Xtreme Power Conversion XPRT-6kVA Guide

Xtreme Power Conversion® Corporation
Xtreme Performance Rack Tower Series
(XPRT-6kVA/10kVA)
User’s & Installation Manual

XPRT-6kVA, XPRT-10kVA USER’S MANUAL UNINTERRUPTIBLE POWER SUPPLY (UPS)
Xtreme Power Conversion® (XPC) Corporation Page 2
TABLE OF CONTENTS
INTRODUCTION......................................................................................................................................................5
EMC STATEMENTS - FCC PART 15....................................................................................................................5
IMPORTANT SAFETY INSTRUCTIONS.............................................................................................................6
SAFETY WARNINGS AND SYMBOLS.................................................................................................................6
GENERAL...................................................................................................................................................................8
TRANSPORT / STORAGE......................................................................................................................................8
MAINTENANCE AND SERVICING.......................................................................................................................9
INTRODUCTION................................................................................................................................................... 10
PRODUCT DESCRIPTION.................................................................................................................................. 10
Double Conversion On-Line Technology.................................................................................................11
Efficiency Optimizer Function.................................................................................................................12
Free Run Mode........................................................................................................................................12
Diagnostic Tests......................................................................................................................................12
System Configuration..............................................................................................................................12
HARDWARE INSTALLATION GUIDE ............................................................................................................. 19
Safety Information..................................................................................................................................20
Installation Procedures...........................................................................................................................21
Tower Installation...................................................................................................................................21
Rack Mount Installation..........................................................................................................................22
Connecting Internal Battery Pack (6kVA Model)....................................................................................24
Connecting Internal Battery Pack (10kVA Model)..................................................................................26
Connecting Additional External BatteryPacks (6kVA Model) ................................................................28
Connecting Additional External BatteryPacks (10kVA Model) ..............................................................31
Connecting Interface Devices .................................................................................................................34
Standard Hardwired Installation Procedure...........................................................................................36

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Optional Power Distribution Units..........................................................................................................40
STARTUP................................................................................................................................................................ 42
Startup 6kVA UPS....................................................................................................................................42
Startup 10kVA UPS (stand-alone not parallel systems)..........................................................................43
OPERATION........................................................................................................................................................... 45
Normal Operation Conditions.................................................................................................................45
Switching the UPS OFF............................................................................................................................45
Maintenance Bypass...............................................................................................................................47
10KVA PARALLEL INSTALLATION AND OPERATION............................................................................. 48
Installation of a parallel system..............................................................................................................49
Installing the parallel connection............................................................................................................51
Startup 10kVA UPS Parallel System........................................................................................................52
Normal Operation Conditions.................................................................................................................52
Switching the UPS OFF............................................................................................................................53
STATUS AND ALARM INDICATIONS.............................................................................................................. 55
On Bypass................................................................................................................................................56
On Battery...............................................................................................................................................56
Battery Low (end of runtime) .................................................................................................................56
Bypass Out of Limits................................................................................................................................57
Overload..................................................................................................................................................57
Replace Battery.......................................................................................................................................57
Alarm Priority..........................................................................................................................................58
Fault Mode..............................................................................................................................................58
Standby...................................................................................................................................................59
Remote Emergency Power Off (REPO) ...................................................................................................59
No Load Shutdown..................................................................................................................................60

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Auto Restart............................................................................................................................................60
BATTERY MANAGEMENT................................................................................................................................. 60
Battery Connection Test.........................................................................................................................60
Quick Battery Test...................................................................................................................................60
Deep Battery Test ...................................................................................................................................60
COMMUNICATION............................................................................................................................................... 61
DB9 Communication Port .......................................................................................................................61
SNMP Interface Card (Option)................................................................................................................62
EXTENDED RUNTIME ........................................................................................................................................ 62
MAINTENANCE..................................................................................................................................................... 63
Safety......................................................................................................................................................63
General....................................................................................................................................................63
Recycling the UPSat theEnd of Service Life...........................................................................................63
Batteries..................................................................................................................................................64
Internal Battery Replacement – 6kVA Model.........................................................................................64
Internal Battery Replacement – 10kVA Model.......................................................................................66
Power Unit Maintenance........................................................................................................................67
Power Unit Replacement – 6kVA Model ................................................................................................68
Power Unit Replacement – 10kVA Model ..............................................................................................68
TROUBLESHOOTING.......................................................................................................................................... 69
SPECIFICATIONS.................................................................................................................................................. 71
SHIPPING LIST ..................................................................................................................................................... 73
OBTAINING SERVICE.......................................................................................................................................... 74
XTREME POWER CONVERSION®(XPC) CORPORATION LIMITED WARRANTY............................. 75
XTREME POWER CONVERSION®LOAD PROTECTION POLICY............................................................ 76
APPENDIX A – SNMP/WEB CARD (OPTIONAL)......................................................................................... 78
Introduction............................................................................................................................................78

