Installation/Operation Manual
Contents
1. 3KVA KVA 208 240 VAC OUTPUT CONFIGURATION 3 208 VAC INPUT OUTPUT G N L L1 H L2 N L3 H N G 208 a 208 240 VAC OUTPUT CONFIGURATION 4 120 208 VAC INPUT OUTPUT G N L LIH LAN L34H N G zs 120 La 208 i 208 240 VAC OUTPUT CONFIGURATION 5 240 INPUT OUTPUT G N L L1 H L2 N L3 H N G 240 208 240 VAC CONFIGURATION 6 120 240 VAC INPUT OUTPUT 420 VAC 120 B 5 208 240 OUTPUT CONFIGURATION 7 208 220 230 240 ee eee errr errr errr iter errr eer 208 220 230 240 VAC Output configurations 1 2 3 4 5 and 6 are only available on units with an isolation transformer 4 Output configuration 7 is only used on units without an isolation transformer When using the isolation transformer ensure that the load is balanced When using 6 AWG wire 2 in are required for wire bending space opposite the terminals 1 1 2 in for 8 AWG 3 for 3 AWG and 4 AWG 3 1 2 in for 2 AWG For 6KVA output configuration 1 use 6 AWG 75 C copper wire For configurations 2 3 4 5 6 and 7 use 6 AW2. OnStar I1 560603 5 0604 5 1003 5 1004 lac 10100 Royalton Cleveland 44133 USA Voice 440 237 3200 e Fax 440 237 1744 Internet http instserv com User s Manual TABLE OF CONTENTS 1 INTRODUCTION 1 UN D 1 olx S E 1 1 ko S ae a oe DOE RE Dus 2 Electrical 2 Operating environmen PME TE cotes es 2 Mechanical aeu t due Mise 2 APA OWE MS And GISDIAY AMT 3 cp 4 1 6 COMMUNICATION 5 oun so ile 6 mera E 6 2 INSTALLATION AND OPERATION nnne 7 2 3 cue bett bibs 7 22 SEO HOT _____ _ __ ____ __ 7 VINO esea _________ ______ 8 10 3e TROUBLESHOOTING nt mn 11 APPLICATION NOTES n 1 1 START UP Qe ES 1 2 QUTPUT VOLTAGE SETIING US a 2 3 DI
3. be rotating and the control panel should show the display as below Fig 1 1 1 Bypass Mode Load LED display depends of load level 2 Then press the button After 10 seconds the control panel will become what is shown in Fig 1 2 1 3 Turn on the output breaker located on the rear panel to provide power to the load Fig 1 2 1 Inverter Mode 4 The UPS should be successfully started 5 f the UPS is in normal operation the user can run a battery mode test by pushing the button The four LED s on the lower half of the control panel i e line bypass battery inverter will flash 6 To turn off the UPS push the OFF button then turn off the line breaker 2 OUTPUT VOLTAGE SETTING Four voltage options are available 208V 220V 230V 240V Users can set the desired voltage through DIP SWITCHES located on the rear panel The output voltage can be switched according to the instructions below 1 Press the OFF button to turn off the UPS 2 Switch the output breaker to the OFF position 3 Turn off Input breaker 4 Wait until the fans stop turning then switch the DIP SWITCHES to the desired voltage position Table 2 1 also printed under DIP SWITCHES shows these four positions and their corresponding voltage levels 5 After setting the switches turn on the Input breaker press the button and then turn on the output breaker NOTE On units with an isolation transformer the secondary voltage will be 1 2
4. AR grt 561003 48 1 45 5 43 5 41 7 7KW VAC 208 220 230 240V 83 3 41 7 41 7 48 10KVA 50 60 170 276 120 120 120 208 561004 41 7 48 41 7 41 7 41 7A 7KW Hz VAC 120 208 240 120 240V INPUT Voltage As listed Phase Single phase with ground Frequency 50 60Hz 5 auto selection Power factor gt 0 97 OUTPUT Output voltage regulation 3 Power factor 0 7 lag to unity Frequency regulation 5 phase lock to input under normal conditions 0 5 of nominal frequency under normal operation or battery mode Distortion 3 0 THD at full linear load 7 THD at full non linear load Overload Capacity gt 130 10 for 200 ms 105 for 10 second Load Crest Ratio 3 1 maximum OPERATING ENVIRONMENT Ambient temperature 10 to 40 degrees Centigrade Operation humidity 2096 to 9096 non condensing Altitude less than 1500M above sea level Storage temperature 15 to 40 C MODEL MEASUREMENTS WEIGHT SG0603 in 200 6 215 5 lb 31 5 10 25 23 25 500604 296 311 6 6 SG1003 38x13 5x26 5in 396 8 429 4 lb SG1004 38x13 5x26 5in 519 6 552 2 lb Fault LED r Main Switch Of Main Switch On and Alarm Silence Load Level and Battery Capacity Level LED Bypass LED Battery LED 1 560603 560604 CONTROL PANNEL Com
