Tripp Lite SmartOnline SU40K User manual

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Owner’s Manual
SmartOnline™3-Phase UPS Systems
Models: SU40K, SU60K, SU60KTV, SU80KTV
Input/Output: 120/208V AC (SU40K, SU60K) or 277/480V AC (SU60KTV, SU80KTV),
50/60 Hz, 3O, 4-wire + ground, wye
Not suitable for mobile applications.
1111 W. 35th Street, Chicago, IL 60609 USA
[phone] • www.tripplite.com
Copyright © 2008 Tripp Lite. All trademarks are the sole property of their respective owners.
WARRANTY
REGISTRATION
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chance to win a FREE Tripp Lite
product! www.tripplite.com/warranty

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Table of Contents
1 Introduction 3
2 Important Safety Instructions 4
3 Control Panel Features 6
4 Front and Rear Panel Features 7
5 Cabinet Installation 9
5-1 Preparation 9
5-2 Unpacking 9
5-3 Placement 10
6 Internal Battery Connection 11
(SU40K Only)
6-1 Internal Battery Wiring Diagrams 11
6-2 Internal Battery Connection Procedure 13
7 Wiring 16
7-1 Wiring Warnings 16
7-2 Wiring Preparation 16
7-3 UPS System Terminal Block Diagram 17
7-4 External Battery Cabinet Wiring Diagrams 17
7-5 Electrical and Cable Data 18
7-6 External Battery Cabinet Wiring 19
7-7 AC Input/Output Wiring (Single UPS) 20
7-8 AC Input/Output Wiring (Parallel UPS – Single Input) 21
8 Operating Modes 22
8-1 Online (Normal) Mode (Single UPS) 22
8-2 Battery Backup Mode (Single UPS) 22
8-3 Auto Bypass Mode (Single UPS) 22
8-4 Manual Bypass Mode (Single UPS) 22
8-5 Online Mode (Parallel UPS) 23
8-6 Battery Backup Mode (Parallel UPS) 23
8-7 Auto Bypass Mode (Parallel UPS) 23
8-8 Manual Bypass Mode (Parallel UPS) 24
9 Start-Up, Shutdown and Bypass 25
9-1 Control Panel and Breaker Diagrams 25
9-2 Preliminary Checklist (Single UPS) 25
9-3 Normal Start-Up Procedure (Single UPS) 25
9-4 Battery Start-Up Procedure (Single UPS) 26
9-5 Manual Bypass Procedure (Single UPS) 27
9-6 Shutdown Procedure (Single UPS) 27
9-7 Preliminary Checklist (Parallel UPS) 28
9-8 Start-Up Procedure (Parallel UPS) 28
9-9 Shutdown Procedure (Parallel UPS) 29
9-10 Manual Bypass Procedure (Parallel UPS) 30
9-11 Switching from Manual Bypass to Normal (Parallel UPS) 31
10 Display and Configuration 32
10-1 Control Panel Diagram 32
10-2 Display Hierarchy 32
10-3 Default Display 33
10-4 Status Messages and Diagrams 33
10-5 Main Menu 35
10-6 UPS System “Measure” Menu 35
10-7 UPS System Setup Menu 36
10-8 Bypass Setup Menu 36
10-9 Output Setup Menu 37
10-10 Battery Setup Menu 38
10-11 Local Setup Menu 40
10-12 Maintenance Menu 41
10-13 Statistics Menu 42
10-14 Event Log Menu 43
10-15 Manual Setup & Test Menu 44
10-16 Firmware Upgrade Menu 45
10-17 Other Menu Choices 45
11 Communications 46
11-1 Communications Interfaces 46
11-2 SNMPWEBCARD Slot 46
11-3 Input Dry Contact Interface 46
11-4 Remote Emergency Power Off (EPO) Circuit Diagram 47
11-5 Auxiliary Dry Contact Input Circuit Diagram 47
11-6 External Battery Cabinet Temperature Inputs 47
11-7 External Battery Status Input 47
11-8 Output Dry Contact Interface Detail 48
11-9 Output Dry Contact Circuit Diagram 49
11-10 RS-232 Serial Port Circuit Diagram 50
11-11 Parallel Redundancy Port 50
12 Specifications 51
12-1 UPS System Technical Specifications 51
12-2 UPS System Floor Loading Table 51
12-3 Battery Pack Floor Loading Table 51
13 Storage and Service 52
14 Warranty and Warranty Registration 52
Español 53
Français 105

