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Emergency Lighting System

1. Figure 13 Internal Battery Form No 003 2287 Rev D 21 Emergency Lighting System Connecting the FirstLine Battery Cabinet to the UPS To be performed by authorized service personnel 1 Inspect battery trays for signs of damage Verify that all terminal connections are sound 2 Use a voltmeter to verify that the battery string is above 408 VDC at the battery input connector shown in figure 14 3 Open the circuit breaker If the cabinet is not equipped with a breaker disconnect each battery string by unplugging all of the red and black power pole connectors 4 With wire sized per the local codes 6 AWG 75 C copper wire minimum to 2 AWG maximum connect to the left battery terminal block 5 Connect the ground wire to the 1 4 20 ground stud with a ring terminal or pressure lug by removing and replacing the top nut and washers only with a 7 16 wrench 6 If the battery cabinet is not equipp
2. Form No 003 2287 Rev D 6 Emergency Lighting System Floor Loading When planning the installation consider the Emergency Lighting System s weight for floor loading The strength of the installation surface must be adequate for point and distributed loading The approximate weights are shown in the following table Table 3 Model Floor Loadings UPS Cabinet Battery Cabinet s Maximum Point Maximum Point Weight Loading Weight Loading System Part Number Rating Vi Lbs Lbs in FLU924 8 20 N 208 120Y 208 120Y FLU924 8 20 B 208 120Y 208 120Y FLU924 8 20 N I 208 120Y 208 120Y FLU924 8 20 B 208 120Y 208 120Y FLU924 8 42 N 480 277Y 208 120Y FLU924 8 42 B 480 277Y 208 120Y FLU924 8 42 N 480 277Y 208 120Y FLU924 8 42 B 480 277Y 208 120Y FLU924 8 44 N 480 277Y 480 277Y FLU924 8 44 B 480 277Y 480 277Y FLU924 8 44 N 480 277Y 480 277Y FLU924 8 44 B 480 277Y 480 277Y FLU924 12 20 N 208 120Y 208 120Y FLU924 12 20 B 208 120Y 208 120Y FLU924 12 20 N I 208 120Y 208 120Y FLU924 12 20 B 208 120Y 208 120Y FLU924 12 42 N 480 277Y 208 120Y FLU924 12 42 B 480 277Y 208 120Y FLU924 12 42 N I 480 277Y 208 120Y FLU924 12 42 B 480 277Y 208 120Y FLU924 12 44 N 480 277Y 480 277Y FLU924 12 44 B 480 277Y 480 277Y FLU924 12 44 N l 480 277Y 480 277Y FLU924 12 44 B 480 277Y 480 277Y FLU924 16 20 N 208 120Y 208 120Y FLU924 16 20 B 208 120Y 208 120Y FLU924 16 20 N I 208 120Y 208 120Y
3. Emergency Lighting System Battery Connection continued 8 If the system has two battery cabinets prepare the second battery cabinet by removing the panels Repeat steps 1 through 7 for the second cabinet The other end of the wires from the second cabinet connect to the right hand battery terminal block using the procedure described in steps 4 and 5 9 If the battery cabinet is equipped with the optional circuit breaker connect the breaker interface cable s as described in Section 5 of this manual then return to this procedure 10 If the battery cabinet does not have an internal breaker close the external breaker Do not close the internal breaker at this time Connect the internal battery of the UPS by connecting the red and black battery plug to the red and black dc input plug Refer to Figure 13 If the UPS has twp internal batteries also connect the second battery plug to the second dc input plug 11 Referring to figure 14 at the external battery cabinet measure the dc voltage from the left hand fuse positive lead of meter to the right hand fuse negative lead of meter The voltage measured should be positive If not the polarity of the battery connections is not correct and must be corrected Expect to measure 400 to 445 Vdc during this test depending on the state of charge of the battery Repeat this test for the second battery cabinet if present 12 If the battery polarity is correct open the external breaker if equ
4. Verify that the UPS output is ON BYPASS by observing that the lamp associated with the bypass line at the static switch block on the mimic display is green and that the lamp associated with the inverter is not lit Operate the MBS to put it in bypass mode It is now safe to turn off the UPS and close the battery breaker s Restart the UPS To transfer back to normal mode 1 2 3 Verify that the UPS is still ON BYPASS by observing the mimic display f not perform a manual transfer to bypass as described above Operate the MBS to put it in normal mode Enable automatic transfer by pressing and holding the ESC key while simultaneously pressing the DOWN ARROW key After a few seconds the mimic display should show that the static switch has transferred the load to inverter Form No 003 2287 Rev D 41 Emergency Lighting System UPS Maintenance The FirstLine UPS is designed to be virtually user maintenance free requiring only the occasional wipe with a damp cloth or non abrasive cleaner Spare kits are available for the FirstLine UPS series please contact Staco Energy Products Co service center for details For maximum availability of the UPS the components that are subject to wear should be replaced as part of a comprehensive preventive maintenance program RECOMMENDED REPLACEMENT INTERVALS Dc Filter Capacitors 5 years AC Filter Capacitors 5 years Fans 2 years Rectifier Chokes 10 years Batt
5. COM NC TB3 terminals 1 2 3 running on inverter TB3 terminals 4 5 6 battery discharging TB3 terminals 7 8 9 low battery reserve TB3 terminals 10 11 12 on bypass TB3 terminals 13 14 15 alarm present VVVVV TB3 Figure 19 TB3 J232 is an RS 232 DCE three wire interface See separate specification for details Not currently enabled future use There are five sets of optically isolated open collector outputs available They are capable of switching up to 30 volts DC and up to 3 milliamps Listed in order of Emitter Collector Vcc 5 0 VDC gt TB4 terminals 1 2 running on inverter gt TB4 terminals 3 4 battery discharging gt TB4 terminals 5 6 low battery reserve gt TB4 terminals 7 8 on bypass 2 Vo gt TB4 terminals 9 10 alarm present w A Typical application TB4 Figure 20 TB4 An RS 232 DCE three wire interface is available The UPS shipped with an installation CD containing monitor software and an RS 232 cable The monitor software will allow a single user to connect the UPS to a computer via the RS 232 port for local monitoring of UPS operation For advanced monitoring Ethernet and SNMP are supported via the RS 232 interface with an external adaptor A 120 volt AC outlet has been provided on the back panel of the UPS for powering the external adaptor Consult the factory for more details The local RS 232 monitor function cannot be used at the same time as the exter