5. G 75 C copper wire For 10KVA output voltage configuration 1 use 2 AWG 115 C copper wire For configurations 2 3 4 5 6 and 7 use 6 AWG 75 C copper wire Tightening torque for pressure wire connectors having screws Slot width over 0 047 in 1 2mm dri Split boit connectors Maximum current Maximum size of Minimum size of Maximum size of rating amperes grounding or groune ag electrode Spes grounding or duct 1 duct 3 TROUBLESHOOTING The TROUBLESHOOTING CHART covers most of the difficulties you may encounter under normal working conditions TROUBLESHOOTING CHART FAULT LED lights alarm UPS failure Call for service beeps continuously Backup time is less than Battery is not fully Hecharge battery for at the rating charged least 6 hours retest the dead battery backup time If problem charger failure remains call for service Buzzer beeps twice per Overloaded Remove the least critical second load OBTAINING SERVICE If the UPS requires service 1 Use the TROUBLESHOOTING CHART to eliminate obvious causes 2 Verify that no circuit breakers are tripped A tripped circuit breaker is the most common problem 3 Call or FAX ISE Inc Technical Support at the following numbers Voice phone 440 237 3200 FAX line 440 237 1744 e mail mailto support instserv com Please have the following information available BEFORE cal
6. PS away from heat emitting sources direct sunshine rain or erosive gas 4 not place any objects on the top of the UPS The function of an alarm silence is available Users can silence the alarm by pressing the ON button Press it again will re activate the alarm except when the battery is in low battery mode 4 Press the button and hold it for more than 0 5 second to ensure safe operation 2 3 WIRING DESCRIPTION The wiring method is described in the following figure NFB Kr cd L e m Processor p Unit c Panel Power Processor Cabinet REAR VIEW Wiring Instructions 1 Utility panel circuit breaker required is 30A or larger 2 Utility wire gauge must be 8 gauge or larger 3 Connect utility per drawing 4 Connect output load connections and jumper wires for correct voltages per drawings not used on units without an isolation transformer SG0603 and 561003 5 Use proper size AWG wires for all connections NOTE STACO ENERGY PRODUCTS DOES CO NOT PROVIDE AC OUTPUT OVERCURRENT PROTECTION OUTPUT OVERCURRENT PROTECTION IS TO BE PROVIDED BY THE USER VOLTAGE CONFIGURATIONS 208 240 VAC OUTPUT CONFIGURATION 1 120 INPUT OUTPUT G N L LIH LN LH N G 120 VAC BA BKVA 208 240 OUTPUT CONFIGURATION 2 120 120 INPUT OUTPUT G L L2 N L3 H N 120 120
7. RUCTIONS This manual contains important instructions for SG SERIES that SHOULD BE FOLLOWED DURING INSTALLATION AND MAINTENANCE OF the UPS and batteries The sound pressure level at the operator s position is equal to or less than 60dB A WARNING CHANGES OR MODIFICATIONS TO THIS UNIT NOT EXPRESSLY APPROVED BY THE PARTY RESPONSIBLE FOR COMPLIANCE COULD VOID THE USER S AUTHORITY TO OPERATE THE EQUIPMENT CAUTION TO REDUCE THE RISK OF ELECTRICAL SHOCK IN CONDITIONS WHERE LOAD EQUIPMENT GROUNDING CANNOT BE VERIFIED DISCONNECT THE UPS FROM THE AC POWER OUTLET BEFORE INSTALLING A COMPUTER INTERFACE CABLE RECONNECT THE POWER CORD ONLY AFTER ALL SIGNALING CONNECTIONS ARE MADE 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 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 This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio in
8. SPLAYS AND ALARMS 2 1 Load level and battery capacity 2 2 Alarm for inverter short circuiting and output over voltage A2 Alarm for bus over voltage sisi A2 4 Alarm for over temperature A3 5 Display and alarmi TOF overload epe CUP DU A3 6 Alarm for BATTERY WEAK or BATTERY BAD A3 7 Alarm for abnormal input voltage E E A4 8 Battery over voltage 2 4 9 Bypass ol o ind 4 TO Inverter 51 9 SIMON Alacer ices 5 4 LIMITED PHODUCT WARRANTY oo sei uie aO agence me PUR A5 1 INTRODUCTION 1 1 EXPLANATION OF SYMBOLS Some or all of the following symbols may be used in this manual or may appear on your unit Please take a moment to familiarize yourself with these symbols and their associated meanings Symbols and Their Meanings Description Attention or consult accompanying documents Dangerous voltage On power connection to tha mains or output enabled stand by Alternating current Direct current Protective earth g