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LEDs.........................................................................................................................................................79
Features..................................................................................................................................................79
Architecture............................................................................................................................................80
Installation..............................................................................................................................................81
Interfaces............................................................................................................................................82
Configuration......................................................................................................................................82
Access..................................................................................................................................................85
INTRODUCTION
Thank you for selecting this uninterruptible power supply (UPS). It provides you with protection for
connected equipment. Please read this manual before installing the XPRT-Series UPS models XPRT-6000
and XPRT-10000 as it provides important information that should be followed during installation and
maintenance of the UPS and batteries, allowing you to correctly set up your system for the maximum
safety and performance. Included is information on customer support and service, if it is required. If you
experience a problem withthe UPS, please refer to the Troubleshooting section in this manual to correct
the problem. If the problem is not corrected, please collect information so that the Technical Support
personnel can more effectively assist you.
EMC Statements - FCC Part 15
Notice: This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with
the instruction manual, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the user will be
required to correct the interference at the users own expense.
Modifications not expressly approved by the manufacturer could void the user’s authority to operate the
equipment under FCC rules.

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IMPORTANT SAFETY INSTRUCTIONS
(SAVE THESE INSTRUCTIONS)
This manual contains important instructions that should be followed during installation and maintenance
of the UPS. It also gives all necessary information about the correct use of the UPS. Before attempting to
install and start up the UPS, carefully read this manual. Keep this manual next to the unit for future
references.
Full understanding of and compliance with the safety instructions and warnings contained in this
manual are the
ONLY CONDITIONS
to avoid any dangerous situation during installation, operation and maintenance work, and to preserve
the maximum reliability of the UPS system.
Xtreme Power Conversion (XPC) Corp refuses any responsibility in case of non-observance,
unauthorized alterations,or improper use of the delivered UPS.
While every care has been taken to ensure the completeness and accuracy of this manual, XPC accepts
no responsibility or liability for any loss or damage resulting from the use of the information contained
in this document.
This document shall not be copied nor reproduced without the permission of XPC.
Due to technical improvements, some of the information contained in this manual may be
changed without notice.
The instructions in this manual are for UPS models XPRT-6000 and XPRT-10000. Check your model number
by looking at the top cover of your UPS. Any difference in instructions is clearly indicated in the text (for
instance ‘XPRT-10000).
SAFETY WARNINGS AND SYMBOLS
Safety Warnings
The text of this manual contains warnings to avoid risk to persons and to avoid damages to the UPS system
and the supplied critical loads. Do not proceed beyond these warnings if you do not fully understand
and/or are not able to meet the mentioned conditions.

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The non-observance of the warnings reminding hazardous situations could result in human injury and
equipment damage.
Please pay attention to the meaning of the following warnings and symbols.
WARNING!
Refers to procedures or operations which, when not correctly performed, could
cause personal injury orserious damage tothe system.
NOTE
Warns theuser about important operationsor procedures described in this
manual.
Safety Symbols
CAUTION
The product may be in danger: when procedures or operations are not correctly
performed, damage to the product may be the result.
DANGER OF ELECTRICALLY LIVE PARTS
Related to all situations with potentially hazardous voltage.
NOTE
Check for sufficient floor and elevator loading capacity. Move the UPS and the
battery pack in its original package to the final destination room. Do not stack
other package on top.
WARNING!
Pay attention to the HEAVY WEIGHT of the UPS when downloading the UPS from
the pallet! Never try to lift the unit by yourself!

