SynQor Headquarters UPS-3000-S-2U Manual

Military Grade UninterrUptible power SUpply
1.888.567.9596 (USA only) |SynQor Headquarters 155 Swanson Road, Boxborough, MA 01719-1316 USA |www.synqor.com
Made in USA
UPS-3000-S-2U
N+M Redundancy
(optional)
Operator’s Guide
UPS-3000 Series

006-0006504 02/27/18 Rev R 2 of 56 UPS-3000 Guide www.synqor.com
Table of Contents
Section I Warnings
Hazardous Voltages ...................................................................................................................................................4
Hazardous Energies...................................................................................................................................................5
Battery Pack..................................................................................................................................................................6
Protection from the Environment .........................................................................................................................6
No User Serviceable Parts........................................................................................................................................6
Section II General Product Information
Product Description ...................................................................................................................................................7
Product Topology ........................................................................................................................................................8
Part Numbering Scheme and Options ............................................................................................................. 10
Electrical Characteristics ..................................................................................................................................... 11
2U Mechanical Diagram....................................................................................................................................... 12
UPS Efficiency............................................................................................................................................................ 13
Total Output Power that can be derived from the AC INPUT ................................................................. 14
Power Cable Wiring Diagram ............................................................................................................................. 17
Power Cable Wire Size............................................................................................................................................ 18
Section III Operation
Set-Up ........................................................................................................................................................................... 19
Start-Up ....................................................................................................................................................................... 20
Shut-Down .................................................................................................................................................................. 20
Power Cable Connections/Disconnections While Operating .................................................................. 21
Cooling System .......................................................................................................................................................... 22
Front Panel Indicators ........................................................................................................................................... 23
LEDs...................................................................................................................................................................... 23
Audible alarm ................................................................................................................................................... 28
Hot Swapping the Battery Packs ........................................................................................................................ 28
Operating Environment......................................................................................................................................... 29
Section IV Multiple UPS Configurations
General Considerations ......................................................................................................................................... 30
Wiring Caution ......................................................................................................................................................... 30
Standard Paralleling -F Option ......................................................................................................................... 31
Expanded Paralleling –R Option ....................................................................................................................... 31
Parallel Configurations of the AC OUTPUTs: Up to Three Units........................................................... 32
Multi-unit Configurations............................................................................................................................. 32

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Parallel Connection of the AC Outputs ............................................................................................................ 33
Two UPS units with AC OUTPUTs Paralleled....................................................................................... 33
Three UPS units with AC OUTPUTs Paralleled.................................................................................... 34
Series Split-Phase Connection of AC Outputs .............................................................................................. 35
3-Phase Connection of AC Outputs .................................................................................................................. 36
Parallel Configurations of the AC OUTPUTs: Up to 32 Unit –R option .............................................. 37
Parallel Connection of DC Outputs ................................................................................................................... 38
Connection of the AC and/or DC INPUTS ...................................................................................................... 38
3-Phase AC INPUT Source............................................................................................................................ 38
Multi-unit AC Output On/Off Control – Standard Parallel (-F option)....................................... 39
Multi-unit AC Output On/Off Control – Expanded Parallel (-R option)..................................... 39
AC Output Neutral Grounding.................................................................................................................... 39
Section V Battery Pack
Battery Technology.................................................................................................................................................. 40
Electronic Circuitry within the Battery Packs .............................................................................................. 40
Battery Capacity....................................................................................................................................................... 41
Storage of the Battery Pack .................................................................................................................................. 41
Battery Pack Replacement .................................................................................................................................. 41
Handling the Battery Pack................................................................................................................................... 42
Section VI Control Interface Details
Control Cable Connections................................................................................................................................... 43
Internal User I/O Circuits............................................................................................................................. 44
Remote On/Off Switch Connections ......................................................................................................... 44
Digital Input/Output Control Signals............................................................................................................... 45
RS232 Serial Interface............................................................................................................................................ 45
Ethernet Interface.................................................................................................................................................... 47
Section VII Maintenance
Battery.......................................................................................................................................................................... 48
Fans ............................................................................................................................................................................... 48
Cleaning....................................................................................................................................................................... 48
Section VIII Trouble-Shooting Guide
Fault Conditions ....................................................................................................................................................... 49
Section IV (continued) Multiple UPS Configurations
Section IV (continued) Multiple UPS Configurations