9. a to approximately one gallon of water The solution should be added until reaction has ceased The resulting liquid should be flushed with water 4 notlay tools or metal parts on top of batteries Discharge static electricity from body before touching batteries by first touching a grounded metal surface 4 Disconnect charging source prior to connecting or disconnecting battery terminals Determine if the battery is inadvertently grounded If inadvertently grounded remove source of ground Contact with any part of a grounded battery can result in electric shock The likelihood of such shock will be reduced if such grounds are removed during installation and maintenance The safe and continuous operation of the UPS depends partially on the care taken by the user Please note the following precautions Do not disassemble the UPS Do not place the UPS near water or an environment of excessive humidity Do not allow liquid or any foreign object to get inside the UPS Do not block air vents in the front of the UPS or air exhaust holes in the back Do not place the UPS under direct sunshine or close to heat emitting source For prevention of UPS failure please do not change the voltage setting switches HAZARDOUS VOLTAGE Battery circuit is not isolated from the input voltage There may be a hazardous voltage between battery terminals and ground Check it before touching Even after disconnection from the mains in
10. and show the display below Ta p Esa Fig 3 8 1 Bypass Mode Fig 3 8 2 Inverter Mode NOTE In Battery Mode the batteries are discharging hence no alarm sounds 9 Bypass STS short alarm The system will detect if the bypass STS gets shorted when the line breaker is turned on If the STS short is detected the display shows as below and the alarm sounds continuously Ir i Fig 3 9 Bypass Short Alarm Page A4 10 Inverter STS short alarm The system will detect if the inverter STS is shorted when the button on the control panel is pressed If the STS short is detected the display shows as below and the alarm sounds continuously Fig 10 1 Inverter STS short alarm LIMITED PRODUCT WARRANTY ENERGY PRODUCTS CO STACO Dayton Ohio warrants this equipment when properly applied and operated within specified conditions to be free from defects in material and workmanship for a period of one year from the date of shipment from the STACO warehouse on repair For equipment sites within the United States this warranty covers replacement of defective equipment at STACO s nearest service center at the sole discretion of Replacement parts and warranty labor expense will be borne by STACO For equipment located outside the United States the STACO warranty covers only defective parts This warranty shall be void if a the equipment is damaged by the customer is improperly used is subj
11. ected to an adverse operating environment or is operated outside the limits of its electrical specifications b the equipment is repaired or modified by anyone other than STACO or STACO approved personnel c has been used in a manner contrary to the product s operating manual or other written instructions EXCEPT AS PROVIDED HEREIN STACO MAKES NO WARRANTIES EXPRESSED OR IMPLIED INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE EXCEPT AS PROVIDED ABOVE IN NO EVENT WILL STACO BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OF THIS PRODUCT EVEN IF ADVISED OF THE POSSIBILITY OF SUCH DAMAGE Specifically STACO is not liable for any costs such as lost profits or revenue loss of equipment loss of use of equipment loss of software loss of data costs of substitutes claims by third parties or otherwise The sole and exclusive remedy for breach of any warranty expressed or implied concerning STACO s products and the only obligation of STACO hereunder shall be the repair or replacement of defective equipment components or parts or at STACO s option refund of the purchase price or substitution with an equivalent replacement product Page A5