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1 – Introduction
Tripp Lite’s SmartOnline 3-Phase UPS Systems are ideal for backing up and protecting data centers, telecommunications (VoIP), networks,
industrial facilities, security/emergency systems and more.
Advanced Features:
True on-line double conversion with superior IGBT inverter technology•
Low input current THD allows 1:1 generator sizing for maximum efficiency and cost savings•
Internal N+1 power module redundancy•
Built-in parallel redundancy (1+1) capability for increased capacity or fault-tolerance•
Up to 80kVA capacity in a compact footprint; up to 160kVA in parallel redundancy (1+1) configuration•
High input power factor and high efficiency with low thermal loss and low noise•
Simplified, easy-to-repair, long-life, high-availability system design•
Redundant auxiliary power and control circuits•
All models support external battery cabinets for extended battery backup runtime•
High-resolution LCD status screen simplifies operation and delivers detailed operational information, including system block diagrams•

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2 – Important Safety Instructions
SAVE THESE INSTRUCTIONS
All sections of this manual contains instructions and warnings that should be followed during the installation and operation of the UPS
systems described in this manual. Read all instructions thoroughly before attempting to move, install or operate the UPS systems described in
this manual. Failure to comply may invalidate the warranty and cause property damage and/or personal injury.
Location Warnings
Install the UPS system in a controlled indoor environment, away from moisture, temperature extremes, flammable liquids and gasses, conductive•
contaminants, dust and direct sunlight.
Install the UPS system in a• level, structurally sound location.
The UPS system is extremely heavy; be extremely careful when moving or lifting the unit.•
Operate the UPS system at indoor temperatures between 32° F and 104° F (0° C and 40° C) only. For best results, maintain indoor temperatures•
between 62° F and 84° F (17° C and 29° C).
Leave adequate space around all sides of the UPS system for proper ventilation. Do not block, cover or insert objects into the external ventilation•
openings of the cabinet.
Do not place any object on the unit, especially containers of liquid.•
Do not mount the unit with its front or rear panel facing down (at any angle). Mounting in this manner will seriously inhibit the unit’s internal•
cooling, eventually causing product damage not covered under warranty.
Do not install the UPS system near magnetic storage media, as this may result in data corruption. Keep all recorded magnetic media a minimum•
of 60 cm (24 inches) away from the UPS system.
Do not attempt to stack the UPS system. Attempting to stack the UPS system may cause permanent damage and create a potential for serious•
personal injury.
The casters are designed for minor position adjustments within the final installation area only. The casters are not designed for moving the UPS•
system over longer distances.
The casters are not designed to provide long-term support for the UPS system after final installation. Use the levelers to provide long-term•
support.
When moving the UPS system, push from the front or rear, not from the sides.•
Do not attempt to unpack or move the UPS system without assistance.•
Connection Warnings
The power supply for this unit must be three phase rated in accordance with the equipment nameplate. It also must be suitably•
grounded according to all applicable local electrical wiring regulations.
The UPS system contains hazardous high voltages that have the potential to cause personal injury or death from electric shock.•
The UPS system has its own energy source (battery – internal and/or external). The output terminals may be live even when the UPS system is•
not connected to an AC supply.
If the UPS system receives power from a motor-powered AC generator, the generator must provide clean, filtered, computer-grade output.•
Use of this equipment in life support applications where failure of this equipment can reasonably be expected to cause the 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.
The UPS system is designed to power modern computer loads and associated peripheral devices. Do not use the UPS system to power pure•
inductive or capacitive loads.
Input and output wiring should be performed by trained, qualified electricians only.•
Due to high leakage current, a proper earth ground connection is essential before connecting the AC supply.•
Isolate the UPS system before working on the circuit. An easily accessible disconnect device should be incorporated in the fixed wiring. The•
disconnect device must be a 4-pole device and must disconnect all line conductors and the neutral conductor.