Section I Warnings
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Section I Warnings
Hazardous Voltages
The INPUT AND OUTPUT POWER connectors and cables of the SynQor UPS may have voltages
that are unsafe. INJURY OR DEATH ON CONTACT may result. Appropriate safety precauons
should be taken. All connecons should be made in accordance with LOCAL ELECTRICAL CODES.
• The UPS CHASSIS should be connected to earth or system ground with Ground Stud on the
rear panel, see mechanical diagrams.
• For the AC INPUT cable and connector:
 Do not assume that a hazardous voltage is not present at the terminals of the AC input
connector, even if the UPS appears to be o.
 Do not make contact with the terminals of the AC input connector.
 Always connect the cable to the UPS before it is connected to the source of AC power.
 Always disconnect the AC input cable from the source of AC power before disconnecng it
from the UPS.
 If the AC input cable is connected to the source of AC power and not connected to the UPS,
do not contact the exposed terminals of the AC input cable.
 Do not assume that the source of AC power is not present.
 Connections between the AC input cable and the source of AC power should not be
accessible.
• For the AC OUTPUT cable and connector:
Do not assume that a hazardous voltage is not present at the terminals of the AC output
connector, even if the UPS appears to be o.
 Do not make contact with the terminals of the AC output connector.
Connect the AC output cable to the UPS before the UPS is turned on.
 If connecon of the load to the AC output cable has exposed conductors, make this connecon
before connecng the AC output cable to the UPS.
 Connecons between the AC output cable and the load should not be accessible.
• For the DC INPUT cable and connector (if present):
 The rated DC input voltage of the UPS is below the level considered hazardous.
 The DC input terminals of the UPS are isolated from the AC input and AC outputs with
reinforced safety insulaon.
 However, never assume the terminals of the DC input connector or the wires of the DC input
cable are safe to contact, even if the UPS or DC input source appears to be o.

Section I Warnings
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• For the DC OUTPUT cables and connectors (if present):
 The rated DC output voltage of the UPS is below the level considered hazardous.
 The DC output terminals of the UPS are isolated from the AC input and AC outputs with
reinforced safety insulaon.
 However, never assume the terminals of the DC output connector or the wires of the DC
output cables are safe to contact, even if the UPS appears to be o.
• For the BATTERY PACK (if not inserted into the UPS):
 When the baery pack is not inserted into the UPS, the baery is internally disconnected
from the power pins of the baery pack’s connector.
 Even if this disconnecon were not present, the DC voltage of the baery is below the level
considered hazardous.
 Do not apply external voltages to the pins of an exposed baery pack connector. It is not
possible to charge the baery pack from an external source, and excess voltages could
damage internal control circuitry.
Hazardous Energies
The INPUT AND OUTPUT POWER connectors and cables of the SynQor UPS may be the source
of high levels of energy. Do not inappropriately make electrical contact between any terminal of
a connector and another, or between any wire of a cable and another, or between any terminal
or wire and the UPS’s chassis or ground. DAMAGING ELECTRICAL ARCS may result. Care should
be taken to avoid accidental electrical contacts of this sort.
When the BATTERY PACK is not inserted into the UPS, the baery is internally disconnected from
the power pins of the baery pack’s connector. An electrical contact between any two of these
power pins or between any power pin and ground should therefore not be damaging. However,
care should take to avoid accidental electrical contacts of this sort.

Section I Warnings
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Section I Warnings
Baery Pack
The individual LITHIUM POLYMER BATTERIES contained in the SynQor baery pack are sealed units
that are further mechanically protected by the baery pack’s chassis and electrically protected by
the baery pack’s electronic circuitry. Under normal condions they do not pose a hazard, but
they should not be physically, thermally or electrically abused.
The TRANSPORT of the baery pack must comply with applicable regulaons of the locality. See
“Baery Pack - Handling the Baery Pack”.
The baery pack should be DISPOSED in accordance with applicable regulaons of the locality
or RETURNED to a factory-authorized Service Center.
Emergency response contact informaon for baery damage, leaks, smoke, or res can be found
at the following link: http://www.SynQor.com/UPS/documents/Contact.pdf. Please contact
the factory for all other quesons regarding the UPS baery pack.
CAUTION: Do not dispose of batteries in a re. The batteries may explode.
CAUTION: Do not open or mutilate batteries. Released electrolyte is harmful to the skin
and eyes. It may be toxic.
Always use the proper SynQor baery pack. See the baery replacement chart on page 41.
Protecon from the Environment
The SynQor UPS is a ruggedly built product having its electronics and baery contained in
sealed chambers. It is capable of withstanding harsh levels of mechanical acceleraon, shock
and vibraon, temperature and pressure variaons, and exposure to water, salt, sand and dust
within the levels specied in the data sheet. THESE LEVELS SHOULD NOT BE EXCEEDED.
Do not obstruct the air intake in the front of the UPS or the fan exhausts in the rear panel of the
UPS while the UPS is operang.
No User Serviceable Parts
The SynQor UPS has no user serviceable parts inside of it. DO NOT REMOVE the cover of the
UPS or any of its connectors. DO NOT OPEN the baery pack. Only factory trained personnel
should perform repairs.