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GENERAL
DANGER! RISK OF ELECTRIC SHOCK.
The UPS has an internal battery supply with a nominal voltage of 144VDC (6kVA)
288VDC (10kVA).
Some of the parts of the UPS are necessarily under a hazardous voltage. Do not
open the unit; there are no user serviceable partsinside.
The outlets and output terminals may be electrically live, even when the UPS is
disconnected from the utility power.
CAUTION
There may be damage to the equipment if procedures and practices are not strictly
observed and followed.
TRANSPORT / STORAGE
NOTE
Check for sufficient floor and elevator loading capacity. Move the UPS and the
battery pack in its original package to the final destination room. Do not stack
other package on top.
WARNING!
Pay attention to the HEAVY WEIGHT of the UPS when removing the UPS from the
pallet! Never try to lift the unit by yourself!
No liability can be accepted for any transport damage when the equipment is not shipped in original
packaging.
Store the UPS in a dry location with the batteries in a fully charged state. Storage temperature must be
within -20 +45 °C (-4°F and 113°F). If the unit is stored for a period exceeding 3 months, optimal battery
lifetime is obtained if the storage temperature does not exceed 30°C (86°F).
If the unit is stored for an extended period of time, the batteries must be recharged periodically. Connect
the unit to a wall outlet and recharge the batteries for 24 hours:

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•if the storage temperature is within -20 and +30°C (-4°F and 86°F): every 3 months
•if the storage temperature is within -20 and +45°C (-4°F and 113°F): every 1 month
CAUTION
In case of storage, pay attention to:
MAINTENANCE AND SERVICING
•All maintenance and servicing, except replacement of the batteries and plug-in cards, is to be
carried out by qualified skilled personnel only
•A battery can present a risk of electrical shock and high short circuit current
•Never dispose of batteries in a fire: they may explode
•Do not open or mutilate batteries: their contents may be extremely toxic. If exposed to
electrolyte, wash immediately with plenty of water
•The batteries must be disconnected during maintenance or service work
•When replacing the batteries, use only the same type and size battery
•The following precautions should be observed when working on batteries:
oRemove watches, rings or other metal objects
oUse tools with insulated handles
oWear rubber gloves and boots
oDo not lay tools or metal parts on top of batteries
oDisconnect charging source prior to connecting or disconnect battery terminals
oDetermine if the battery is inadvertently grounded. If inadvertently grounded, remove
source of ground. Contact with any part of a grounded battery can result in electrical
shock. The likelihood of such shock will be reduced if such grounds are removed during
installation and maintenance.
•Avoid charging in a sealed container

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NOTE
Do not attempt to service the UPS unless you have had proper training. Refer all
maintenance and servicing, except replacement of the batteries, power unit (10kVA),
and plug-in cards, to properly qualified, skilled, and competent service personnel.
Qualified, skilled personnel are persons who (because of their training, experience, and position as well as
their knowledge of appropriate standards, regulations, health and safety requirements and working
conditions) are authorized to be responsible for the safety of the equipment, at all times whilst carrying
out their normal duties and are therefore aware of, and can report, possible hazards (observe IEC 60364
and national wiring regulations and accident prevention rules).
INTRODUCTION
The information provided in this manual covers single phase 6000 and 10000 VA uninterruptible power
systems, their basic functions, operating procedures, options available, and emergency situations. It also
includes information on how to ship, store, handle, and install the equipment. Only detailed
requirements of the UPS units are described herein, and installation must be carried out in accordance
with this manual. Electrical installation must also carefully follow local legislation and regulations. Only
qualified personnel should conduct these installations as failure to acknowledge electrical hazards could
prove to be fatal.
PRODUCT DESCRIPTION
Many different kinds of sensitive electrical equipment can be protected by an Uninterruptible Power
Supply (UPS) including computers, workstations, process control systems, telecommunications systems,
sales terminals, other critical instrumentation, etc. The purpose of the UPS is to protect these systems
from poor quality utility power, complete loss of power, or other associated problems.
Electrical interference exists in many forms, causing problems in AC power, from lightning, power
company accidents and radio transmission motors, air conditioners, and vending machines. Protection
of sensitive electrical equipment is vital to protect against power outages, low or high voltage
conditions, slow voltage fluctuations, frequency variations, differential and common-mode noise,
transients, etc.
To prevent power line problems from reaching critical systems causing damage to software, hardware,
and equipment malfunctions, the UPS maintains constant voltage, isolating critical load output and
cleaning the utility AC power.

