Falcon SG2K-1T-HW User's Manual
Contents
1. Battery Fuse Holder Prior to installing the battery fuse depress this button of one second to pre charge the UPS and immediately install the battery fuse Cooling Fans DO NOT BLOCK AIR FLOW Hardwire Terminal Block 1 Secondary Input Circuit 8 821 Breaker a 9 Driv cin ge rae Gr 9 o 15 CHAPTER 5 COMMUNICATIONS INTERFACES RS 232 INTERFACE Location The RS 232 interface is standard on all SG series UPS models The port is located on the UPS rear panel via a DB 9 female connector Supported Protocols UPSILON 2000 amp SEC Smart Mon 6 TX BAUD RATE 2400bps 3 ae DATA LENGTH 8 bits 4 STOP 1 bit 42082 PARIT Y None DB 9 Connector Pin Assignment Pin Function explanation Pp 2 RS 232 Rx INPUT RS 232 Tx OUTPUT Oo Ground 5 0 CAUTION When making a connection between a computer and the UPS RS 232 port always use the green cable supplied with the UPS CAUTION There are communications options that WILL DISABLE the RS 232 port and render it inoperable The options are as follows a Internal SNMP HTTP agent option installed into the UPS communications option slot The following options WILL NOT affect the operation of the RS 232 port a Falcon Opto Coupler based signal interface board installed to the communications o2. FALCON OWNER S OPERATING MANUAL Hardwire Uninterruptible Power Supply Models SG2K 1T HW SG2K 2T HW SG3K 1T HW SG3K 2T HW Detailed SG Series product specifications are available in PDF format at www falconups com FALCON Electric Inc 5106 Azusa Canyon Irwindale California 91706 626 962 7770 Fax 626 962 7720 Email sales falconups com 2006 Falcon Electric Inc All rights reserved All other brand names and trademarks are the property of their respective owners The information stated in this document is subject to change without notice 2006 04 05 Falcon Falcon Electric and UPS Plus logos are registered trademarks of Falcon Electric Inc Rev NR TABLE OF CONTENTS SG UPS Features SG Series Online UPS Block Diagram Important Safety Instructions READ FIRST Chapter 1 SG Series UPS Overview True Regenerative Online Design Input Power Factor Correction Microprocessor Control SNMP HTTP Remote Management Dip Switch Settings Dlagrams Chapter 2 Installation Instructions UPS Input and Output Requirements UPS Output Requirements UPS Startup Extended Battery Bank Interconnection Extended Battery Bank Installation Procedure Extended Battery Bank Selection Guide Chapter 3 Operation Front Panel Indicators amp Function Key Diagram Front Panel Function Description Audible Alarms Category One Alarms Category Two Alarms Chapter 4 Rear Panel Details SG2K 1T HW amp SG3K 1T H
3. TX amp TXC models only 208Vac lli5Va 00 Up Down 230Vac 3125Vac GREEN MODE SWITCH SETTINGS FOR ALL MODELS FUNCTION GREEN MODE ON GREEN MODE OFF CHAPTER 2 Installation Instructions For Hardwire Models 1 0 UPS Input amp Output Requirements Note All SG Series hardwire UPS models must be installed by a licensed electrician in accordance with the National Electrical Code NEC ANSI NFPA70 and all local regulations It is further required that the input of SG Series hardwire UPS be wired to a building service panel incorporating a dedicated branch rated circuit breaker of the proper rating MODEL REQUIRED BRANCH RATED CIRCUIT BREAKER SG2K 1T HW 120Vac 50 60Hz 14 2A 1 phase 2 wire plus ground 20A SG2K 2T HW 208 240Vac 50 60Hz 7 4A 1 phase 2 wire plus ground 15A SG3K 1T HW 120Vac 50 60Hz 21 4A 1 phase 2 wire plus ground 30A SG3K 2T HW 208 240Vac 50 60Hz 11 2A 1 phase 2 wire plus ground 20A WIRE GAUGE CHART MODEL AC INPUT AC OUTPUT S Mcd 1 120 Vac 120 Vac 208 240 Vac 2 208 240 Vac 75 C CU T9 C CU 786 CU 5 C CU 75 CU CU 75 C CU Yee mecs 75 C CU 5 C CU ONLY USE WIRE WITH SOLID COPPER CONDUCTORS FOR ALL INPUT OUTPUT BATTERY WIRING SCREW TORQUE SPECIFICATIONS FOR INPUT OUTPUT WIRING BLOCK UPS Wire Gauge Torque inch pounds 18 10 Awg 8 6 Awg 25 30 CAUTION To reduce th
4. 20 screws as specified Refer to Pages 9 10 for the terminal wiring designations for your specific SG UPS model 2 0 UPS STARTUP Verify the following is included in the UPS shipping carton 1 UPS 1 Software Diskette s amp Manual 1 Owners Manual amp 1 UPS Computer Cable Verify the UPS unit is configured for the proper input output voltage and frequency This information is stated on the nameplate label located on the rear or the side panel of the unit If any special input plug and output receptacle configurations were specified at the time of order verify for proper configuration Note If you have requested the UPS input and output voltage be factory configured disregard the following switch setting instructions Set the Dip switches located on the UPS rear panel for the nominal UPS output voltage desired See the dip switch setting tables located on page 6 In most cases the nominal UPS output voltage should be set to match the incoming utility voltage This will assure a close matching voltage in the event the UPS is placed on bypass NOTE Disregard the ON marking on the side of the actual dip switch housing use the tables in this manual or the silkscreen on the UPS rear panel only Dip switch 3 enables or disables the Green Mode function The UPS is shipped from the factory with the switch set in the disabled position up If SW3 is switched down or to the enabled position the Green Mode function