12. f the protected equipment These sealed lead acid batteries have pressure operated vents 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 batteries replace with the same number of the following type Matsushita Panasonic Electric Works Type LCR12V7 2P 12V 7 2 AH or CSB Battery Co Ltd Type GP1270F2 12V 7 0AH 4 CAUTION Do not dispose of any battery in a fire as it may explode Lead acid batteries generate hydrogen gas Do not smoke when near batteries 2 CAUTION Do not open or mutilate the battery or batteries The electrolyte is a dilute sulfuric acid Released electrolyte is harmful to the skin and eyes It may be toxic It is electrically conductive and corrosive 2 CAUTION A battery can present a risk of electric shock and high short circuit current The following precautions should be observed when working on batteries Remove watches rings and or other metal objects Use tools with insulated handles Wear rubber gloves and boots Wear full eye protection and protective clothing f electrolyte contacts the skin wash it off immediately with water If electrolyte contacts the eyes flush thoroughly and immediately with water Seek medical attention Spilled electrolyte should be washed down with a suitable acid neutralizing agent Use approximately 1 pound of bicarbonate sod
13. ling technical support A Your Name and address B Where and when the unit was purchased C All of the model information on the rear of your UPS D Any information on the failure including LEDs that may be illuminated E A description of the protected equipment including model numbers if possible 4 A technician will ask you for the above information and if possible help solve your problem over the phone In the event that the unit requires factory service the technician will issue you a Return Material Authorization Number 4 If the UPS is under warranty the repairs will be done at no charge If not there will be a charge for repair 5 Pack the UPS in its original packaging If the original packaging is no longer available ask the technical support technician about obtaining a new set It is important to pack the UPS properly in order to avoid damage in transit Never use Styrofoam beads for a packing material Include a letter with your name address day time phone number RMA number a copy of your original sales receipt and a brief description of the trouble 6 Mark the on the outside of all packages The factory cannot accept any package without the marked on the outside 7 Return the UPS by insured prepaid carrier to the shipping address provided with the RMA APPLICATION NOTES 1 START UP 1 Turn on Input breaker the rear panel after checking the power wiring The cooling fans should
14. munication Communication LOAD Infarts EL e AS 400 Interface Input Fuse 4 Output Breaker 4 i zi Battery 1 sain Output Breaker Breaker Input Breaker Conductor Conductor Box TE SG0603 SG0604 REAR VIEW SG1003 SG1004 REAR VIEW 1 4 SWITCHES AND DISPLAYS ON OFF switches Push the ON button until the alarm sounds to turn on UPS Push OFF button until the alarm sounds to turn off UPS LINE LED This light is on when the incoming AC line is normal BYPASS LED This light is on when the UPS is providing power directly from the incoming AC line through the bypass route INVERTER LED The light is on when the UPS is operating in INVERTER MODE FAULT LED The light is on when the UPS is in fault condition and the alarm will sound continuously LOAD LEVEL amp BATTERY CAPACITY LEVEL The lights form the bar graph indicate how much load or battery capacity is present in the UPS Each LED represents a different level first LED 0 35 second LED 35 55 third LED 55 75 fourth LED 75 95 fifth LED 95 110 The bar graph shows load level during line mode The number of LEDs increases upwards as the load increases The UPS will go to battery mode when line power fails and the bar graph displays remaining battery capacity The number of LEDs decreases upwards with the decreasing of battery capacity 1 5 Safety IMPORTANT SAFETY INST
