Santak CASTLE On-Line Series User manual

3C15KS/3C20KS

Thank you for selecting a SANTAK product to protect your
electrical equipment.
This manual contains important instructions that you
should follow during installation and maintenance of the
UPS and batteries. Please read all instructions before
operating the equipment and save this manual for future
reference.

Safety Instructions
Please read carefully the following user manual and the
safety instructions before installing or operating the unit!
Operation Safety
1. Please read all instructions before operating the equipment and
connecting to mains power, save this manual for future reference.
2. Please pay attention to all the warning indication, understand and
follow all the instruction.
3. Do not install the UPS where it would be exposed to direct sunlight ,
Rain or damp environment.
4. Do not install the UPS near to heating equipment or heating source
and heating environment.
5. Do not block ventilation openings on the UPS’s housing. Ensure
the air vents on the front, side and rear of the UPS are not blocked.
Recommended at least 50cm of space on each side.
6. Use dry cloth for cleaning.
7. Use dry-chemical fire extinguisher when UPS present fire danger,
do not use fluid-fire extinguisher, fluid- fire extinguisher will cause
hazards shock.
Electricity Safety
Do not remove the enclosure. This system is to be serviced by qualified
service person only. There are NO USER SERVICEABLE PARTS inside
the UPS.
1. Assure UPS is reliably connected to earth properly, verify
connecting wire and battery polarity is correct before turn on UPS
with mains power.
2. If UPS requests moving to another place or reconnecting power
wire, it is imperative to disconnect all the power connections of
UPS, and turn off UPS.

3. Please used the UPS accessories specified by SANTAK.
4. Shock Risk.
If equipment powered by UPS require any type of maintenance, it
is imperative to disconnect it from UPS before maintenance.
If input or output terminal need any maintenance or installation, it is
imperative to disconnect all the power connections of UPS and turn
UPS off.
BATTERY SAFETY
1. The service lifetime of UPS battery depends on ambient temperature,
high ambient temperature will impact the service lifetime of UPS battery.
Replace battery on regularly can help to keep UPS running efficiently
and provide backup time as expected.
2. Batteries must be maintained and replaced only by qualified person.
3. Batteries have a high short-circuited current and pose a risk of shock.
Take all precautionary measures specified below and any other
measures necessary when working with batteries:
A. remove all jewellery, wristwatches, rings and other
metal objects.
B. use only tools with insulated grips and handles.
C. Wear rubber gloves and boots.
D. Do not lay tools or metal parts on top of batteries.
E. Disconnect the charging source prior to connecting or
disconnecting battery terminals.
4. Do not attempt to dispose of batteries by burning them. It could cause
explosion.
5. Do not open or destroy batteries. Effluent electrolyte can cause injury to
the skin and eyes. It may be toxic. If cause injury by Effluent electrolyte,
use cool water for washing and go to hospital ask for help immediately.
6. Do not short the battery with metal objects, It could cause an electric
shock, fire or explosion.

Maintenance
1. The operation environment and store environment will impact on
the service lifetime and reliability of UPS.
Do not install or store the UPS in the places where are listed
below.
A. Do not install UPS in place where the ambient temperature
lower than 0℃ or higher than 40℃.
B. Do not install/store UPS in place where the relative humidity
lower than 20% or higher than 90%.
C. Do not install/store UPS in place where there is flammable
or corrosive gas, place with large amounts of conductive
dust, place exposed to shock or vibration, or outdoor.
2. If you would store the UPS for a long period, the storing area
temperature should be the range of -25°C to 55°C , and before
turning on UPS, it is highly suggested to put UPS in the ambient
temperature above 0°C and last at least 2 hours.