5. life support and other designated critical devices ANY SUCH USE BY A USER AUTOMATICALLY VOIDS AND DISCLAIMS ANY AND ALL WARRANTIES INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND EXPRESS WARRANTIES THAT THIS PRODUCT WILL CONFORM TO ANY AFFIRMATION OR PROMISE FOR THIS PRODUCT AND THE USER AGREES THAT IN NO EVENT SHALL FALCON ELECTRIC INC BE LIABLE FOR CONSEQUENTIAL OR INDIRECT DAMAGES LIMITS OF LIABILITY LIMITATION OF LIABILITY THERE IS NO LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL LOSS OR DAMAGE UNDER THESE WARRANTIES INCLUDING BUT NOT LIMITED TO LIABILITY FOR INJURY LOSS OF LIFE PROPERTY DAMAGE LOSS OF USE LOSS OF DATA LOSS OF TIME INCONVENIENCE OR COMMERCIAL LOSS OR BREACH OF IMPLIED OR EXPRESSED WARRANTIES ANY AND ALL SUCH LIABILITY IS EXPRESSLY EXCLUDED IN NO EVENT SHALL FALCON ELECTRIC BE RESPONSIBLE FOR ANY AMOUNT EXCEEDING THE ACTUAL MARKET VALUE OF THE PRODUCT Some states do not permit the exclusions of limitations of incidental or consequential damages so these limitations may not apply to you TRANSFER This Falcon Electric Limited New Product Warranty is not transferable in the event of the product ownership being transferred during the warranty coverage period ITEM COVERAGE Effective January 1 2000 FALCON ELECTRIC hereby warrants product shipped under this Agreement to be free from defective workman ship for a period of two years following date of shipme
6. numbers and date of purchase on hand prior to your call This information is located on the identification label on the rear panel of the unit This information is essential in retrieving your unit s historical records Should our service department determine service is required you will be given a Return Material Authorization number along with return shipping instructions The RMA number issued must appear on the outside of the shipping carton The original shipping container must be used when returning any SG series product Falcon Electric will not assume any responsibility for shipping damage In the event of shipping damage you will be notified of the damage and be instructed to file a claim with the freight carrier You will be billed for all repairs caused by the shipping damage You must submit a copy of our repair invoice to the carrier for reimbersment All units must be returned prepaid The address and shipping instructions will be given to you at the time the RMA is issued 7 Requesting Technical Information or Support You may request technical information or support by email or telephone Please send your technical or support questions by email to SUPPORT FALCONUPS COM You may contact a FALCON support engineer directly by calling the FALCON support line between 9 00 am and 4 00 pm PST 800 842 6940 8 FALCON Web Support Product data sheets specification and owner s manuals are available in Adobe Acrobat PDF
7. plugs output receptacles or any other part 6 BROKEN OR TAMPERED WARRANTY SEALS Falcon Electric will deem all warranties null and void in the event warranty seals are broken or show signs of removal or tampering 7 CONSEQUENTIAL DAMAGES This Limited New Product Warranty does not cover any consequential or secondary damages that may be suffered as a result of usage of the product or the need to repair or replace a warranted part except to the extent coverage of such damage is required by the state whose law governs the Falcon Electric Limited New Product Warranty 8 REPAIRS BY UNAUTHORIZED SERVICE ORGANIZATIONS OR PERSONNEL Otherwise covered repairs when the prescribed repair is not performed by the Falcon Electric Service Center or by a Falcon Electric authorized third party service organization 9 LIABILITY FROM USE OF THE PRODUCT Liability for damage to property or injury or death of any person arising out of the operation maintenance or use of the product 10 Warranty void if the battery is allowed to discharge below the minimum battery cutoff point To prevent such discharge remove the battery fuse or switch the battery disconnect to the off position when the unit is to be stored without the AC power being supplied to the UPS for more than two days The battery must be recharged every three to four months when not in use 11 This product is not recommended and Falcon Electric Inc will not knowingly sell this product for use with
8. signal DB 9F PIN amp JUMPER ASSIGNMENTS DESCRIPTION J1 1 2 short N O J1 2 3 short N C JP2 open common for low battery only Utility Loss At loss of utility voltage contact activates Utility Loss N C At loss of utility voltage contact activates JP1 shorted Utility Loss common amp all other shorted JP commons JP1 open Utility Loss common only 6 Remote Shutdown common O Remote Shutdown J2 1 2 short outside power J2 2 3 short inside power 1 2 shorted Applying an external 12V signal across the DB 9 pins six and seven while the UPS is on battery will turn the UPS off 2 3 shorted Applying a short directly across the DB 9 pins six and seven while the UPS is on battery will turn the UPS off On Bypass or Alarm Upon the UPS going to bypass or a UPS failure the contact activates J3 1 2 short N O J3 2 3 short N C M JP3 shorted On bypass Alarm common amp all other shorted JP 0 N oA N 5 commons JP3 open On bypass Alarm common only 17 Typical Falcon Opto coupler Interface Card PIN ASSIGNMENT FOR THE FALCON UA88373 OPTO COUPLER OPTION BOARD no bypass signal Remote Shutdown Applying a 5 12Vdc voltage level for gt 500ms while the UPS is on battery will shutdown the UPS Not Used Not Used Not Used Utility Loss Alarm Signal Low Battery Signal VEN 18 APC Style Dry Contact Relay Board PIN amp JUMPER