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2 – Important Safety Instructions
Battery Warnings
The UPS system does not require routine maintenance. There are no user-serviceable parts inside. Only qualified service personnel should open•
the access panels for any reason.
Batteries present a risk of electrical shock and burns from high short-circuit current. Battery connection or replacement should be performed•
only by qualified service personnel, observing proper precautions. Turn off the UPS system before connecting or disconnecting internal
batteries. Use tools with insulated handles. Do not open the batteries. Do not short or bridge the battery terminals with any object.
Replace batteries with equivalent batteries available from Tripp Lite. Do not operate the UPS system without batteries.•
The batteries are recyclable. Refer to local codes for disposal requirements.•
Do not dispose of the batteries in a fire, mutilate the batteries or open the battery coverings.•
Battery fuses should be replaced by qualified service personnel only. Blown fuses must be replaced with the same number and type of fuses.•
Potentially lethal voltages exist within the UPS system as long as the battery supply is connected. Service and repair should be performed•
by trained personnel only, while the UPS system is turned off or placed into bypass mode. Disconnect internal batteries (if present) before
performing any service work by switching off the internal battery circuit breaker and removing the battery fuse(s). Disconnect external batteries
(if present) by switching off the external battery cabinet breaker and disconnecting the external battery cabling from the UPS system.
Do not connect or disconnect batteries when the UPS system is operating from the battery supply or when the unit is not in bypass mode.•
Do not remove the plastic sleeves covering internal batteries.•
Internal and external batteries must be replaced by equivalent batteries available from Tripp Lite.•
Before connecting an external battery cabinet to the UPS system, read the external battery cabinet’s documentation. Use only external battery•
cabinets that have been approved by Tripp Lite.
If the UPS system remains off for an extended period of time, it should be turned on periodically to allow the batteries to recharge. The UPS•
system should be turned on and the batteries should be recharged at least one uninterrupted 24-hour period every 3 months. Failure to recharge
the batteries periodically may cause irreversible battery damage.
Wiring Warnings
See• Section 7-1 for wiring warnings

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3 – Control Panel Features
“NORMAL” LED:• This green light illuminates to indicate that the UPS system is in online (normal) mode. The primary AC input supply is
present and within standard operating parameters.
“BATTERY” LED:• This amber light illuminates when the UPS system is in battery backup mode, discharging the batteries to provide power
to connected equipment. An audible alarm will also sound.
“BYPASS” LED:• This amber light illuminates when the UPS system is in bypass mode (auto bypass or manual bypass). Battery backup
power will not be available to connected equipment while the UPS system is in bypass mode, but connected equipment loads will be
supported by the bypass power source.
“FAULT” LED:• This red light illuminates when any UPS system or input power fault occurs. Available diagnostic information will be
displayed on the LCD screen.
LCD Status Screen:• This illuminated LCD status screen displays text and graphics to indicate a wide range of UPS system operating
conditions and diagnostic data. Note: The LCD backlight will turn off after 10 minutes of inactivity. Turn on the backlight by momentarily
pressing the ON button or one of the scroll buttons.
“ESC” (Escape) Button:• Press this button to return to the previous page or menu.
Scroll Buttons (• and ): Press these buttons to move the cursor up or down and navigate the control panel menus and screens. These
buttons are also used for data entry in several screens.
Enter Button (• ): Press this button to select a menu item or confirm a setting change.
ON Button:• Press and hold this button for 3 seconds to turn the UPS system’s inverter ON.
OFF Button:• Press and hold this button for 3 seconds to turn the UPS system’s inverter OFF. If the UPS system is in online (normal) mode,
it will switch to auto bypass mode. Note: If the UPS system remains off for an extended period of time, the batteries should be recharged
periodically. The UPS system should be turned on and the batteries should be recharged at least one uninterrupted 24-hour period every
3 months. Failure to recharge the batteries periodically may cause irreversible battery damage.
“EPO” (Emergency Power Off) Button:• Press this button to turn the UPS system’s output OFF and also disable bypass output.
If the UPS system is in battery backup mode when the EPO button is activated:
Main output and bypass output are turned off, the alarm sounds, fans shut down after approximately one minute, and control circuitry•
remains active.
Releasing the EPO button (by pressing it again) turns off the UPS system completely, including the alarm and control circuit. Press the•
ON button for 3 seconds to restart the UPS system.
If the UPS system is in online (normal) mode when the EPO button is activated:
Main output and bypass output are turned off, the alarm sounds, fans and control circuitry remain active.•
Releasing the EPO button (by pressing it again) turns off the alarm and places the UPS system in auto bypass mode. Press the ON button•
for 3 seconds to return the UPS system to online (normal) mode.
See Section 10 – Display and Configuration for detailed information about the control panel’s menus and displays.
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A E F G H I J KBCD
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4 – Front and Rear Panel Features
Note: Individual models may vary from diagrams. Unit shown with front bezels removed.
Control Panel:• The control panel allows the operator to monitor and control the UPS system. See Section 3 – Control Panel Features for
more information.
Internal Power Modules:• 20kVA internal power modules can be replaced in the field without powering down connected equipment loads.
The number of internal power modules varies by model. The internal power modules are capable of N+1 redundancy.
Internal Battery Pack Compartment (SU40K only):• Internal batteries must be connected by a qualified electrician. See Section 6 –
Internal Battery Connection for more information.
Output Circuit Breaker Switch (Q4):• Controls AC output power.
Manual Bypass Circuit Breaker Switch (Q3):• Controls AC input power to the UPS system during manual bypass operation.
Bypass Input Circuit Breaker Switch (Q2):• Controls AC input power to the UPS system during auto bypass operation.
Main Input Circuit Breaker Switch (Q1):• Controls AC input power to the UPS system during online (normal) operation.
Levelers:• The levelers provide long-term support for the UPS system.
Casters:• The casters are designed for small position adjustments within the final installation location only; they are not designed for moving
the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation.
Use the levelers to provide long-term support.
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SU40K shown (front)