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Double Conversion On-Line Technology
A double conversion on-line technology UPS provides completely isolated, clean, uninterrupted single-
phase power to your critical systems, while maintaining the batteries for their maximum potential. In
the event that the power failure lasts longer than the UPS backup time, the UPS will shut down avoiding
battery damage. When the input AC voltage returns, the UPS will automatically return online to
recharge the batteries.
As shown in fig. 1 block diagram:
•An input filter reduces transients on the incoming utility.
•To maintain full battery charge, the AC input power isrectified and regulated in the rectifier
feeding power to the battery converter and inverter.
•DC power is converted to AC in the inverter, passingit on to the load.
•Power is maintained from the battery during a power failure.
•The converter increases voltage appropriately for the inverter.
FIG. 1 - BLOCK DIAGRAM

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Efficiency Optimizer Function
The Efficiency Optimizer Function is a new feature for the UPS, adding cost effectiveness, minimizing
power loss and reducing power consumption. Alternating between bypass and on-line modes is
achieved automatically and in accordance with the conditions of the utility power. On-line mode may be
used during times of intermittent power, and bypass mode used when power flows smoothly, in order
to obtain greatest efficiency. Irregularities can be detected in less than a second, and on-line mode
reactivates immediately. Switching back to on-line mode occurs when input voltage is outside ±10% of
nominal (±15% selectable), when input frequency is outside of ±3Hz or when no input line is available.
Although high efficiency is standard, the default operation is in on-line mode. Bypass can be activated in
the LCD panel; though on-line can be run permanently if preferred.
Free Run Mode
The UPS operates in Free Run Mode when input frequency is outside of the selected input frequency
range. Free Run Mode is when output frequency does not match input frequency. When starting the
UPS, the frequency regulation detected is 50 or 60 Hz ±0.25Hz.
Diagnostic Tests
When the UPS is started, a diagnostic test is automatically executed, checking the electronics and
batteries, reporting any problems on the LED display.
An Xtreme Battery Management system always monitors the conditions of the batteries, sending any
forewarnings if replacement of batteries is required. Every 30 days of normal mode operation, a battery
discharge test is automatically performed, reporting any problems on the LED display.
Except during the first 24 hours after startup while the UPS is in charging mode, diagnostic tests can be
performed manually from the front panel at any time.
System Configuration
The UPS device and the internal batteries make up the system. Depending on the site and load
requirements of the installation, certain additional options are available for the solution.
Planning a UPS system, the following should be taken into consideration:
•The total demand of the protected system shall dictate the output power rating (VA). Allow a
margin for future expansion or calculation inaccuracies from measured power requirements.
•Backup time required will indicate the battery size needed. If the load is less than the UPS
nominal power rating, thenactual backup time is longer.
•The following options are available:
oExtended Battery Packs (maximum of 3 battery packs of same model)

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§XPRT-BP4-90000019 for 6000
§XPRT-BP5-90000030 for 10000
oConnectivity Options –SNMP/WEB card
§XPRT-SNMP2-90000031
o4-Post Mounting Rail Kit
§XPRT-RR2-90000032
o10kVA Power Distribution Unit e/w (8)5-20R+(2)L5-20R+(2)L6-30R
§XPRT-PDU3-90000035
oPower Distribution Units for additional receptacles
§XPD1420HV-90000045 provides 12FT 5-20P INPUT + (14)5-20R
§XPD1420HVA-90000050 provides 12FT 5-20P INPUT + (14)5-20R + AMP METER
See the Specification section of this manual for addition model information.
FIG 2 – 6kVA FRONT VIEW

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FIG 3 – 10kVA FRONT VIEW

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FIG 4 – XPRT-6000HB-90000036 BUNDLE REAR VIEW
(WITH UPS, INTERNAL BATTERY & HARDWIRE PDU)
FIG 4 – XPRT-6000B-90000013 BUNDLE REAR VIEW
(WITH UPS, INTERNAL BATTERY & RECEPTACLE PDU (4) 5-20R + (1) L6-30R + (1) L14-30R)

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FIG 4 – XPRT-10000B-90000014 REAR VIEW
(STANDARD HARDWIRE + INTERNAL BATTERIES)
FIG 4 – XPRT-10000-90000016 + XPRT-PDU3-90000035 REAR VIEW

