Santak CASTLE RACK 6K User manual

RACK 6K(S)/10K(S)

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
SAVE THESE INSTRUCTIONS. This manual contains important instructions that
should be followed during installation and maintenance of the UPS and
batteries.
The UPS models that are covered in this manual are intended for installation in
an environment within 0 to 50°C, free of conductive contaminant.
Certification standards
•
Safety: EN 62040-1
•
EMC: IEC/EN 62040-2
•
IEC 61000-4-2 (ESD): level 3.
•
IEC 61000-4-3 (Radiated field): level 3.
•
IEC 61000-4-4 (EFT): level 4.
•
IEC 61000-4-5 (Fast transients): level 4.
•
IEC 61000-4-6 (Electromagnetic field): level 3.
•
IEC 61000-4-8 (Conducted magnetic field): level 4.
•
Performance: IEC/EN 62040-3
Special symbols
The following are examples of symbols used on the UPS or accessories to alert you
to important information:
RISK OF ELECTRIC SHOCK - Observe the warning associated with the risk of electric
shock symbol.
Important instructions that must always be followed.
Do not discard the UPS or the UPS batteries in the trash.
This product contains sealed lead acid batteries and must be disposed as it's explain
in this manual. For more information, contact your local recycling/reuse or
hazardous waste center.
This symbol indicates that you should not discard waste electrical or electronic
equipment (WEEE) in the trash. For proper disposal, contact your local
recycling/reuse or hazardous waste center.
Information, advice, help.
Refer to the user manual.

Safety of persons
 RISK OF VOLTAGE BACKFEED. The system has its own power source (the
battery). Isolate the UPS and check for hazardous voltage upstream and
downstream during lockout-tagout operation. Terminal blocks may be
energized even if the system is disconnected from the AC power source.
 Dangerous voltage levels are present within the system. It should be opened
exclusively by qualified service personnel.
 The system must be properly grounded.
 The battery supplied with the system contains small amounts of toxic materials.
To avoid accidents, the directives listed below must be observed:
- Servicing of batteries should be performed or supervised by personnel
knowledgeable about batteries and the required precautions.
- When replacing batteries, replace with the same type and number of
batteries or battery packs.
- Do not dispose of batteries in a fire. The batteries may explode.
- Batteries constitute a danger (electrical shock, burns). The short-circuit
current may be very high.
 Precautions must be taken for all handling:
- Wear rubber gloves and boots.
- Do not lay tools or metal parts on top of batteries.
- Disconnect charging source prior to connecting or disconnecting battery
terminals.
- Determine if battery is inadvertently grounded. If inadvertently grounded,
remove source from ground. Contact with any part of a grounded battery
can result in electrical shock. The likelihood of such shock can be reduced if
such grounds are removed during installation and maintenance (applicable
to equipment and remote battery supplies not having a grounded supply
circuit).
Product safety
 The UPS connection instructions and operation described in the manual must
be followed in the indicated order.
 CAUTION - To reduce the risk of fire, the unit connects only to a circuit
provided with branch circuit overcurrent protection for :
63A rating, for 6kVA models,
100A rating, for 10kVA models
The upstream circuit breaker for Normal AC/Bypass AC must be easily
accessible. The unit can be disconnected from AC power source by opening this
circuit breaker.
 An additional AC contactor is used for backfeed protection and must comply
with IEC/EN 62040-1 (the creep age and clearance distances shall meet the

basic insulation requirements for pollution degree 2).
 Disconnection and overcurrent protection devices shall be provided by others
for permanently connected AC input (Normal AC/Bypass AC) and AC output
circuits.
 Check that the indications on the rating plate correspond to your AC powered
system and to the actual electrical consumption of all the equipment to be
connected to the system.
 For PLUGGABLE EQUIPMENT, the socket-outlet shall be installed near the
equipment and shall be easily accessible
 Never install the system near liquids or in an excessively damp environment.
 Never let a foreign body penetrate inside the system.
 Never block the ventilation grates of the system.
 Never expose the system to direct sunlight or source of heat.
 If the system must be stored prior to installation, storage must be in a dry
place.
 The admissible storage temperature range is -25°C to +60°C with battery(-15°C
to +40°C without battery).
Special precautions
 The unit is heavy: wear safety shoes and use vacuum lifter preferentially for
handling operations.
 All handling operations will require at least two people (unpacking, lifting,
installation in rack system).
 Straps are provided only for unpacking manually the unit from the carton;
don’t use the straps to carry the unit around. The unit can slip from the straps
during handling (risk of injury and product damage):
- keep 12in / 30cm minimum distance between the straps
- lift the unit carefully and keep it at low height
- keep the unit horizontal during unpacking.
 Before and after the installation, if the UPS remains de-energized for a long
period, the UPS must be energized for a period of 24 hours, at least once every
6 months (for a normal storage temperature less than 25°C). This charges the
battery, thus avoiding possible irreversible damage.
 During the replacement of the Battery Module, it is imperative to use the same
type and number of element as the original Battery Module provided with the
UPS to maintain an identical level of performance and safety.