15. of the DIP SWITCH setting The voltage setting has been successfully changed when the UPS switches to INVERTER mode 41 208 220 t 230 Page A1 3 DISPLAYS AND ALARMS 1 Load level and battery capacity is represented 5 LEDs on the upper half of control panel 6th LED means FAULT When the UPS is in on line mode the 5 LEDs represent load level They denote 0 35 3595 5595 55 75 7596 9596 and 95 105 from bottom to top of maximum load capacity If the load amount reaches 10596 13096 the UPS is in overload such that the 6 LEDs would illuminate simultaneously The UPS will then switch to BYPASS mode 10 seconds later In addition if the load is over 13096 the UPS will switch to BYPASS immediately Fig 3 1 1 Inverter Mode Fig 3 1 2 Bypass Mode B During an AC line power failure these 5 LEDs represent the remaining battery capacity The LED s will extinguish by the sequence from bottom to top as the battery voltage level decreases Fig 3 1 3 Battery Mode 2 An alarm will sound continuously during inverter short circuiting or an output over voltage condition Fig 3 2 1 Line Mode 3 An alarm will sound continuously during a bus over voltage condition Fig 3 3 1 Line Mode Fig 3 3 2 Battery Mode Page A2 4 An alarm sounds continuously during an over temperature condition 3 4 1 3 4 2 5 Display and alarm for overload The alarm will so
16. put voltage components inside the UPS are still connected to the battery and area hazardous potential Disconnect the battery supply circuit before carrying out servicing or maintenance work 1 6 The UPS provides 232 serial port to with a host computer The host computer can monitor the UPS through this RS232 communication port The data format of RS232 is as follows Baud Rate 2400 bps Data Length 8 bits Ending Code 1 bit Parity Bit none 1 7 RS 232 INTERFACE The following is the pin assignment and description of DB 9 connector Pin Description iO 2 5232 Rx input 3 Ho232 Tx output 5 Ground input 2 INSTALLATION AND OPERATION 2 1 UNPACKING AND INSPECTION Examine packing carton for damage Notify the carrier immediately if damage is present Retain the packing carton for future use 2 2 INSTALLATION The UPS should be installed by professional service personnel To prevent an overbalance of this equipment the supporter must be mounted at the bottom of the enclosure Please install the supporters to the UPS at the bottom of both sides with six screws see figure With the installation of the supporters tipping of the UPS should be prevented The socket outlet should be near the equipment and easily accessible Notes The UPS should be placed in a flat location with a distance of at least 10cm from the wall to the vent In addition keep the U
17. round Alarm silence Overload Battery check Recyclable Do not dispose with ordinary trash 1 2 SYSTEM DESCRIPTION The SG SERIES UPS is an advanced true on line sine wave uninterruptible power system with automatic bypass It provides reliable regulated transient free AC power to your sensitive equipment ranging from computers and telecommunication systems to computerized instruments Because the UPS is in the on line topology type of design conditioned power is provided continuously to its connected devices Unlike standby UPS s its on line structure always regulates and filters output power when commercial power is present During line power failure the unit employs its internal maintenance free battery to supply back up power without any transfer time In the event of an overload or inverter failure the UPS will transfer to bypass mode as an alternate source The UPS can transfer back to the inverter mode automatically after the overload condition has been cleared All transfers noted above occur with zero transfer time that can ensure your equipment s continuous operation 1 3 PRODUCT SPECIFICATIONS ELECTRICAL amp MECHANICAL SPECIFICATIONS namme MODEL Current RATING Voltage Output Voltage 580603 aow He VAC lama _ SG0603 28 8 27 3 26 25A 4 2KW Hz VAC 208 220 230 240V up 960604 25 28 8 25 25 25 4 2KW Hz VAC 120 208 240 120 240V Pup