9. ASSIGNMENT FOR THE FALCON UA88377 RELAY OPTION BOARD APC Style Board PIN 19 CHAPTER 6 Maintenance amp Technical Support 1 Care amp Maintenance Falcon SG Series UPSs are designed to be maintenance free They can be cleaned with a damp cloth or non abrasive cleanser providing the UPS is turned off and the input plug is disconnected from the utility source On a regular basis check the vents to make sure they are kept free from accumulation of dust dirt or lint 2 Battery Life vs Temperature For full battery life keep the UPS close to an ambient temperature of 77 F The batteries should never be exposed to temperatures below 40 F and above 104 F 3 Battery Replacement This UPS contains sealed maintenance free batteries VRLA When situated in a typical office environment with the proper charging and limited cycling the batteries can last many years In home office or computer room environments the batteries should be replaced every three to five years Should you require battery replacement contact the Falcon Service Department see page 20 for contact information WARNING Never attempt to service batteries High voltage exists within the unit which could cause electrical shock Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries When replacing the UPS batteries use the same numb
10. FOR FURTHER INSTALLATION INSTRUCTIONS 10 NDD 0200 SG 2 3kVA TOWER EXTENDED BATTERY BANK SELECTION GUIDE FOR 2KVA HW MODELS BATTERY OPTION MODELS SGB2S7 2K3 SGB2S7 2K3 SGB5S7 2K6 SGB2S7 2K3 SGB5S7 2K6 SGB5S7 2K6 W O Charger BATTERIES 12 Pieces of 12V 24 Pieces of 12V 30 Pieces of 12V 36 Pieces of 12V 60 Pieces of 12V 90 Pieces of 12V 6 each of 12V of CASES 1 Mini Tower 2 Mini Towers 1 Floor Standing 3 Mini Towers 2 Floor Standing 3 Floor Standing Inches 13 8x 7 6 x 18 9 13 8 x 7 6 x 18 9 32 1 x 10 2 x 21 8 13 8 x 7 6 x 18 9 32 1 x 10 2 21 8 32 1 x 10 2 x 21 8 mm 350 x 193 x 480 350 x 193 x 480 814 x 193 x 554 350 x 193 x 480 814 x 193 x 554 814 x 193 x 554 RUN TIME 300W 170 Min 310 Min 390 Min 470 Min 760 Min 1200 Min RUN TIME 500W 180 Min 225 Min 260 Min 465 Min 690 Min RUN TIME 1000W 100 Min 120 Min 215 Min 330 Min RUN TIME 1400W 140 Min 225 Min RUN TIME 700W 120 Min 155 Min 185 Min 320 Min 490 Min CHARGER OPTION INFORMATION BATTERY OPTION MODELS SGB2S7 2K3 1 SGB2S7 2K3 1 SGB5S7 2K6 1 SGB2S7 2K3 1 SGB5S7 2K6 1 SGB5S7 2K6 1 With 120Vac Charger BATTERY OPTION MODELS Pra ram SGB2S7 2K3 2 SGB2S7 2K3 2 SGB5S7 2K6 2 SGB2S7 2K3 2 SGB5S7 2K6 2 5 557 2 6 2 Charger CHARGER OUTPUT 82 5Vdc 4A 82 5Vdc 4A 82 5Vdc 4A 82 5Vdc 4A 82 5Vdc 4A 82 5Vdc 4A OF CHARGERS FOR 3KVA HW MODELS BATTE
11. L6 20R HW Models Hardwire Hardwire Not Available Contact the factory for other input output options Environmental Altitude 7 000 Feet Controls and Indicators Line Inverter Battery Reserve Load Bypass Alarm Crest Battery amp Load Capacity Level Audible Alarms DC Mode Low Battery Over Under Voltage Over Under Frequency High Temp Over Load Fault Alarm RS 232 Serial Port Bundled UPSilon 2000 Software Mechanical Dimensions H x W xD inch es mm 13 8 x 7 6 x 18 9 350 x 193 x 480 13 8 x 7 6 x 30 0 350 x 193 x 720 Weight Ib 68 4 31 81 4 37 150 0 68 Agency Listing 1T Models UL 1778 CUL FCC Class A HW Models UL 1778 amp CUL pending 2T Models except HW models UL 1778 CUL CE available with Schuko plug only Available Options Option A 60 Hz to 50 Hz Frequency Conversion External Battery Packs Extended Run Time Battery Packs minutes to hours Fast Battery Charger Fast Charger internal to the Extended Battery Pack Cabin et Required for battery times 2 hours or more 24
12. LY In the event this UPS is to be turned off or stored for more than two weeks the battery circuit breaker must be turned to the off position to prevent battery discharge If placed in long term storage every four months the UPS must be plugged in and turned on for 24 hours to allow the batteries to recharge and prevent battery damage Failure to follow these procedures will invalidate your warranty Select a suitable location for the UPS VERIFY THE FLOOR OR SURFACE SUPPORTING THE UPS WILL SUPPORT THE WEIGHT OF THE UPS AND ANY OPTIONAL EXTENDED BATTERY BANKS SG2K 2T HW amp SG2K 2T HW UPS MODELS 68 4 Ibs 31 kg SG3K 2T HW amp SG3K 2 HW UPS MODELS 81 4 Ibs 37 kg If unattended computer shutdown and monitoring are desired connect the green UPS Computer cable to the DB 9 connector located on the UPS rear panel Then install the shutdown and monitoring software provided with the UPS For your reference UNIX shutdown and monitoring software is available from Falcon Electric at an additional cost Verify the location selected has adequate ventilation to allow for the proper cooling of the UPS DO NOT BLOCK UPS FANS OR AIR VENTS THE UPS MUST NOT BE INSTALLED IN AN ENCLOSED AREA VIEW OF OUTPUT VOLTAGE amp GREEN MODE SELECT SWITCHES LOCATED ON THE UPS REAR PANEL DIP SWITCHES EHE E20 STABLE Histon SDS 3 GREEN MODE DISABLE t SWITCH SETTINGS FOR ALL MODELS PU mola CITC modets oni E models
