Falcon SG800-1, SG800-2 SG1K-1T, SG1K-2T SG2K-1T Use and care manual

BATTERY
REPLACEMENT
GUIDE
Uninterruptible Power Supply Models:
SG1K-1T, SG1K-2T
®
2004 Falcon®Electric Inc. All rights reserved.
All other brand names and trademarks are the property of their respective owners.
The information stated in this document is subject to change without notice. 2004-02-02
Falcon®, Falcon® Electric and UPS Plus logos are registered trademarks of Falcon Electric Inc
FALCONElectric Inc., 5116 Azusa Canyon Rd., Irwindale, California 91706, [phone], Fax [phone], Email: [e-mail]

IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This guide contains important instructions which must be followed during the maintenance of
this UPS and its batteries. Please read all instructions before operating this equipment and
save this guide for future reference.
Servicing of batteries should be performed or supervised by personnel knowledgeable
of batteries and the required precautions. Keep unauthorized personnel away from
batteries. When replacing the UPS batteries, use the same number and type of
batteries.
High voltage exists within the unit, which could cause electrical shock. Always unplug
this UPS and remove the UPS battery fuse (if present) prior to attempting battery
replacement.
This UPS contains its own energy source (batteries). The output receptacles may carry
live voltage even when the UPS is not connected to an AC source.
This UPS contains sealed maintenance-free batteries (VRLA). When situated in a
typical office environment, with the proper charging and limited cycling, the batteries
can last many years. In home, office or computer room environments, the batteries
should be replaced every three to five years. In critical applications replace the
batteries every two years.
When replacing the UPS batteries, use the same number and type of batteries. The
batteries approved for the Falcon SG1K-1T & SG1K-2T models are as follows:
3 pieces of Yuasa/Enersys NP7-12, 7Amp Hour, 12Vdc VRLA Type Battery
or
3 pieces of CSB GP 1272 F2, 7.2 Amp Hour, 12Vdc VRLA Type Battery
NEVER dispose of batteries in a fire, as batteries will explode.
NEVER dispose of used batteries in the trash or landfill as it is a violation of federal
and state laws. The batteries must be recycled.
For battery recycling information, please contact:
www.enersysinc.com/default.asp or
www.csb-battery.com/Top/english/recycle_state.htm
for the name and address of the nearest battery recycling facility.
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
1

Never open or mutilate the battery or batteries. Released electrolyte is
harmful to the skin and eyes. It may be toxic.
A battery can present a risk of electrical shock and high short circuit current.
ALL BATTERY SERVICING OR REPLACEMENT MUST BE PERFORMED BY
A QUALIFIED SERVICE TECHNICIAN.
ALL BATTERY SERVICING OR REPLACEMENT IS PERFORMED AT THE
RISK OF THE PERSONS, ENTITIES OR COMPANIES PERFORMING THE
BATTERY SERVICING OR REPLACEMENT OF FALCON ELECTRIC INC.
PRODUCTS.
THE FOLLOWING IS GIVEN AS A GUIDE ONLY. THE PERSON(S)
PERFORMING THE BATTERY REPLACEMENT MUST HAVE PRIOR
KNOWLEDGE AND EXPERIENCE IN UPS BATTERY REPLACEMENT, AND
IN THE PROPER CARE, HANDLING AND RECYCLING OF SEALED LEAD
ACID BATTERIES.
LIMITATION OF LIABILITY:
FALCON ELECTRIC, INC. ASSUMES NO LIABILITY FOR INCIDENTAL OR
CONSEQUENTIAL LOSS OR DAMAGE DUE TO THE THIRD PARTY SERVICING
OR REPLACEMENT OF BATTERIES IN FALCON PRODUCTS, INCLUDING BUT
NOT LIMITED TO, LIABILITY FOR INJURY, LOSS OF LIFE, PROPERTY DAMAGE,
LOSS OF USE, LOSS OF DATA, LOSS OF TIME, INCONVENIENCE OR
COMMERCIAL LOSS, OR BREACH OF IMPLIED OR EXPRESSED WARRANTIES.
ANY AND ALL SUCH LIABILITY IS EXPRESSLY EXCLUDED. IN NO EVENT
SHALL FALCON ELECTRIC INC. BE RESPONSIBLE FOR ANY AMOUNT. IF
FALCON ELECTRIC INC. DETERMINES THAT ANY THIRD PARTY SERVICE WORK
HAS BEEN PERFORMED IMPROPERLY OR IN AMANNER INCONSISTENT WITH
FALCON ELECTRIC INC. SERVICING AND WORKMANSHIP CRITERIA ALL
EXISTING WARRANTIES IN EFFECT FOR THAT PRODUCT WILL BECOME NULL
AND VOID.
CAUTION
CAUTION
2

Battery Replacement Guideline
1. Per the picture below detailing the SG1K-1T rear panel, remove the battery fuse. For
SG1K- 2T models there is no rear panel mounted battery fuse. Go to step 2.
2. Per the picture below remove the two screws securing the UPS top cover to the rear
panel.
3. Per the picture below, turn the UPS so the bottom of the UPS is facing you (UPS on
its side).
4. Remove the four screws securing the UPS top cover to the bottom of the UPS
chassis.
5. Carefully return the UPS and top cover to the upright position.
6. Carefully slide the top cover off toward the rear panel direction. Take care to ensure
the top cover does not short on any of the internal UPS electronics when removing.
Screw # 1 securing the
top cover to the rear
panel
Screw # 2 securing the
top cover to the rear
panel
UPS Battery fuse
4 screws securing the
top cover to the bottom
of the UPS chassis
3