18. rs hemodialysis systems peritoneal dialysis systems neonatal ventilator incubators ventilators for both adults and infants anesthesia ventilators and infusion pumps as well as any other devices designated as critical by the United States FDA Hospital grade wiring devices and leakage current may be ordered as options on many STACO ENERGY PRODUCTS CO UPS systems STACO ENERGY PRODUCTS CO does not claim that units with this modification are certified or listed as Hospital Grade by STACO ENERGY PRODUCTS CO or any other organization Therefore these units do not meet the requirements for use in direct patient care 5 The UPS contains voltages which are potentially hazardous repairs should be performed qualified service personnel The UPS has its own internal energy source battery The output may be hot even when the UPS is not connected to the AC supply The voltage internal batteries create is 240 VOLTS For the safety of the UPS do not connect an imbalanced load 4 insulated grounding conductor should be identical in size thickness and insulation material to the grounded and ungrounded branch circuit supply conductors The wire which should be green or green with one or more yellow stripes is to be installed as part of the branch circuit that supplies the unit Grounding conductor must be minimum 8 AWG wire The grounding conductor described in the above item shall be grounded to the earth end o
19. terference regulations of the Canadian Department of Communications Le pr sent appeil num rique n emit pas de bruits radio lectroniques d passant les limites applicables aus appareils num rique de las Class A prescrites dans le R lement sur le brouillage radio lectronique dicte par le minister d s Communications du Canada STACO ENERGY PRODUCTS CO LIFE SUPPORT POLICY As a general policy STACO ENERGY PRODUCTS CO STACO ENERGY PRODUCTS CO does not recommend the use of any of its products in life support applications where failure or malfunction of the STACO ENERGY PRODUCTS CO product can be reasonably expected to cause failure of the life support device or to significantly affect its safety or effectiveness STACO ENERGY PRODUCTS CO does not recommend the use of any of its products in direct patient care STACO ENERGY PRODUCTS CO will not knowingly sell its products for use in such applications unless it receives in writing assurances satisfactory to STACO ENERGY PRODUCTS CO that a the risks of injury or damage have been minimized b the customer assumes all such risks and c the liability of SI ACO ENERGY PRODUCTS is adequately protected under the circumstances Examples of devices considered to be life support devices are neonatal oxygen analyzers nerve stimulators whether used for anesthesia pain relief or other purposes auto transfusion devices blood pumps defibrillators arrhythmia detectors and alarms pacemake
20. und once every 0 5 seconds during an overload condition While in inverter mode the alarm can be silenced by pressing the OFF button In the Battery Test mode the UPS will go to BYPASS immediately and the alarm will sound continuously Fig 3 5 3 Battery Mode Overload Fig 3 5 4 Battery Test 6 Alarm for WEAK BATTERY or BAD BATTERY BATTERY when the battery voltage goes below 215V the Battery LED will flash BAD BATTERY If the battery voltage falls below 140V an alarm will sound continuously The Battery LED will flash and the FAULT LED will illuminate and the UPS will stay in INVERTER mode If AC line power fails during this condition the UPS will shut down Fig 3 6 1 Weak Battery Fig 3 6 2 Bad Battery Page A3 7 Alarm for abnormal input voltage During Start up the Line LED will flash if the input voltage drops below 185V or above 261V Pressing the button will not switch the UPS Bypass Mode to Inverter Mode B During operation the UPS will switch from Inverter Mode to Battery Mode if the input voltage drops below 170V or above 276V C In Battery Mode the UPS does not change mode even if the line power recovers when voltage is below 170V or above 276 If voltage is between 185V and 261 the UPS will switch back to Line Mode T Fig 3 7 1 Bypass Mode Fig 3 7 2 Battery Mode 8 Battery Mode over voltage alarm When the battery voltage exceeds 300V the alarm will sound continuously
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