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Note: Individual models may vary from diagrams. Unit shown with front bezels removed.
Levelers:• The levelers provide long-term support for the UPS system.
Casters:• The casters are designed for small position adjustments within the final installation location only; they are not designed for moving
the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation.
Use the levelers to provide long-term support.
Accessory Slot:• Remove the cover panel to install a Tripp Lite SNMPWEBCARD accessory. The SNMPWEBCARD accessory provides an
Ethernet interface for the UPS system and enables remote monitoring and control via SNMP, Web browser or telnet. Call [phone] for
more information about the SNMPWEBCARD accessory.
RS-232 Serial Communications Port:• This DB9 port connects the UPS system to compatible workstations or servers, enabling automatic
shutdown during extended blackouts and monitoring of operating and power conditions.
Parallel Redundancy Port:• This DB9 port connects the UPS system to another UPS system of identical type and capacity for use in a
parallel redundancy (1+1) configuration. See Section 7 – Wiring and Section 8 – Operating Modes for more information.
Input Dry Contact Interface:• This interface receives dry contact signals that allow the UPS system to receive commands and monitor
external battery conditions. See Section 11 - Communications for more information.
Output Dry Contact Interface:• This interface allows the UPS system to send information via dry contact communications. See Section 11 –
Communications for more information.
Internal Battery Circuit Breaker Switch (SU40K only):• Controls the input/output power of the UPS system’s internal batteries.
Terminal Block Cover:• Remove the terminal block cover to access the UPS system’s input, external battery cabinet, output and grounding
connection terminals. Wiring conduits pass through the circular knockouts in the terminal block cover. See Section 7 – Wiring for more
information, including a detailed diagram of the terminal block.
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4 – Front and Rear Panel Features (continued)
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SU40K shown (rear)