CONTENT
1. INTRODUCTION ................................................................................. - 1 -
1.1 SYMBOL AND EXPLANATION ................................................................ - 2 -
1.2 FRONT VIEW ...................................................................................... - 2 -
1.3 REAR VIEW ....................................................................................... - 3 -
1.4 PRODUCT SPECIFICATION ................................................................... - 3 -
2. INSTALLATION ................................................................................... - 5 -
2.1 INSPECTION THE PACK AND EQUIPMENT. .............................................. - 5 -
2.2 POWER CABLE ................................................................................... - 6 -
2.3 UPS POWER CONNECTION ................................................................ - 6 -
2.4 EBM CONNECTING AND INSTALLATION ................................................ - 8 -
2.5 UPS CONNECT TO COMPUTER PORT ................................................. - 9 -
2.6 UPS PARALLEL FUNCTION (OPTIONAL) ...................................... - 10 -
2.7 EPO(OPTIONAL) ............................................................................. - 14 -
2.8 MAINTENANCE SWITCH (OPTIONAL) .................................................. - 15 -
2.9 USB PORT(OPTIONAL) .................................................................... - 15 -
2.10 CONNECTIVITY CARDS( OPTIONAL) ................................................ - 16 -
2.11 SOFTWARE .................................................................................... - 17 -
3. CONTROL PANEL ............................................................................ - 19 -
4. OPERATION ...................................................................................... - 23 -
4.1 TURNING ON UPS ........................................................................... - 23 -
4.2 TURNING OFF UPS .......................................................................... - 25 -
5. MAINTENANCE ................................................................................ - 27 -
6. TROUBLE SHOOTING ..................................................................... - 28 -

- 1 -
1. Introduction
The Castle On-Line-Series is an uninterruptible power supply
incorporating double-converter technology. It provides perfect protection
specifically for Computer equipment, communication systems and industry
control systems.
The double-converter principle eliminates all mains power
disturbances. A rectifier converts the alternating current from the socket
outlet to direct current. This direct current charges the batteries and
powers the inverter. On the basis of this DC voltage, the inverter generates
a pure sinusoidal AC voltage, which permanently supplies the loads.
Computers and periphery are thus powered entirely by the mains
voltage. In the event of power failure, the maintenance-free batteries
power the inverter. In the event of inverter failure/Overload, UPS transfer
to bypass mode, after the failure/overload remove, UPS transfer to inverter
mode continue supplies the loads.
This manual covers the UPS listed as follows. Please confirm
whether it is the model you intend to purchase by performing a visual
inspection of the Model No. on the rear panel of the UPS.
3C15KS: Three phase input single phase output, can used with external
EBM to get longer backup time.
3C20KS: Three phase input single phase output, can used with external
EBM to get longer backup time.

- 2 -
1.1 Symbol and Explanation
Some or all of the following symbols may be used in this manual. It is
advisable to familiarize yourself with them and understand their meaning:
1.2 Front view
3C15KS/3C20KS

-3 -
1.3 Rear View
3C15KS/3C20KS
1.4 product specification
Model
3C15KS
3C20KS
Dimensions W*D*H(mm)
248*500*616
248*500*616
Weight(kg)
31
31
Power Rating(VA/W)
15KVA/13.5KW
20KVA/18KW
Input Voltage
Voltage range
208Vac-476Vac(Line to Line)
120Vac-275Vac(phase to phase)
Current*
30A max
39A max
Frequency range
40Hz-70Hz
Power factor
0.99
Bypass Mode
Voltage Range
187Vac-264Vac(Line to Line)
Current
86A
114A
Frequency range
46Hz-54Hz
Output
①EPO (Optional)
②USB (Optional)
③Fan
④RS232
⑤Bypass Breaker
⑥AC Input Breaker
⑦Beam Frame
⑧Terminal Cover
⑨Maintenance Bypass
Switch (Optional)
⑩Intelligent Slot
⑪ Parallel Card(Optional)