13. ND FUNCTION KEYS LOAD LEVEL INDICATOR LEDS first or bottom LED is lit when the output load is greater than 25 of the rated output of the UPS The second LED is lit when the output load is greater than 50 of the rated output of the UPS third LED is lit when the output load is greater than 75 of the rated output of the UPS BATTERY LEVEL INDICATOR LEDS The third or top LED is lit when the battery is fully charged The Second LED is let when the battery level is above the low battery warning Level The first LED is lit when the battery level is above the battery cutoff voltage LINE SITE WIRING FAULT INDICATOR LED For models configured for standard 120 volt domestic usage this LED is lit to a steady on state when Utility voltage is present However should the LED flash on and off it is an indication that the HOT and NEUTRAL wires are reversed some where in the building wiring Typically at the wall outlet It is normal for this LED to flash with 208 and 240 volt domestic models as these voltages are normally LINE to LINE without a neutral BATTERY MODE INDICATOR LED This LED is lit when the unit is operating from battery 12 10 BYPASS INDICATOR LED When this LED is lit the UPS bypass is active Should the Alarm LED be lit at the same time the UPS detected an internal failure and the UPS must be serviced INVERTER INDICATOR LED When this LED is lit the UPS inverter is
14. PS battery connector Connect the other end of the cable to the top battery connector on the first battery bank See illustration above 4 lf a second battery bank is to be connected connect one end of the second battery interconnect cable to the bottom battery connector on the first battery bank and connect the other end of the cable to the top battery connector of the second battery bank See illustration above Follow the instructions in the proceeding step for additional battery banks Reinstall the battery fuse For all battery banks that have the battery charger option installed from the factory perform the following a Verify the battery charger circuit breaker is in the off down position D On the battery bank nameplate label located on the rear panel verify the battery charger input voltage matches your utility source 120Vac or 230Vac Connect the input line cord s to the battery bank s power inlet Plug the other end of the power cord into a utility receptacle Turn on the battery charger circuit breaker s up The batteries in the external battery banks are now being charged NOTE Internal battery bank chargers do not charge the UPS batteries NOTE When the battery banks and UPS need to be shutdown for more than two weeks turn off the battery charger circuit breaker disconnect the interconnecting cables and remove the battery fuse from the UPS battery or damage may occur 8 RETURN TO PAGE 5 Paragraph 8
15. RY OPTION MODELS SGB2S7 3K3 SGB2S7 3K3 SGB5S7 3K6 SGB2S7 3K3 SGB5S7 3K6 SGB5S7 3K6 W O Charger BATTERIES 16 Pieces 12V 7AH 32 Pieces 12V 7AH 40 Pieces 12V 7AH 48 Pieces 12V 7AH 80 Pieces 12V 7AH 160 Pieces 12V 7AH BATTERIES IN UPS 8 each of 12V 7AH of CASES 1 Mini Tower 2 mini Towers 1 Floor Standing 3 Mini Towers 2 Floor Standing 4 Floor Standing HxWxD 13 8 x 7 6 x 18 9 13 8 x 7 6 x 18 9 32 1 x 10 2 x 21 8 13 8 x 7 6 x 18 9 32 1 x 10 2 x 21 8 32 1 x 10 2 x 21 8 Inches 350 x 193 x 480 350 x 193 x 480 814 x 259 x 554 350 x 193 x 480 814 x 259 x 554 814 x 259 x 554 mm RUN TIME 500W 135 Min 260 Min 310 Min 380 Min 640 Min 1350 Min RUN TIME 1000W 115 Min 140 Min 170 Min 300 Min 620 Min RUN TIME 2100W 20 5 Min 125 Min 270 Min CHARGER OPTION INFORMATION BATTERY OPTION MODELS SGB2S7 3K3 1 SGB2S7 3K3 1 SGB5S7 3K6 1 SGB2S7 3K3 1 SGB5S7 3K6 1 SGB5S7 3K6 1 With 120Vac Charger BATTERY OPTION MODELS With 208 240Vac Charger CHARGER OUTPUT 110Vdc 4 5A 110Vdc 4 5A 110Vdc 4 5A 110Vdc 4 5A 110Vdc 4 5A 110Vdc 4 5A OF CHARGERS 1 1 1 jf 1 2 4 SGB2S7 3K3 2 SGB2S7 3K3 2 SGB557 3K62 SGB257 3K3 2 SGB587 3K6 2 SGB5S7 3K6 2 RUN TIME 1500W 105 Min 190 Min 400 Min NOTE The backup times stated are for reference only Backup time may vary due to the type of load battery age or condition environmental conditions etc 11 CHAPTER 3 OPERATION gt UPS FRONT PANEL INDICATOR A
16. W Rear Panel SG2K 2T HW amp SG3K 2T HW Rear Panel Chapter 5 Communications Interfaces RS 232 Interface DB 9 Communications Option Slot Contact Closure amp Opto Interface Options Chapter 6 Maintenance amp Technical Support Care amp Maintenance Battery Life vs Temperature Battery Replacement Storing the UPS and Batteries FCC Considerations Technical Support amp RMA Procedure Requesting Technical Information or Support FALCON Web Support Warranty Specifications O1 C C C9 C9 SG SERIES UPS FEATURES Hardwire Input and Output Conneciton True Double Conversion On Line Design Input Power Factor Correction Wide Input Voltage Window Pure Sinewave Output Precision Output Voltage Regulation Superior Brownout Surge and Transient Protection Internal System Bypass Eliminates Generator Frequency amp Voltage Drift Microprocessor Control amp RS 232 Communications UPSILON Monitoring amp Shutdown Software Optional Frequency Conversion Optional Extended Battery Packs amp Chargers Optional External Maintenance Bypass Switch Optional Internal SNMP HTTP Interface Card Two Year Warranty SG SERIES ON LINE UPS SYSTEM BLOCK DIAGRAM Oe IHWEHTEH i FILTER m SANTE H Dc Duc Gc WvEHTEIR IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions which must be followed during the ins
17. batteries During this initial 24 hour charging period battery backup time may be substantially reduced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amp UPS INTERCONNECTION Mini tower models shown same applies for floor standing banks TYPICAL mm 1ST CABLE BATTERY ees aa 9 CONNECTOR oc nt PASS ES TO ADD MORE BANKS 3 DAISY CHAIN TO NEXT 7 a BANK FROM THIS o 2ND CABLE UPS BATTERY FUSE e o 24 OPTIONAL BATTERY OPTIONAL BATTERY CHARGER CIRCUIT 4 CHARGER CIRCUIT BREAKER 7 BREAKER a POWER INLET FOR POWER INLET FOR OPTIONAL CHARGER sl OPTIONAL CHARGER 128 2ND BATTERY BANK 1ST BATTERY BANK INSTALLATION PROCEDURE FOR EXTENDED BATTERY BANKS k Remove the battery fuse located on the UPS rear panel See illustration above 2 Locate the battery interconnect cable s 3 Connect one end of the battery interconnect cable to the the U