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Section II General Product Information
Product Descripon
The SynQor UPS-3000 Series is an advanced technology military-grade uninterrupble power
supply (UPS) that uses lithium polymer baeries and highly ecient power electronic circuitry
to achieve a high power level and baery run-me in a low-prole, low-weight, rack-mountable
package. It provides voltage and frequency condioning, electrical isolaon, and power ow
smoothing between the power inputs and its power outputs. It provides baery backed-up
power when other power sources are not present.
A communicaon/control port is available to permit monitoring and control by a host computer
system. Front panel LEDs and an audible alarm provide informaon on the status of the UPS and
the baery pack.
The UPS-3000 Series products can draw power from an AC input having a wide range of voltage
and frequency levels, or from an oponal 28 V nominal DC input. The AC input has priority over
the DC input. The UPS provides up to 3000 VA and 2500 W of AC output power at 115 Vac. The
pure sine wave AC output voltage can drive any non-linear load with a crest factor up to 2.5, and
any load power factor from 0.0 to 1.0. There are two oponal DC outputs at various voltage and
power levels. The total AC plus DC output power is limited to 2500 W.
The electronic circuitry within the UPS-3000 Series products is designed, qualied and screened
according to SynQor’s Mil-COTS Standards. It complies with the requirements of MIL-STD-704F,
MIL-STD-1399-300B, MIL-STD-1275D and MIL-STD-461F, as well as IEC-EN61000 specicaons
for world-wide commercial ulity applicaons.
The UPS-3000 Series products are designed and manufactured to withstand the harsh environments
and use encountered in military applicaons. The electronic circuitry and baery are contained in
a sealed chamber constructed from a die-cast aluminum chassis that is weather-proof and shock-
proof. Redundant, water-proof fans on the rear panel draw cooling air over the heat-sink ns below
the sealed chamber. Military-grade circular connectors are used, and oponal aached connector
covers are available for when the cables are not aached. The UPS-3000 Series products comply
with a wide range of tesng according to MIL-STD-810G.
The UPS-3000 Series is a 2U high unit that has two standard baery packs which provide >10
minutes of full-power run-me and weighs approximately 65 lbs.
The SynQor UPS-3000 Series products are designed and manufactured in the U.S.A.

Section II General Product Information
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Product Topology
The SynQor UPS-3000 Series products use a true on-line double conversion topology that
provides protecon to the load from spikes, noise, surges, brownouts, blackouts, etc. in the
input power sources. They also provide smoothing of load transients and nonlinear load
proles so that the input power sources are not subjected to these disturbances. There is
a seamless transfer from any power source to another so that there is no disrupon in the
output voltage waveform.
As the gure below shows, there is a nominal 28 V mid-bus within the UPS that draws power
from one of up to three power sources: the AC INPUT, the oponal DC INPUT or the baery
(with that order of priority based on availability). EMI lters are present at all external inputs
and outputs.
AC
INPUT
DC
INPUT
DC2
OUTPUT
2x DC1
OUTPUT
AC
OUTPUT
AC to DC
w/ PFC
and
ISOLATION
BATTERY
with
CHARGER
and
ELECTRONIC SWITCH
(OPTIONAL)
(Not available with DC2 Option)
ELECTRONIC
SWITCH
ISOLATED
INVERTER
BULK ENERGY
STORAGE
CAPACITOR
ISOLATED
DC-DC
CONVERTER
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ISOLATED
DC-DC
CONVERTER
CIRCUIT
BREAKER
SINGLE-POLE
ELECTRONIC
BREAKER
Power ows from the AC INPUT through an AC-DC converter that has Power Factor Correcon
(PFC) and high-frequency safety isolaon stage. Power ows from the DC INPUT through an
electronic switch that is closed when the AC INPUT power is absent and the DC INPUT voltage is
within its specied range. Otherwise, a second electronic switch is closed to connect the baery
to the mid-bus.