7. Remove the two screws securing the battery hold-down bracket. Next, unplug the
sensor board connector.
8. Remove the third screw securing the battery hold-down bracket (see detail picture)
9. Gently lift the battery hold down bracket and rotate it off of the batteries. Use care
not to pull the remaining wiring connected to the battery hold down bracket.
10. Immediately disconnect the red battery wire marked 15+ connected to the + (red)
terminal of BATT 3.
11. Lift the batteries to an upright position and disconnect the black wire marked
15- and disconnect the two black battery jumper wires.
Battery hold down
bracket
2 screws securing hold
down bracket
Third screw securing
the battery hold down
bracket
Unplug top sensor
board connector
4
Exposed Batteries
Removed Battery Hold
Down Bracket
BATT 1 BATT 2 BATT 3

12. Note the position of the three batteries and remove them from the chassis. See the
battery connection diagram below.
WHEN REMOVING AND INSTALLING THE NEW BATTERIES, EXTREME CARE MUST
BE USED NOT TO SHORT METAL CHASSIS PARTS ACROSS THE BATTERY
TERMINALS AND NOT TO SHORT THE BATTERIES TO EACH OTHER OR
PERSONAL INJURY MAY RESULT.
13. Verify the UPS chassis is positioned as shown in step 9 and position the three new
batteries upright in the UPS chassis as shown in the battery connection diagram
above.
14. Reconnect the Red 15+ wire to the + (red) terminal on BATT 3 as shown.
15. Reconnect one end of the 1st Black jumper wire to the - (black) terminal of BATT 3
and reconnect the second end of the 1st jumper to the + (red) terminal of BATT 2
as shown.
16. Reconnect one end of the 2nd Black jumper wire to the - (black) terminal of BATT 2
and reconnect the second end of the 2nd jumper to the + (red) terminal of BATT 1
as shown above.
17. Using a DC Volt Meter touch the red lead of the meter on the + (red) BATT3
terminal and touch the black meter lead to the - (black) BATT 1 terminal. The meter
should read +36-41Vdc if the batteries are connected correctly. If the voltage
readings incorrect or reads -36-41Vdc check all battery wiring connection and
meter lead polarity. This voltage must read +36-41Vdc before performing the next
step.
CAUTION
+
+ +
RED 15+ WIre
to RED (+)
TERMINAL
1st Black Jumper Wire
2nd Black Jumper Wire
BLACK 15-
Wire to
BLACK
TERMINAL
-
--
Battery Connection Diagram
BATT3BATT2
BATT1
5

18. If the UPS is model SG1K-2T,. temporally connect one end of a 100 ohm, 10 watt
resistor to the - (black) terminal of BATT 1. Next, touch the metal fast-on terminal to
the other end of the resistor for 30 seconds. Next, remove the resistor and
reconnect the Black 15- wire to the - (black) terminal of BATT 1 as shown on the
previous page. This is necessary to precharge the UPS electronics.
19. If the UPS is model SG1K-1T, reconnect the Black 15- wire to the - (black) terminal
of BATT 1 as shown in the battery connection diagram on the previous page.
20. Recheck all battery connections to make sure the fast-on terminals are all the way on
and are tight.
21. Lay BATT 1 down on its side on the direction indicated by the associated arrow in the
battery connection diagram on the previous page.
22. Lay BATT 2 down on its side on the direction indicated by the associated arrow in the
battery connection diagram on the previous page. (BATT 2 Terminals should be facing
and opposite the terminals on BATT 1).
23. Lay BATT 3 down on its side on the direction indicated by the associated arrow in the
battery connection diagram on the previous page. (The bottom of BATT 2 should be
flat against the bottom of BATT 1).
24. Dress the battery wiring between and around the batteries so that the wires will not
be pinched between the battery hold down bracket when reinstalled. Also check to
make sure that no wiring can be pinched or shorted to the battery terminals.
25. Carefully rotate the battery hold down bracket back up over the batteries. Dress
wiring around the bracket and verify no wiring is pinched under the bracket or
between the bracket and the batteries.
26. Reinstall the third screw removed in step 8 and tighten.
27. Reinstall the two screws removed in step 7 and tighten
28. Reconnect the sensor board connector removed in step 7 and verify the lock is in
place with the mating connector.
29. Perform a last visual inspection. Check all wiring and connections. Make sure no
wiring will be pinched or shorted when the UPS top cover is reinstalled.
30. Set the UPS in an upright position.
31. Position the top cover so the open side slides over the rear of the UPS and continue
to slide it forward until the front of the top cover is flush with the UPS front plastic
bezel. Verify no wiring has been pinched. Use care not to short the top cover to the
internal UPS electronics.
6

32. Reinstall the two rear panel screws removed in step 2 and tighten.
33. Gently place the UPS on its side with the bottom facing you.
34. Reinstall the four screws removed in step 4 and tighten.
35. If the UPS is model SG1K-1T reinstall the battery fuse and cap.
36. Connect the UPS to an utility power source.
37. Turn on the UPS power switch located on the rear panel. The UPS should power up
and function normally as defined in the Owner’s Manual.
38. Leave the UPS turned on for 24 hours to allow the batteries to fully charge.
7