- 4 -
Rating Voltage
220Vac(±1%)
Rating Current
68A
91A
Frequency range
46Hz-54Hz
Power factor
0.9
Output Overload
105%-125%, load transfer to bypass mode
after 10min(0-30℃) or 1minutes(30℃-40);
125%-150%,load transfer to bypass mode after
30s;
Over 150%, load transfer to bypass after 0.5s
Load crest ratio
3:1( max)
THD
<2%( 100% Line load)
Battery(under high temperature, battery life will decrease)
Backup time
Depend on external battery capacity
Recharge time
Depend on external battery capacity
EMC Standard
EN62040-2:2005/GB7260-2:2009
Safety Standard
EN62040-1:2008+A1:2013
YD Standard
YD/T1095-2008/CQC3108-2011
Operation temperature
0-40℃
Store temperature
-25℃ to 55℃
Relative humidity
20% to 90%
Altitude
<1000m
*The max current is under 176Vac input, full rating load and empty
battery charging.
Waring: this is a product for commercial and industrial application
in the second environment installation restrictions or additional measures
may be needed to prevent disturbances.
note: It is recommended that the UPS output line is not more than
10m, the external communication line, and the machine line and the
temperature detection line is not more than 3m, otherwise it may need to
take installation restrictions or additional measures to suppress interference.
Altitude load=Rating load * Altitude correction factor.
Altitude
(m)
1000
1500
2000
2500
3000
3500
4000
4500
5000
Altitude
correction
factor
100%
95%
91%
86%
82%
78%
74%
70%
67%
note: if UPS used over 1000m altitude, the rating must be
derating according to above table.

-5 -
2. Installation
Danger: For safety consideration, please make sure cut off all the
mains power.
Note:
1. Installation and power cable connection must be conducted by
qualified person according to local regulations.
2. We recommend UPSs installed as floor standing equipment.
3. After installation, ensure the air vents on the front, side and rear of
the UPS are not blocked. Recommended at least 50cm of space on each
side.
4. If it is necessary to connect the inductance load such as a monitor
or a laser printer to the UPS, the start-up power should be used for
calculating the capacity of the UPS, as its start-up power consumption is too
big when it is started.
2.1 Inspection the pack and equipment.
1. Open UPS pack, inspection whether UPSs have been damaged
during shipment.
2. If find any equipment damaged, please contact your local
SANTAK representative.
Accessory: 1 pcs of user manual.
Recycle
The UPS package is recycling, please save it for further use.

- 6 -
2.2 Power cable
Note:
The diameter and cross-sectional area denpends of power cable
depend on the UPS rating power, the minim diameter and cross-sectional
area of power cable see below power cable table.
Model
3C15KS
3C20KS
Input
G
25mm2
25mm2
N
25mm2
25mm2
L1/L2/L3
25mm2
25mm2
Battery
+
25mm2
25mm2
-
25mm2
25mm2
G
25mm2
25mm2
Output
L
25mm2
25mm2
N
25mm2
25mm2
G
25mm2
25mm2
2.3 UPS Power Connection
DANGER: In order to avoid the Mains power switch current
overload when UPS carries with rating load, the Mains power switch rating
current must be more than the bypas switch rating current.(bypass mode
max current refer to 1.4 product specification)
It is suggested to install an external isolating device against current
backfeed between Mains input and UPS (see Fig.). After the device is
installed, it must add a warning label with the following wording or the
equivalent on the external AC contactor : RISK OF VOLTAGE BACKFEED.
Isolate the UPS before operating on this circuit, then check for hazardous
voltage between all terminals.

-7 -
1. Select power cable referring to power cable table.
2. Open UPS terminal cover.
3. Connect the protective earthing conductors to the rear panel left
earthing terminal.
4. Connect the protective bonding conductors to the rear panel right
earthing terminal.
5. Connect the output cable to the output terminal.
6. Connect the input cable to the input terminal, if EBM is required,
connect EBM cable to the EBM terminal.
DANGER: Inorder to reduce the risk of fire and hazards shock,
make sure all the connections are reliable and stightly！