18. ctification from the UPS for example electric drills vacuum cleaners or hair dryers Never connect surge protected plug strips to the UPS output CAUTION DO NOT remove or unplug the input cord when the UPS is turned on This removes the safety ground from the UPS and the equipment connected to the UPS CAUTION This UPS contains its own energy source batteries The output receptacles may carry live voltage even when the UPS is not connected to an AC source IMPORTANT Should any SG Series UPS units be stored for more than two weeks it is mandatory that the battery fuse be removed prior to storage or battery damage will result CHAPTER 1 SG Series UPS Overview General Common for all models 1 Verify the following is included in the UPS shipping carton 1 UPS 1 Software Diskette s amp Manual 1 Owners Manual amp 1 UPS Computer Cable Verify the UPS unit is configured for the proper input output voltage and frequency This information is stated on the nameplate label located on the rear or the side panel of the unit If any special input plug and output receptacle configurations were specified at the time of order verify for proper configuration Set the output voltage and green mode switches located on the UPS rear panel for the nominal UPS output voltage desired See the switch setting tables located on page 5 In most cases the nominal UPS output voltage should be set to match the incoming util
19. e risk of fire connect only to a circuit providing over current protection incorporating the specified branch rated over current protection device in accordance with the National Electrical Code ANSI NFPA 70 6 11 UPS Output Requirements Note The outputs of the SG2K 2T HW amp SG3K 2T HW hardwire models are not configured for 240 120Vac split phase operation Should a 240 120Vac split phase output configuration be required please contact the factory MODEL RECOMMENDED BRANCH RATED OUTPUT CIRCUIT BREAKER SG2K 1T HW Output 1 100 110 115 or 120Vac selectable 1 phase 2 wire plus ground 20A SG2K 2T HW Output 1 200 220 230 or 240Vac selectable 1 phase 2 wire plus ground 15A SG3K 1T HW Output 1 100 110 115 or 120Vac selectable 1 phase 2 wire plus ground 30A SG2K 2T HW Output 1 200 220 230 or 240Vac selectable 1 phase 2 wire plus ground 20A Terminal Wiring Designations 1 Utility L1 4 UPS Output L1 2 Utility L2 or Neutral 5 UPS Output L2 or Neutral 3 Input and Output Grounds View of the Input Output Hardwire Terminal Block This terminal block is located on the UPS rear panel and shown with the access cover plates removed Use only the lower terminals and wire securing screws when making wiring connections to the UPS DO NOT USE THE UPPER TERMINAL CONNECTIONS Refer to the Wire Gauge Table on Page 7 for recommended wire sizes Refer to the Torque Specification Table on Page 7 and tighten all
20. er and type of batteries NEVER A NEVER dispose of batteries in a fire as batteries will explode B NEVER dispose of used batteries or the UPS in the trash or landfill as it is against federal and state laws The UPS and Batteries must be recycled For UPS and battery recycling information please contact our service department for the name and address of the nearest battery recycling facility CAUTION A Do not open or mutilate the battery or batteries Released electrolyte is harmful to the skin and eyes It may be toxic B A battery can present a risk of electrical shock and high short circuit current REFER ALL BATTERY SERVICING OR REPLACEMENT TO A QUALIFIED SERVICE TECHNICIAN NEVER ATTEMPT TO REPLACE THE BATTERIES YOURSELF The following precautions should be observed by a qualified technician when working with batteries 1 Remove watches rings or other metal objects 2 Use tools with insulated handles 3 Wear rubber gloves and boots 4 Do not lay tools or metal parts on top of batteries Storing the UPS and Batteries Should you need to store the UPS for a long period fully recharge the battery just prior to storage and recharge the battery every 4 months by plugging the UPS into a power outlet It is recommended that the batteries charge for 24 hours after long term storage FCC Considerations Note This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to
21. format on our corporate website WWW FALCONUPS COM 22 LIMITED NEW PRODUCT WARRANTY AGREEMENT GENERAL PROVISIONS FALCON ELECTRIC INC hereby warrants product shipped under this agreement to be free from defective workmanship for a period of two years following date of shipment This Limited New Product Warranty Agreement only applies to covered repairs to the product occurring within the United States and Canada EXCLUSIONS The following are not covered by the Falcon Electric Limited New Product Warranty 1 DAMAGE DUE TO ACCIDENTS FRAUD INTENTIONAL NEGLIGENCE MISUSE IMPROPER INSTALLATION UNAUTHORIZED ADJUSTMENTS MODIFICATIONS ALTERATIONS DISCONNECTION TAMPERING Accidents or acts of nature or other events beyond the control of Falcon Electric damage from impact contaminant fire or water misuse of the product such as sustained overloading improper installation or operation operation in an uncontrolled environment 2 DAMAGE DUE TO IMPROPER INSTALLATION OR LACK OF MAINTENANCE Lack of proper maintenance as outlined the owner s manual 9 NORMAL MAINTENANCE Cleaning replacement of leaking or outdated batteries 4 DAMAGE DUE TO ALTERATIONS Alterations by changing or adding to the product by any unauthorized personnel or service organization 5 DAMAGE CAUSED BY OTHER THAN ORIGINAL EQUIPMENT PARTS Any malfunctions caused by the use of other than Falcon Electric original equipment parts such as batteries line cords and