Contents
1. Introduction ................................................................................................... 1
1.1 Environmental protection ....................................................... 1
2. Presentation ................................................................................................... 3
2.1 Front panel ................................................................................ 3
2.2 Rear panels ............................................................................... 3
2.3 Circuit diagram ........................................................................ 4
3. Installation ...................................................................................................... 5
3.1 Inspecting the equipment ...................................................... 5
3.2 Unpacking the Unit .................................................................. 5
3.3 Checking the accessory kit .................................................... 6
3.4 Install the unit ............................................................................ 6
4. Power cables connection ............................................................................... 7
4.1 Access to terminal blocks(AC to UPS) ................................... 8
4.2 Access to terminal blocks(PDU to UPS)(Optional) ............... 9
4.3 Parallel Installation and Operation(Optional) ...................... 9
5. Operation ..................................................................................................... 14
5.1 Control panel ......................................................................... 14
5.2 LCD description ...................................................................... 15
5.3 Display functions .................................................................... 17
5.4 Operation Mode .................................................................... 17
5.5 UPS startup and shutdown .................................................... 18
5.6 LCD operation ........................................................................ 19
6. Communication ............................................................................................ 21
6.1 Communication ports ........................................................... 21
6.2 Network Management Card (Optional) ............................ 22
6.3 UPS Management Software ................................................. 22
7. UPS maintenance ......................................................................................... 23
7.1 Equipment care ..................................................................... 23
7.2 Transporting the UPS .............................................................. 23
7.3 Storing the equipment .......................................................... 23
7.4 Replacing batteries ............................................................... 24
7.5Recycling the used equipment ............................................ 25
8. Troubleshooting ........................................................................................... 25
8.1 Typical alarms and faults ...................................................... 26

9. Specifications ............................................................................................... 30
9.1 Model specifications ............................................................. 30
10 Glossary ....................................................................................................... 33

1
1. Introduction
Thank you for selecting UPS to protect your electrical equipment. The UPS has
been designed with the utmost care.
We recommend that you take the time to read this manual to take full
advantage of the many features of your UPS (Uninterruptible Power System).
Before installing your UPS, please read the booklet presenting the safety
instructions. Then follow the indications in this manual.
1.1 Environmental protection
Products are developed according to an eco-design approach.
Substances
This product does not contain CFCs, HCFCs or asbestos.
Packing
To improve waste treatment and facilitate recycling, separate the various
packing components.
•
The cardboard we use comprises over 50% of recycled cardboard.
•
Sacks and bags are made of polyethylene.
•
Packing materials are recyclable and bear the appropriate identification
symbol
Materials Abbreviations Number in
the symbols
Polyethylene terephthalat
PET
01
High
-
density polyethylene
HDPE
02
Polyvinyl chloride
PVC
03
Low
-
density polyethylene
LDPE
04
Polypropylene
PP
05
Polystyrene
PS
06
Follow all local regulations for the disposal of packing materials.
Product
The product is made up of recyclable materials.
Dismantling and destruction must take place in compliance with all local
regulations concerning waste. At the end of its service life, the product must be
transported to a processing center for electrical and electronic waste.
Battery
The product contains lead-acid batteries that must be processed according to
applicable local regulations concerning batteries.
The battery may be removed to comply with regulations and in view of correct
disposal.