Section II General Product Information
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The AC OUTPUT is created by an inverter that draws power from the mid-bus. This inverter provides
high-frequency safety isolaon and a pure-sinusoidal output voltage waveform. An oponal
electronic breaker can be added to the AC output. This one pole hot side only electronic breaker
allows for fault tolerant, glitch free operaon when several UPS units are placed in parallel.
Oponal DC outputs at various voltage and power levels are available. The DC1 opon provides
two separate 500 W outputs which cannot be used directly in parallel. The DC2 opon provides
a single parallelable output up to 2500 W. When the DC2 opon is selected, the DC Input is not
available. The DC1 and DC2 outputs are isolated from each other as well as the AC output.
Bulk energy storage capacitors are connected to the mid-bus to help smooth imbalances in
power ow between the inputs and outputs of the UPS.
There is a baery charger circuit that draws power from the mid-bus. It ensures the baeries
are normally fully charged and that the various cells are equalized. The baery also contains
protecon circuitry to avoid damage due to improper charging or discharging, or to excessive
temperatures.
There is a communicaon/control port that provides a digital interface to a host computer system.
UPS in Transit Case Option

Section II General Product Information
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Part Numbering Scheme and Opons
This table shows the part numbering scheme for the full line of SynQor UPS products:
Family Output Power Battery Pack
Size Height AC Input Frequency
AC Output
Voltage
AC Output
Neutral Wire
AC Output
Set Point
Frequency
DC Input /
DC2 Output
Dual DC1
Output
Voltage
Additional Options
UPS 3000 S 2U L 1 G 6 D 28 000
UPS 3000: 3000 VA
2500 W S: Standard 2U: 3.40” L:
W:
47-65 Hz
47-800 Hz
1:
2:
5:
6:
4:
50 Hz
60 Hz
400 Hz
S: Not Installed 00:
None 000: None
D: DC Input 12: 12 V 0CE: CE Marking
G: Grounded M: DC2 Out 15: 15 V E00: Ethernet /
115 Vrms F: Floating * 24 VDC with 24: 24 V SNMP
230 Vrms R:AC Output Droop Share 28: 28 V ECE: Ethernet /
Electronic R: DC2 Out 40: 40 V SNMP &
Breaker * 28 VDC with 50: 50 V CE Marking
Droop Share
Not all combinations make valid part numbers, please contact SynQor for availability. See the Product Summary web page for more options.
* Note: Order “F: Floating” option when conguring the AC output for multi-unit combinations of up to 3 units.
Order “R: AC Output Electronic Breaker” option for fault-tolerant, glitch-free parallel systems of up to 32 units with N+M redundancy;
The AC output neutral wire will not be connected to the chassis
Example: UPS-3000-S-2U-L1G6D28-000
The UPS-3000 Series of products provide up to 3000 VA and 2500 W of total output power
(AC plus DC).
• A 2U high, 65 lbs. rackmount unit that uses two standard baery packs which provide >10 minutes of baery
run-me at full power
Each format has various opons that can be specied according to the part numbering scheme
shown in the table:
• The allowable frequency of the AC INPUT can either be in the 47-65 Hz range (for 50 Hz and/or 60 Hz systems)
or in the 360-800 Hz range (for 400 Hz and Variable Frequency systems)
• The output voltage of the UPS-3000 Series can be 115 Vrms or 230 Vrms.
• The AC output can be congured with its neutral wire internally grounded to the chassis of the UPS or le
oang for shipboard applicaons.
• The inial set-point frequency of the AC OUTPUT voltage can be 50 Hz, 60 Hz or 400 Hz. Regardless of the inial
set-point frequency, the actual frequency can be set through the communicaons/control port.
• There is an oponal DC INPUT that is specied to comply with MIL-STD-704F and MIL-STD-1275D for 28 V
systems.
• Two oponal DC OUTPUT capabilies are available: DC1 with up to 2x500 W capability, and DC2 with up to
2500 W capability.
• RS232 serial port and logic-level I/O communicaon are included in the standard model. An Ethernet port
providing web and SNMP interfaces is an available opon.
• The Electronic Breaker opon adds fault tolerant, glitch free mul-unit operaon for N+1 or N+M redundancy.
This opon also allows up to 32 units to be combined to form single-phase, split-phase, or 3-phase systems
The UPS-3000S-2U data sheet showing these specicaons and other informaon can be found
at the web site www.SynQor.com/UPS.