22. is activated When the load connected to the output of the UPS drops to under 10 of the full rated UPS output for 30 seconds the UPS is automatically placed into bypass and the inverter is turned off NO BATTERY BACKUP IS PROVIDED AFTER THE GREEN MODE HAS ACTIVATED Dip switch settings must be made while the UPS is turned off Any changes made while the UPS is turned on will not take effect until the UPS is turn off and back on again since the switch settings are read by the microprocessor only during initial UPS power up To prevent accelerated battery discharge during shipment the UPS has been shipped with the battery fuse removed DEPRESS THE PRECHARGE BUTTON FOR ONE SECOND AND IMMEDIATELY INSTALL THE BATTERY FUSE PRIOR TO TURNING ON THE UPS INPUT CIRCUIT BREAKER OR PLUGGING IN THE UPS CAUTION NEVER REMOVE THE BATTERY FUSE WHILE THE UPS AC CIRCUIT BREAKER IS TURNED ON AND OPERATING FROM THE UTILITY VOLTAGE OR UPS DAMAGE MAY RESULT UPS SHOULD BE COMPLETELY SHUT DOWN PRIOR TO DISABLING THE INTERNAL BATTERY SUPPLY CAUTION In the event this UPS is to be turned off or stored for more than two weeks the battery fuse should be removed to prevent excessive battery discharge If placed in long term storage every four months the UPS must be plugged in and turned on for 24 hours to allow the batteries to recharge and prevent battery damage Failure to follow these procedures may invalidate your warranty 8 10 11 Select a sui
23. ity voltage This will assure a close matching voltage in the event the UPS is placed on bypass NOTE Disregard the ON marking on the side of the actual dip switch housing use the tables in this manual or the silkscreen on the UPS rear panel only Dip switch 3 enables or disables the Green Mode function The UPS is shipped from the factory with the switch set in the disabled position up If SW3 is switched down or to the enabled position the Green Mode function is activated When the load connected to the output of the UPS drops to under 10 of the full rated UPS output for 30 seconds the UPS is automatically placed into bypass and the inverter is turned off NO BATTERY BACKUP IS PROVIDED AFTER THE GREEN MODE HAS ACTIVATED Dip switch settings must be made while the UPS is turned off Any changes made while the UPS is turned on will not take effect until the UPS is turn off and back on again since the switch settings are read by the microprocessor only during initial UPS power up To prevent accelerated battery discharge during shipment this UPS was shipped with the battery circuit breaker turned off TURN THE BATTERY DISCONNECT CIRCUIT BREAKER ON PRIOR TO TURNING ON THE UPS INPUT CIRCUIT BREAKER NEVER TURN THE BATTERY CIRCUIT BREAKER OFF WHILE THE UPS AC CIRCUIT BREAKER IS TURNED ON AND OPERATING FROM THE UTILITY VOLTAGE OR UPS DAMAGE MAY RESULT UPS MUST BE COMPLETELY SHUT DOWN PRIOR TO DISABLING THE INTERNAL BATTERY SUPP
24. ne long beep prior to a short beep The SG UPS is in an OVER LOADED OVER CREST CONDITION Remove some load from the UPS output to correct this condition SG UPS IS INOVERLOAD OR OVER CREST d One short beep is sounded when either the ON OFF or TEST buttons are pressed and held This notifies the user the associated actions have been initiated by the UPS WHEN SG UPS FRONT PANEL ON OFF AND TEST BUTTONS ARE DEPRESSED e One short beep is sounded when the SELF TEST button has been pressed and held This notifies the self test has been started WHEN SG UPS FRONT PANEL TEST BUTTON DEPRESSED 2 Category two alarms a Three short beeps indicate the SG UPS output voltage is out of proper operating range SG UPS OUTPUT VOLTAGE IS OUT OF PROPER RANGE b Four short beeps indicate the SG UPS output frequency is out of proper operating range The UPS must be repaired SG UPS OUTPUT FREQUENCY IS OUT OF PROPER RANGE c Five short beeps indicate the SG UPS is in an over temperature condition Check for proper UPS cooling fan operation or blockage SG UPS INTERNAL TEMPERATURE IS TOO HIGH d Should the internal POWER UP SELF TEST fail the SG UPS will sound the following alarms denoting the failure mode continuous rapid beeping for about 5 seconds then the SG UPS shuts down The UPS output voltage is out of range c ee UPS OUTPUT VOLTAGE IS OF RANGE contin
25. ner unit providing the end user agrees to pay for all shipping costs associated with transportation of the loaner unit both from and return to the Falcon Electric U S Service Center C All shipping costs for product submitted beyond 90 days of the original date of invoice is the responsibility of the end user 2006 02 Rev A 23 SG Series UPS PLUS 2 amp Model Number SG2K 1T SG2K 2T SG3K 1T SG3K 2T SG2K 2TX SG3K 2TX SG2K 1T HW SG2K 2T HW SG3K 1T HW SG3K 2T HW SG2K 2TXI SG3K 2TXl Nominal VA 2000 3000 2000 3000 Electrical Input Frequency 50 60 Hz 5 Auto Tracking gt 0 95 gt 86 Electrical Output AC Voltage Switchable Frequency 50 60 Hz Auto Tracking Frequency Stabi lity 0 3 Battery Mode 7 for 100 load variation lt 3 Linear Load lt 5 Non Linear Load 105 load for 50 Seconds 3 1 Battery DC Voltage 1 2 Load 20 Minutes 15 Minutes 20 Minutes 15 Minutes Battery times are approximate Transfer Time Line Fails Recovers Zero UPS to Bypass or Reverse lt 4ms After Overload Auto Transfer to UPS Electrical Connections T Models 6 Cord with 6 Cord with 6 Cord with 6 Cord with 6 Cord with 6 20P L6 20P 5 20P 6 20P L6 20P L5 30P 6 20P L6 20P or Schuko or Schuko or Schuko HW Models Hardwire Hardwire Not Available Output T Models 6 5 15R or 6 IEC 320 6 5 15R or 6 IEC 320 2 5 20R amp 1 L6 20R or 1 L6 20R or 1