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1.2 Electronic equipment protection
The uninterruptible power system (UPS) protects your sensitive electronic
equipment from the most common power problems, including power failures,
power sags, power surges, brownouts, line noise, high voltage spikes,
frequency variations, switching transients, and harmonic distortion.
Power outages may occur unexpected, and the power quality will be erratic.
These power problems have the potential to corrupt critical data, destroy
unsaved work sessions, and damage hardware - causing hours of lost
productivity and expensive repairs.
With the UPS, you can safely eliminate the effects of power disturbances and
guard the integrity of your equipment. Providing outstanding performance and
reliability, UPS’s unique benefits include:
 True online double-conversion technology with high power density, utility
frequency independence, and generator compatibility.
 Selectable High Efficiency mode of operation.
 Standard communication options: one RS232 communication port, one
USB communication port, one dry in port and dry out port.
 Optional connectivity cards with enhanced communication capabilities.
 Firmware that is easily upgradable without a service call.

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2. Presentation
2.1 Front panel
6K/6KS/10K/10KS UPS
EBM
2.2 Rear panels
6K/6KS/10K/10KS
EBM

4
1. Intelligent slot
2. USB
3. Dry IN/OUT
4. RS232
5. EPO
6. RJ11 (connect to PDU, only for RT model)
7. Parallel card (optional)
8. Output breaker
9. Output socket
10. Input/Output terminal (4pole IPL, IPN, OPL, OPN. PE is screw)
11. Input breaker (optional)
12. EBM connector
13. Fuse board cover (replace EBM fuse)
14. EBM plug
15. EBM connector
2.3 Circuit diagram

5
3. Installation
It is recommended to move the equipment to the installation site by using a
pallet jack or a truck before unpacking.
The system may be installed only by qualified electricians in accordance with
applicable safety regulations.
The cabinet is heavy, please install it with at least two peoples.
3.1 Inspecting the equipment
If any equipment has been damaged during shipment, keep the shipping
cartons and packing materials for the carrier or place of purchase and file a
claim for shipping damage. If you discover damage after acceptance, file a claim
for concealed damage.
3.2 Unpacking the Unit

Unpacking the unit in a low-temperature environment may cause
condensation occurred in and on the cabinet. Do not install the unit until
the inside and outside of the unit are absolutely dry (hazard of electric
shock).
Remove the packing materials and lift the unit out with two people at least.
 UPS
 EBM
Note:
The cabinet is heavy, please see spec weight provided on the carton/label.
Do not lift the unit’s front panel and rear panel.
Discard or recycle the packaging in a responsible manner, or store it for future
use.
Packing materials must be disposed in compliance with all local regulations
concerning waste. Recycling symbols are printed on the packing materials to
facilitate sorting.

6
3.3 Checking the accessory kit
Verify that the following additional items are included with the unit:
UPS 6K/10K UPS 6KS/10KS
EBM
Battery power cable \ V *
USB cable O O
RS232 cable V V
Parallel cable O O
Dry contractor V V
EPO contractor * *
Ear bracket V V V
Rail kit O O O
User manual V V V
V: standard configuration
*: assembled to unit
O: optional configuration
If you ordered other accessories, please contact with local sale center.
3.4 Install the unit
This procedure is suitable for 19 inch rack cabinet installation with a minimum
of 800mm depth.
 UPS model
Identify the final position and keep ‘2U’ space for this installing.
Note that you already installed a ‘rail kit’ to rack cabinet for this operation, and
‘1U’ rail kit is recommended to be selected.
1. Install ‘Ear bracket’ to the unit by the M4 screws(flat head).
2. Slide the unit into ‘rail kit’ and make sure tighten the ‘rack mounting screw’ .
 EBM model
Identify the final position and keep ‘3U’ space for this installing, and it is

7
recommended to be installed below to UPS.
Note that you already installed a ‘rail kit’ to rack cabinet for this operation, and
‘2U’ rail kit is recommended to be selected.
1. Install ‘Ear bracket’ to the unit by the M4 screws(flat head).
2. Slide the unit into ‘rail kit’ and make sure tighten the ‘rack mounting screw’ .
3.Connect EBM to UPS with ‘Battery power cable’.
4. Power cables connection
Recommended protective devices and cable cross-sections
Recommended upstream protection
UPS power
rating
Upstream circuit
6
000VA
D curve
–
63
A
1
0
000VA
D curve
–
100
A
to UPS Normal AC / Bypass AC source
G N(L2) L1
Read the Safety instructions page 3 regarding backfeed protection requirements.
Recommended cable cross-sections
N(L2)

