode

When the UPS is in AC mode or Converter mode, and the battery test command is

enabled through LCD or monitoring software, the UPS will start Battery test. This

operation is used to check the battery status.

Warning Status

If some error occurs in the UPS (but is still running normally), the buzzer will alarm

and warning code will appear in the LCD for troubleshooting.

Fault Mode

When fatal error occurs in the UPS, it will beep continuously and go to fault mode.

It will display fault codes in LCD.

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