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5 – Cabinet Installation
Read Section 2 – Important Safety Instructions Before Installation
5-1 Preparation
The UPS system must be installed in a structurally sound area with a level floor that is able to bear the weight of the UPS system, any external
battery cabinet and other equipment that will be installed nearby. The installation site should also have a dedicated AC circuit available that is
compatible with the UPS system’s input requirements. (See Section 12 – Specifications for details on input requirements and floor loading
requirements.) Before unpacking the unit, you should transport the shipping container closer to the final installation site to minimize the distance
you will need to move the unit after the protective shipping container has been removed. If you plan to store the UPS system for an extended
period before installation, follow the instructions in Section 13 – Storage and Service. (Unpacking and storage instructions are also printed on the
“Unpacking and Storage Instructions” sheet secured to the shipping container.) Warning: Do not attempt to unpack or move the UPS system
without assistance.
5-2 Unpacking
Inspect the shipping container(s) for visible damage. If you•
determine that the unit has been damaged during shipping, contact
Tripp Lite for assistance. Do not attempt to use the UPS system if
it has been damaged or mishandled.
Confirm that the shipping container is upright and use a
screwdriver to remove its top panel, front panel and back panel.
Also remove the plastic wrap and interior cushioning material.
Confirm that the model name and rating at the rear of the cabinet
match the unit you ordered. Examine the cabinet for any damaged
or loosened parts. Confirm that the shipping container includes the
accessories that ship with the unit. The UPS system should include
an RS-232 serial cable, a parallel redundancy cable, a remote EPO
wiring connector, a dry contact input connector (4 contacts), a dry
contact output connector (12 contacts) and a software CD-ROM. If
anything is missing or damaged, contact Tripp Lite for assistance.
Confirm that the unit is stable, then remove the side panels from
the shipping container.
Remove the bolts from the shipping brackets securing the unit•
to the pallet, then remove the shipping brackets from the UPS
system. Warning: Be extremely careful, as the unit could shift
unexpectedly.
Use several of the screws you removed in step 1 to attach the top
panel of the shipping container to the front edge of the shipping
pallet. The smooth surface of the panel should face upward so
that it can be used as a ramp for rolling the unit off the shipping
pallet. Do not attempt to use the top panel as a ramp if it is cracked
or otherwise structurally damaged. Make sure the casters at the
bottom of the unit are unlocked. Using extreme caution, slowly roll
the unit down the ramp with the aid of several assistants.
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5 – Cabinet Installation (continued)
5-3 Placement
Use the casters to move the UPS system for a short distance over•
a level, smooth, stable surface. Do not attempt to use the casters
to move the UPS system over longer distances. The UPS system
should be moved close to its final installation location inside
its shipping container before it is unpacked from the shipping
container. Use a mechanical device of sufficient capacity to move
the shipping container. Warning: The UPS system could tip if it
is moved over an unstable surface. Be extremely careful when
moving the UPS system. Push the UPS system from the front or
rear, not from the sides.
Position the UPS system in a structurally sound area with a•
level floor that is able to bear the weight of the UPS system,
any external battery cabinets and other equipment that will be
installed nearby. The installation site should also have a dedicated
AC circuit available that is compatible with the UPS system’s
input requirements. (See the Section 12 – Specifications for
more information about input requirements and floor loading
requirements.) The UPS system must be installed in a clean,
secure environment with a relative humidity less than 90% (non-
condensing). Operate the UPS system at indoor temperatures
between 17° C and 29° C (62° F and 84° F). Prevent damage to
cabling by using suitable protective conduits. In order to maintain
proper airflow and service access, you must maintain the following
clearances:
At least 100 cm clearance in front of the UPS system.•
At least 50 cm clearance behind the UPS system.•
At least 50 cm clearance above the UPS system.•
Warning: The cooling fans circulate air from front to back. Do not
use any air conditioning or fan that blows air directly toward the
rear of the UPS system.
After moving the UPS system to its final location, lock the casters•
Aand use the levelers Bto stabilize the cabinet. Ensure that all
four levelers make firm contact with the floor.
For emergency use, install a fire extinguisher rated for energized•
electrical equipment fires (Class C rating or exact equivalent, with
a non-conductive extinguishing agent) near the UPS system.
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100 cm
50 cm
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6 – Internal Battery Connection (Model SU40K Only)
DANGER! LETHAL HIGH VOLTAGE HAZARD!
Potentially lethal high voltage exists within the batteries, even when not connected to a UPS system. Battery connection
should be performed by qualified service personnel only, following all the precautions listed in this manual and adhering to
local electrical codes. Read Section 2 – Important Safety Instructions before proceeding.
Internal battery connection is for model SU40K only. Each internal battery pack consists of two strings of batteries: one string with a black cable
and one string with a red cable.
6-1 Internal Battery Wiring Diagrams
Review the internal battery wiring diagrams prior to connecting the internal batteries. The UPS system can accept up to four internal battery packs
(each pack consists of two strings; each string consists of 10 batteries).
AC/DCMAIN INPUT
Q1Q2
Q3
Q4
OUTPUTDC/AC
12V, 20PCS 12V, 20PCS
B+ N B-
B+
B-
N
UPS
12V, 20PCS 12V, 20PCS
XFMR XFMR
SU40K shown
SU40K shown
VBoard W1: RED, W2: BLUE, W3: WHITE, W4: BLACK 12V, 9AH, 10PCS
12V, 9AH, 10PCS
12V, 9AH, 10PCS
12V, 9AH, 10PCS
RED RED
RED RED
BLACK BLACK
BLACK BLACK
RED RED
RED RED
BLACK BLACK
BLACK BLACK
B+
W1
W1
W1
W1
W2
W2
W2
W2
12V, 9AH, 10PCS
12V, 9AH, 10PCS
12V, 9AH, 10PCS
12V, 9AH, 10PCS
W4
W4
W4
W4
W3
W3
W3
W3
B-
N
VBoard