26. nt Coverage under this Falcon Electric New Product Warranty Agreement commences with the date of shipment defined as the date on the Bill of Lading If no Bill of Lading is issued the date of shipment shall be shown on seller s shipping document The Falcon Electric Limited New Product Warranties expire one year from the aforementioned commencement date Falcon Electric Inc reserves the right to make changes additions and or other improvements in its products without incurring any obligation to install them on its products previously sold This Warranty is valid for product as sold 1 For product located in the continental United States and Canada deemed by Falcon Electric to be covered under this warranty Falcon Electric will pay shipping costs associated with the return and repair of product under the following conditions only a Falcon Electric will pay shipping costs both to and from our U S Service Center for the first 30 days from the original date of invoice During this 30 day period Falcon Electric may elect to ship a new unit to replace the defective product b After the first 30 days and up to 90 days from the original date of invoice the end user is responsible for shipping costs associated with sending the defective unit to the Falcon Electric U S Service Center Falcon Electric will pay shipping costs associated with returning the repaired product to the end user During this 60 day period Falcon Electric may elect to offer a loa
27. operating and powering the connected load GREEN MODE LED INDICATOR This LED is lit when the connected output load of the UPS drops to under 10 of the full rated output of the UPS providing SW3 is in the down position Green Mode Enabled as shown on page 7 The UPS is automatically set to bypass mode and the inverter is turned off reducing the power requirement NO BATTERY BACKUP IS PROVIDED IN THIS MODE The UPS is shipped from the factory with SW3 in the up or disabled position OVER CREST INDICATOR LED This LED lights when the connected load getting close to the peak current rating of the UPS ALARM INDICATOR LED This LED is lit during the following conditions a The inverter voltage is too high or low b UPS over temperature condition c The battery voltage is too high d The internal DC Bus has an under or over voltage condition e The internal microprocessor or memory failure ON OFF BUTTON The following describes the different modes of operation for this button a Depressing this button when the UPS is off and the utility voltage is not present or with the UPS input circuit breaker in the off position will cause the UPS to DC start and run on internal battery until the ON OFF button is depressed again b Pressing this button while the UPS is on and utility is present will place the UPS into bypass mode c Pressing this button when with the UPS input circuit breaker off or when the utility voltage is not p
28. 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 his own expense If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures a Reorient or relocate the receiving antenna b Increase the separation between the equipment and the receiver c Connect the equipment into an outlet on a circuit different from that to which the receiver is connected d Consult the dealer or an experienced radio television technician for assistance 21 6 Technical Support Should your FALCON Electric SG Series UPS require service or you need technical assistance you can contact us at Falcon Electric Inc 5106 Azusa Canyon Road Irwindale CA 91706 Service 800 842 6940 Voice 626 962 7770 Fax 626 962 7720 Email service falconups com WWW FALCONUPS COM Please have your UPS model serial
29. ption slot b Any Falcon relay based dry contact signal interface board installed into the communications option slot CAUTION DB 9 Signals are not isolated and intended for connection to like RS 232 interfaces DO NOT APPLY ANY OTHER VOLTAGES TO THESE PINS DRY CONTACT amp OPTO COUPLER INTERFACE BOARD OPTIONS Typical Falcon Dry Contact Relay Board DB 9 4 S Imm Cc o B T 5 Ld PIN amp JUMPER ASSIGNMENT FOR THE FALCON UA88374 RELAY OPTION BOARD no on bypass signal Low Battery When UPS reaches low battery contact activates J1 1 2 short N O J1 2 3 short N C JP2 shorted Low Battery common amp all other shorted JP commons JP2 open common for low battery only JP1 shorted Utility Loss common amp all other shorted JP commons JP1 open Utility Loss common only Remote Shutdown J2 1 2 short outside power J2 2 3 short inside power 1 2 shorted Applying an external 12V signal across the DB 9 pins six and seven while the UPS is on battery will turn the UPS off 2 3 shorted Applying a short directly across the DB 9 pins six and seven while the UPS is on battery will turn the UPS off Alarm Upon a UPS fault or failure the contact activates J3 1 2 short N O J3 2 3 short N C JP3 shorted Alarm common amp all other shorted JP commons JP3 open Alarm common only PIN amp JUMPER ASSIGNMENT FOR THE FALCON UA88376 RELAY OPTION BOARD with on bypass