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(W/ PDU (4) 5-20R + (2) L5-20R + (2) L6-30R)
FIG 5 – FRONT PANEL – HORIZONTAL
FIG 6 – FRONT PANEL – VERTICAL

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UPS Off Switch
Switches the UPS from normal operation to bypass and from bypass or battery to standby
UPS On Switch
Switches on the UPS, starts quick battery test, mute the buzzer
Green Utility Available LED
Indicates availability of utility input power
Yellow Battery LED
This LED will be in during on-battery operation: the utility input power fails, and the internal batteries
(and external battery packs if available) supply the power until either the batteries are depleted or the
utility input power returns
Green Operation LED
This LED will be on when the output is supplied by the UPS (not on bypass)
Yellow Bypass LED
This LED will be on when the UPS operates in Bypass Mode: the utility input power is passing directly to
the load. If this LED blinks, then the input voltage is out of bypass tolerance
Red Alarm LED
This LED is on in case of an alarm
LED Bar Runtime Capacity (Green)
These LEDs indicate theremaining available battery runtime forthe actual load in % of the maximum
runtime. When the Alarm LED ison, this barmay showa combination of LEDs, describing theAlarm
cause.
1 LED = 0-20%
2 LEDs = 21-40%
3 LEDs = 41-60%

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4 LEDs = 61-80%
5 LEDs = 81-100%
LED Bar Load (Green or Yellow)
These LEDs indicate to what extent the output capacity of the UPS is used by theactual load for each
output line (L1 and L2). If for example, the 25%, 50%, and 75% LEDs are on for Line 1, and the 25% and
50% LEDs are on for Line 2, the load exceeds 50% of the maximum load for Line 1 and 25% of the
maximum load for Line 2. Ifall 5 LEDs areon, the unit operates inoverload. As this is an abnormal
situation, the alarm LED will also be on.
1 LED = 0-25% Green
2 LEDs = 26-50% Green
3 LEDs = 51-75% Green
4 LEDs = 76-100% Green
5 LEDs = >100% Yellow
Remote Emergency Power Off (EPO) Port
A customer supplied switch located remotely can be used to open the EPO connection and allows the
UPS output receptacles to be switched off. Since the EPO shuts down the equipment immediately,
orderly shutdown procedures are not followed by any power management software. The UPS will have
to be manually restarted in order to regain power to the outlets on the UPS.
HARDWARE INSTALLATION GUIDE
Inspect the UPS for damage after unpacking. If any damage is present please immediately notify the carrier
and place of purchase.
NOTE
The internal battery packs for these UPS ship separately. FOR the 6kVA model
there is 1 internal battery pack, and for the 10kVA model there are 2 internal
battery packs are shipped separately.
WARNING! In case of recognizable damage:
DO NOT connect any voltage to the unit
DO NOT put the unit into operation

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Safety Information
Information presented here is vital to all personnel. Please read all Safety information.
IMPORTANT
Before making any connection and switching on the XPRT Series UPS, please check
the following conditions:
•All electrical connections are to be realized by qualified skilled personnel only.
•To avoid potential health risks, electrical components should not be mechanically damaged or
destroyed. Do not touch electronic components. They may be electrostatic sensitive and are for
that reason easily damaged due to improper handling.
•Avoid locations that are excessively humid, near water, near heat sources or in direct sunlight. It is
important that the unit has adequate ventilation. Maintain air movement around and through the
unit. Do not block the air vents.
•The ambient temperature should not exceed 40°C(104°F). Optimal battery lifetime is obtained if
the ambient temperature does not exceed 30°C (86°F).
•Avoid spilling liquids or dropping any foreign object into the UPS.
•The UPS should only be powered from a two phase, four wire AC source equipped with neutral
and earth connection. The input utility is 100 - 127 Volts (Line-N) and 60 Hz (if the input utility
frequency is 50Hz, the output frequency of the UPS can be changed).
•The total power demand of the connected equipment does not exceed the rated output power
of the XPRT Series UPS
•The branch circuit supply has to be protected as follows:
UPS model Branch protection
XPRT-6000 30A slow
XPRT-10000 60A slow
CAUTION
To reduce risk of fire, connect the UPS only to a circuit provided with fuse or
circuit breaker values asshown above.