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UPS System
Battery Back
Connector
UPS System
Battery Back
Connector
Fuse Block Bracket
6 – Internal Battery Connection (continued)
SU40K shown
6-1 Internal Battery Wiring Diagrams (continued)

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6 – Internal Battery Connection (continued)
6-2 Internal Battery Connection Procedure
Place the UPS system in bypass (or turn it completely off) and turn•
off the internal battery circuit breaker switch, located on the rear of
the UPS system.
Remove the battery access bezels, located on the front of the UPS•
system.
Remove the battery cartridge fuses from each fuse block.•
Disconnect the blue and white jumper cables attached to each fuse•
block. Warning: When disconnecting the jumper cables, pull
them straight away from the fuse block with even force. Do not
wiggle them side-to-side, as this may damage the connector.
Remove the fuse block bracket. Note its orientation before•
removal.
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6-2 Internal Battery Connection Procedure (contiinued)
Slide a battery string with a red cable into an empty slot within•
the battery compartment. Make sure the battery string is oriented
as shown in the diagram. Note: Start with the empty slots at the
bottom of the battery compartment and work toward the empty
slots at the top of the battery compartment.
Slide a battery string with a black cable into an empty slot within•
the battery compartment, next to the battery string that you inserted
in step 6. Make sure the battery string is oriented as shown in the
diagram. Repeat steps 6 and 7 as needed until all the battery strings
have been inserted into the empty battery slots.
Reconnect the fuse block bracket. (The letters on the fuse block•
bracket should be upright when it is in the correct orientation.)
Connect the blue and white jumper cables on each internal battery•
pack to the corresponding fuse block. The labeling next to the fuse
block identifies the correct fuse block for each cable.
Insert the battery cartridge fuses into each fuse block. The fuses are•
interchangeable. Make sure the fuses are firmly snapped into place.
Warning: Battery cartridge fuses must be inserted last due to
potential arcing of connectors. Blown fuses must be replaced
by a qualified electrician. Replace only with fuses of the same
type and rating.
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6 – Internal Battery Connection (continued)
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10
TERMINALS
TERMINALS
SIDE VIEW
SIDE VIEW