30. resent will turn off the UPS TO TURN UPS ON CONNECT THE UPS TO UTILITY POWER AND TURN ON THE MAIN CIRCUIT BREAKER LOCATED ON THE REAR PANEL DO NOT PRESS THE ON BUTTON LOCATED ON THE FRONT PANEL OR THE UPS WILL BE PLACED INTO BYPASS MODE TO TURN UPS OFF TURN OFF THE MAIN CIRCUIT BREAKER LOCATED ON THE REAR PANEL AND DEPRESS THE ON OFF BUTTON UNTIL THE UPS BEEPS AND WAIT FOR THE UPS TO SHUTDOWN AND TURN OFF ABOUT 30 SECONDS 11 TEST BUTTON The following describes the different modes of operation for this button a Pressing the Test button while in Green Mode will disable Green Mode b Pressing the Test button while utility is present will put the UPS through a self test diagnostic c Pressing the Test button while in battery mode will turn the battery Audible alarm off Depressing it again will turn the Audible alarm back on 13 AUDIBLE ALARMS Audible alarm signals are divided into two different levels of alarm status Category one alarms represent normal or correctable operational alarms Category two alarms are sounded in the event of abnormal operation 1 Category one alarms a Two short beeps followed by three short beeps Notifies the user that the SG UPS is configured with the optional battery pack and is in BATTERY MODE SG UPS IS IN BATTERY MODE b A continuous short beep The SG UPS is operating from battery and is in a LOW BATTERY operation SG UPS IS IN A LOW BATTERY CONDITION c O
31. table location for the UPS near enough to the computer or equipment to to be protected Connect the power cord s for the equipment to be protected to the UPS output receptacles VERIFY THE TABLE OR SURFACE SUPPORTING THE UPS WILL SUPPORT THE WEIGHT OF THE UPS AND ANY OPTIONAL EXTENDED BATTERY BANKS 2KVA 3KVA UPS MODELS 150 0 Ibs 68kg If extended battery banks are to be connected to the UPS please refer to page 8 for further instructions If unattended computer shutdown and monitoring are desired connect the green UPS Computer cable to the DB 9 connector located on the UPS rear panel Then install the shutdown and monitoring software provided with the UPS For your reference UNIX shutdown and monitoring software is available from Falcon Electric at an additional cost Verify the location selected has adequate ventilation to allow for the proper cooling of the UPS DO NOT BLOCK UPS FANS OR AIR VENTS THE UPS MUST NOT BE INSTALLED IN AN ENCLOSED AREA Turn the input circuit breaker located on the UPS rear panel to the on position The internal UPS fan and front panel line indicator should turn on followed by the bypass LED and after several seconds the inverter LED Turn on the connected equipment and verify the UPS does not go into overload by observing the front panel load indicator LEDs The UPS optional external battery bank s and additional chargers should be installed and turned on for 24 hours to charge the
32. tallation operation and maintenance of this UPS and its batteries Please read all instructions before operating this equipment and save this manual for future reference CAUTION All of the models presented herein are designed for installation and use in a protected temperature controlled environment free of contamination CAUTION This UPS utilizes voltage that may be hazardous Do not attempt to disassemble This unit contains no user replaceable parts Refer all servicing to Falcon Electric Inc CAUTION THIS UPS IS NOT INTENDED TO BE USED IN CONJUNCTION WITH LIFE SUPPORT OR OPERATING ROOM EQUIPMENT CAUTION Always unplug this UPS and remove the UPS battery fuse prior to cleaning and never apply liquid or spray detergent on the UPS CAUTION Never attempt to service batteries High voltage exists within the unit which could cause electrical shock Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries When replacing the UPS batteries use the same number and type of batteries IMPORTANT Allow at least 24 hours after the UPS is first installed and turned on to fully charge the internal battery and assure the maximum backup time is available DO NOT DO NOT plug this UPS into its own output as this may damage the UPS NEVER CONNECT equipment that could overload the UPS or demand half wave re
33. uous rapid beeping for about 2 seconds and the SG UPS shuts down The SG UPS performed a DC start but there is no output frequency set in the UPS memory Plug the UPS into your local utility power and turn the UPS on to set it for your local utility power frequency The SG UPS performed DC start but there is no output frequency set in memory Connect the UPS to your local utility power and turn on the UPS Your local utility frequency is now set into the UPS memory The next time the UPS is DC Started its output frequency will be set automatically 14 SG2K 1T HW amp SG3K 1T HW Typical Rear Panel Overview Dip Switches Battery fuse as received in bag At the time of initial installation remove the bag from the unit and install the battery fuse e in Battery Fuse Holder Prior to installing the battery fuse depress this button of one second to m PASS semir 21 pre charge the UPS and immediately install the battery fuse Cooling Fans DO NOT BLOCK AIR FLOW Hardwire Terminal Block E E X 9 Secondary Input Circuit 5 79 Breaker 1 45 EJT e Di F CIRCUIT BREAKER e e o SG2K 2T HW amp SG3K 2T HW Typical Rear Panel Overview Dip Switches Battery fuse as received in bag At the time of initial installation remove the bag from the unit and install the battery fuse e in
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