8
Model 6K 10K
Protective earthing conductor
Min cross section 6mm^2 (8AWG) 10mm^2 (6AWG)
Input L, N, G
Min conductor cross section 6mm^2 (8AWG) 10mm^2(6AWG)
Input fuse 80A 100A
Output L,N,
Min conductor cross section 6mm^2 (8AWG) 10mm^2(6AWG)
It is recommended that an external isolating device should be installed between
the mains input and UPS as shown in Figure
AC Contactor: 208-240V, 63A (6 kVA)
208-240V, 100A (10 kVA)
4.1 Access to terminal blocks(AC to UPS)
High leakage current:
Earth connection essential before connecting supply.
Common input/output sources connection
This type of connection must be carried out by qualified electrical personnel
Before carrying out any connection, check that the upstream protection devices
(Normal AC source and Bypass AC source) are open "O" (Off).
Always connect the ground wire first
1. Remove the cover of terminal block.

9
2. Connect the AC cable to terminal blocks refer to the indication on rear panel
3. Tie up the AC cable to the rear panel.
4. Install back the cover of terminal block.
4.2 Access to terminal blocks(PDU to UPS)(Optional)
If you ordered PDU model, please connect the UPS’s terminal blocks from PDU’s
source, detail operation please refer to PDU’s user manual.
4.3 Parallel Installation and Operation(Optional)
As long as the UPS is equipped with parallel board and parallel cables, up to 3
UPSs can be connected in parallel to configure a sharing and redundant output
power.

10
How to install a new parallel UPS system:
1) Before installing a new parallel UPS system, please prepare the input
/output wires, breakers, and a main maintenance mechanical switch or
static switch.
2) Independent battery packs for each UPS.
3) Remove the cover plate of parallel port on the UPS, connect each UPS one
by one with parallel cable, and make sure the cable is screwed tightly.
4) Install ‘cable locker’ to protect the ‘parallel cable’ for each UPS.

11
5) Connect the input and output wires and make sure all the breakers are
turned off.
6) Turn on the input breakers for the parallel UPS.
7) Pressing button continuously for more than 1 second for one UPS of
the system, then the system will turn to online mode.
8) Regulate the output voltage of the each UPS separately, and check if the
difference of output voltage is less than 0.5V among the parallel system. If
the difference is more than 0.5V, the UPS need to be regulated.
9) If the difference output voltage is less than 0.5V, turn off the input breakers
to let UPS shut down. And then switch on the output breakers for all the
UPS.
10) Switch on the input breakers for the parallel UPS. Pressing button
continuously more than 1 second for one UPS of the system, then the

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system will turn to online mode, after these operations, the system will
work normally in parallel mode.
Note: The output wiring requirement as below:
1) If the distance between the UPS and breaker panel is less than 20 meters in
parallel system, the length difference between input and output cable of
the UPSs is required to be less than 20%.
2) If the distance between the UPS and breaker panel is more than 20 meters
in parallel system, the length difference between input and output cable of
the UPSs is required to be less than 5%.
2. How to join a new UPS to parallel system:
1) Firstly, a main maintenance mechanical switch or static switch should be
installed for the parallel system.
2) Regulate the output voltage of the new UPS: check if the output voltage
difference between the new UPS and the parallel system is less than 0.5V.
3) Ensure the bypass of the parallel system is normal and the auto bypass
setting is “enable”, then press the button to turn off the UPS, the UPS
will turn to bypass mode.
4) Set the main maintenance switch or static switch from “UPS” to “BPS”, then
switch off the main output breaker, input breaker and mains breaker, then
the UPS will shut down.
5) Connect the cable and wire for the new ups.
6) Switch on the input breakers and mains breaker, and make sure that every
UPS work in bypass mode.
7) Switch on the O/P breakers and main O/P breaker，transfer the main
maintenance switch or static switch from “BPS” to “UPS”.
8) Press the button of one UPS, all the ups will turn on, after that, the
system will work in Line mode.
3. How to remove a single UPS from parallel system:
1) Firstly, a main maintenance mechanical switch or static switch should be
installed for the parallel system.
2) Ensure the bypass is normal and the auto bypass setting is “enable”, press
the button to turn off the UPS system, and the UPS system will turn to
bypass mode.
3) Transfer the main maintenance switch or static switch from “UPS” to “BPS”,
then switch off the output breakers, input breakers and mains breaker in
the parallel system, and the UPS will shut down.