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6 – Internal Battery Connection (continued)
6-2 Internal Battery Connection Procedure (contiinued)
Use a voltmeter (user-supplied) to test the voltage of each internal•
battery pack. Observing proper polarity, connect the voltmeter’s
black probe to the battery pack’s black connector; connect the
voltmeter’s red probe to the battery pack’s red connector. Make
sure the voltmeter’s probes touch the metal contacts inside the
battery pack’s connectors. The battery pack’s acceptable DC
voltage range is between 220V and 280V DC (nominal 240V DC).
If several voltmeter tests yield results outside the acceptable DC
voltage range, contact Tripp Lite for assistance in determining the
possible causes of the incorrect voltage reading before proceeding.
Connect the• black cable for each internal battery pack to the
nearest black connector located inside the UPS system’s battery
compartment. Connect the red cable for each internal battery
pack to the nearest red connector located inside the UPS system’s
battery compartment. Warning: Observe proper polarity by
connecting negative to negative (black to black) and positive
to positive (red to red). Failure to observe proper polarity will
damage the UPS system and create a serious risk of personal
injury and property damage.
Replace the battery access bezels.•
Turn on the internal battery circuit breaker switch. If you placed•
the UPS system in bypass, return it to the previous operating mode.
If you turned the UPS system off, turn it on. If you still need to
wire the UPS system, proceed to Section 7 – Wiring.
Note: If you need to remove or replace internal battery packs, modify
steps 6 and 7 by removing and/or replacing the existing internal battery
packs, as required.
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7 – Wiring
DANGER! LETHAL HIGH VOLTAGE HAZARD!
All wiring should be performed by a qualified electrician, in accordance with the warnings in this manual and all applicable
electrical and safety codes. Incorrect wiring may damage the UPS system severely and cause serious personal injury and
property damage. Read Section 2 – Important Safety Instructions before proceeding.
7-1 Wiring Warnings
De-energize all input and output power sources of the UPS system before installing cables or making electrical connections.•
Use flexible cable of sufficient length to permit UPS system servicing. The maximum cable length is 10 m (32.8 ft).•
Use ferrule caps to cover termination cables and prevent frayed ends from shorting on the UPS system terminal block.•
Use cabling rated VW-1, FT-1 or better.•
Use cable sleeves and connector clamps.•
The neutral conductor must be the same size as the current conductors.•
Tighten all connections with a torque of at least 3.95 N·m (35 in·lb)•
Confirm that all cables are marked correctly according to their purpose, polarity, phase and diameter.•
If the UPS system’s input/output power source is wye-wye, then “Neutral” and “Ground” must not be connected.•
If the input power source has VNG>0, install an isolation transformer before the UPS system and input power source, then connect the UPS•
system’s “Neutral” and “Ground” together.
For equipment requiring a neutral connection to an IT power distribution system, the disconnect device must be a four-pole device and must•
disconnect all line conductors and the neutral conductor. If a disconnect device interrupts the neutral conductor, it must simultaneously interrupt
all line conductors.
Allow the batteries to charge uninterrupted for 24 hours after the initial wiring connection.•
Observe proper polarity by connecting negative to negative and positive to positive. Failure to observe proper polarity will damage the UPS•
system and create a serious risk of personal injury and property damage.
Observe proper phase by connecting R to R, S to S, T to T and N to N. Failure to observe proper phase will damage the UPS system and create a•
risk of personal injury and property damage.
7-2 Wiring Preparation
De-energize all input and output (AC and DC) of the UPS system and external battery cabinet (if present).•
Mark all cables according to their correct purpose, polarity, phase and diameter.•
Review the diagrams in• Section 7-3 and Section 7-4 to familiarize yourself with the terminal blocks.
Consult the table in• Section 7-5 to find the correct electrical input/output characteristics for the UPS system.
Note: If the UPS system’s input/output power source is wye-wye, then “Neutral” and “Ground” must not be connected. If the input power source
has VNG>0, install an isolation transformer before the UPS system and input power source, then connect the UPS system’s “Neutral” and
“Ground” together.

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7 – Wiring (continued)
SU40K and BP480V40C shown for illustration only; consult the battery cabinet’s documentation for exact specifications
7-3 UPS System Terminal Block Diagram
7-4 External Battery Cabinet Wiring Diagrams
Input
Grounding Terminals
RR SS TT NN+ –N
Output
External Battery
Connection
+
N
–
+
N
–
External Battery
Cabinet Breaker
Switch