- 8 -
Terminals:
3C15KS/3C20KS
7. Make the straps through across the Beam frame.
8. Adjust the straps to proper position, Fix the input cable, output
cable, EBM cable tightly.
9. Re-screw the terminal cover.
2.4 EBM Connecting and Installation
The norminal DC voltage of battery pack for Castle 3C15KS/20KS
is192Vdc/216Vdc/240Vdc. The battery pack consists of 16/18/20 pieces

-9 -
of 12V maintenance free batteries in series. EBM consists multi-battery
packs.Inorder to avoid hazards shock, make sure Battery/battery string
connecting in compliance with below procedure.
1. Connect proper battery string, recommend use fuse for protection in
battery string.
2. Select proper power cable(refer 2.2 power cable table) connect
EBM and UPS. Make sure install a DC breaker(eg.EATON
LZMN1-A160) between UPS and EBM connection. The minimum
rating voltage and rating current of DC breaker not less than below
table.
Battery nummber
16 pcs
18 pcs
20 pcs
Battery voltage
192Vdc
216Vdc
240Vdc
Battery current
3C15KS
85A
75A
68A
3C20KS
113A
100A
90A
DANGER:
1. Inorder to avoid hazards shock, do not connect EBM to UPS
Before finish EBM connecting.
2. The default battery pack consists16 pieces battery, UPS/EBM
connect to the wrong quantity will cause serious hazards. Make
sure UPS connect to the correct quantity battery pack. The
battery quatity can be displayed on the UPS LCD panel. The
battery quantity must be set by qualified person at initial
installation.
3. If battery quantity requests for adjustment, please contact with
our service person for support.
Note: Make sure the battery string switch is turn off before
connecting.
3. Connect EBM to UPS, after finish connecting between EBM and
UPS, UPS output does not carry with any load, then turn on EBM
switch to On possiton, and turn on mains power switch, UPS
begins to charge EBM at the time.
Note: Verify the battery connect to UPS with the correct polarity.
2.5 UPS Connect To Computer Port
RS232 interface is for the monitoring software and firmware update.
UPS connect to monitor device by RS232 cable.

-10 -
1. One end of RS232 cable connect to computer RS232 port.
2. One end of RS232 cable connect to UPS RS232 port.
RS232 communication default setting:
BAUD RATE
DATA LENGTH
STOP BIT
PARITY
2400 bps
8 bits
1 bit
None
2.6 UPS PARALLEL FUNCTION (Optional)
1. Brief introduction of the redundancy
N+X is currently the most reliable power supply structure. N represents
the minimum UPS number that the total load needs, X represents the
redundant UPS number, i.e. the fault UPS number that the system can
handle simultaneously. When the X is larger, the reliability of the power
system is
higher. For occasions where reliability is highly depended on, N+X is the
optimal mode. As long as the UPS is equipped with parallel cables, up to 3
UPSs can be connected in parallel to realize output power sharing and
power redundancy.
2. Parallel installation and operation
Parallel UPS is an optional function for user, before installing a new
parallel UPS, user need to prepare parallel accessories and ask service
person to help for installation. The quantity of parallel UPS is up to 3max.
Each parallel UPS need an independent battery pack.
1) Service person installs the parallel card on UPS, connect each
UPS one by one with the parallel cable, the parallel card is the
communication port between UPSs.

- 11 -
2) Connect the output wire of the parallel UPSs to an output terminal
block, load connect to the output terminal block via load wire.
Note: Strictly follow the wire requirement of single UPS to perform The
wiring of each UPS.The distance between the UPSs in parallel is less than
20 meters. The difference between the wires of input and output of the
UPSs is required to be less than 20%.The distance between the UPSs in
parallel is more than20 meters. The difference between the wires of input
and output of the UPSs is required to be less than 10%.
3) The parallel UPS input terminal panel and output terminal panel
see below, the wires of each parallel UPS must follow the wire
requirement for single UPS. Wire connection diagram see next

- 12 -
page.
4) Each parallel UPS need an independent battery pack.
* Recommend to install maintenance switch if need . UPS parallel function,
it can help to simplify parallel UPS maintenance.

-13 -
3C15KS/3C20KS