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7 – Wiring (continued)
7-4 External Battery Cabinet Wiring Diagrams (continued)
7-5 Electrical and Cable Data
12V, 20 Batteries 12V, 20 Batteries
B+ N B-
B+ B-N
UPS
External Battery Cabinet
B Cabinet: 26AH per Battery
C Cabinet: 40AH per Battery
AC/DCMAIN INPUT
Q1Q2
Q3
Q4
OUTPU
T
DC/AC
XFMR XFMR
Input and Output Battery Input and Output Battery
Model Input/Output Breaker Size Fuse Size Cable Size Cable Size
SU40K 120/208V AC, 3O, 150A 120A 1/0 AWG 6 AWG
4-wire + ground, wye
SU60K 120/208V AC, 3O, 225A 160A 4/0 AWG 4 AWG
4-wire + ground, wye
SU60KTV 277/480V AC, 3O, 100A 160A 4 AWG 4 AWG
4-wire + ground, wye
SU80KTV 277/480V AC, 3O, 125A 220A 2 AWG 2 AWG
4-wire + ground, wye

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7 – Wiring (continued)
7-6 External Battery Cabinet Wiring
Warning: External battery cabinets vary. Read the external battery cabinet’s documentation before attempting to connect it to the UPS
system. Use only external battery cabinets that have been approved by Tripp Lite.
Note: An external battery cabinet is required with models SU60K, SU60KTV and SU80KTV. It is optional with model SU40K. Contact Tripp Lite
for external battery cabinet ordering information.
De-energize all input and output (AC and DC) of the UPS system•
and external battery cabinet, and confirm that the external battery
cabinet breaker switch Ais off. (If the UPS system has already
been wired to an AC power source, see Section 9-6 for shutdown
instructions.)
Remove the terminal block covers from the UPS system and•
external battery cabinet.
Connect the positive (+), neutral (N) and negative (-) UPS•
system connection terminals of the external battery cabinet to the
corresponding positive (+), neutral (N) and negative (-) external
battery connection terminals of the UPS system. See Section 7-3
and the external battery cabinet’s documentation for terminal
block diagrams. See Section 7-4 for wiring diagrams. See Section
7-5 for cable size requirements. Cabling should be protected by
flexible conduit and routed through the appropriate knockouts in
the terminal block cover. Warning: Observe proper polarity by
connecting negative to negative and positive to positive. Failure
to observe proper polarity will damage the UPS system and
create a risk of personal injury and property damage.
Connect the external battery cabinet’s grounding terminal• Ato the
UPS system’s corresponding grounding terminal Bwith a 4 AWG
(5.189 mm) ground cable. Keep the ground cable connected at all
times after installation.
Connect the UPS system’s grounding terminal• Ato your facility’s
earth ground Bwith a 4 AWG (5.189 mm) ground cable. Keep the
ground cable connected at all times after installation.
Replace the terminal block cover of the external battery cabinet. If•
you do not plan to wire the AC input/output of the UPS system at
this time, replace the terminal block cover of the UPS system.
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3
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+
N
–
+
N
–
N
A
A
B
B
A

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7 – Wiring (continued)
7-7 AC Input/Output Wiring (Single UPS)
After de-energizing all input and output (AC and DC) of the UPS•
system, remove the terminal block cover from the UPS system.
If you did not connect the ground cable in• Section 7-6, connect the
UPS system’s grounding terminal Ato your facility’s earth ground
Bwith a 4 AWG (5.189 mm) ground cable. Keep the ground cable
connected at all times after installation.
Remove the UPS system’s front bezel to expose the circuit•
breakers. First, confirm that the main input circuit breaker switch
Aand the bypass input circuit breaker switch Bare both off.
Second, confirm that the manual bypass circuit breaker switch C
is off. Third, confirm that the output circuit breaker switch Dis
off.
Confirm the phase of each cable, then connect the cables according•
to the UPS system terminal block diagram in Section 7-3. See
Section 7-5 for cable size requirements. Cabling should be
protected by flexible conduit and routed through the appropriate
knockouts in the terminal block cover. Warning: Observe proper
phase by connecting R to R, S to S, T to T and N to N. Failure
to observe proper phase will damage the UPS system and
create a risk of personal injury and property damage.
Replace the UPS system’s terminal block cover.•
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5
B
+
N
–
RS T
N
RS T
N
D B AC
A