6. I at the end designates the presence of an input isolation transformer The nominal input output voltages are 120 208 VAC 480V 60 Hz input is available when using an input transformer 480 480 Vac is available when using an input and output transformer Input and output overcurrent protection and disconnect switch must be provided by others WARNING Only qualified service personnel such as a licensed electrician should perform the UPS installation and initial startup Risk of electrical shock Wiring Preparation To begin wiring the UPS 1 Verify that the electrical connections to the installation site have been properly installed 2 A wall mounted user supplied readily accessible disconnection device must be incorporated in the input wiring Compare the circuit breaker ratings to the ones in Table 6 on page 14 Form No 003 2287 Rev D 11 Emergency Lighting System 3 Switch off utility power to the distribution point where the UPS will be connected Be absolutely sure there is no power 4 Determine your equipment s grounding requirements according to your local electrical code 5 Remove the UPS rear panel 6 Conduit landing plates are located at the rear bottom of the base to accommodate bottom wire entry to the cabinet see Figure 7 Remove plate and drill or punch hole to fit conduit bushing with Greenlee punch or similar device Make certain that the bushing will be clear in the opening i
7. INPUT O STATIC aisi v SWITCH 208Y RECTIFIER INVERTER STANDARD 208Y STANDARD J TRANSFORMER BATTERY 480V OUTPUT MODELS STANDARD AUTOTRANFORMER 480V INPUT MODELS EXTENDED s BATTERY SOME MODELS ISOLATION TRANSFORMER OPTION 208A EXTERNAL 480A BATTERY S Figure 9 Wiring Single Line Diagram Form No 003 2287 Rev D 17 Emergency Lighting System l o begin wiring the Battery Cabinet s 1 Switch off utility power to the distribution point where the UPS is connected Be absolutely sure there is no power 2 Removing and replacing the front panel gt Pull the top of the panel outward until the ball studs unsnap gt Lift the panel up and off the cabinet To replace the panel gt Lower the shoulder screws at the bottom of the panel into the keyhole slots on the cabinet gt Press the panel inward until the ball studs snap into place KEYHOLE SLOT SHOULDER SCREW OPTIONAL 4 CIRCUIT BREAKER BL N BALL STUD Sunc Figure 10 Removing the Battery Cabinet Front Panel 3 If the optional circuit breaker is included switch it to the Off position Remove the inner front cover by removing the 12 twelve screws mounting it to the enclosure Form No 003 2287 Rev D 18 Emergency Lighting System 5 Conduit landing plates are located at the front bottom of the base to acco
8. Reverse polarity will cause equipment damage that is not covered by the equipment warranty There is a polarity verification procedure below that will help to prevent mishaps Wires should be marked using colored tape to avoid confusion Note that the terminal block in the UPS and the terminal blocks in the Extended Battery Cabinet all use the left hand terminal for the positive connection and the right hand terminal for the negative connection Before connecting the wires between the UPS and the Extended Battery Cabinet the UPS must be powered down the front outer panel must be removed the front inner safety panel must be removed and all internal batteries must be disconnected by unplugging the red and black battery plug from the DC input plug for each battery string Most units have one battery string but a second string is an option in the tall cabinet version On the Extended Battery Cabinet the front outer panel must be removed the front inner safety panel must be removed and all internal batteries must be disconnected by unplugging the red and black battery plugs between each battery string and the plug pair between the lowest battery string and the input output panel Connect the three wires positive negative and ground to the external battery terminal block and the grounding stud at the UPS end Connect the Extended Battery Cabinet end of the three wires to the terminal block on the left and to the ground stud The positive wire goes
9. Insure the battery is connected as described in Section 4 5 Reinstall the rear cover the top cover and the front inner access panel Reinstall the decorative front panel 6 If one or more Extended Battery Cabinets are connected to the UPS close the circuit breaker on each cabinet if they are equipped with this option Close the external circuit breaker for the battery if so equipped T Apply power to the UPS 8 Press the on off button to start the UPS Normal Operation To start the UPS press the on off power button O If the bypass input is qualified voltage frequency and phase sequence correct the UPS will start on bypass The rectifier and inverter will automatically start and the static switch will transfer the load to the inverter To stop the UPS press the on off button In an emergency the UPS can be stopped by lifting the guard and pressing the EPO button Emergency Power Off Activation of Emergency Power Off either via the front panel EPO button or via the Remote Emergency Power Off function TB1 on the Customer Interface will also cause the system to reset interrupting any display or communication process that is underway The output circuits of the UPS should not be considered safe unless the UPS is Off AND the input power source to the UPS has been removed by opening the input disconnect device which is external to the UPS Form No 003 2287 Rev D 33 Emergency Lighting System If one or
10. Remove front cover panel and interior panel 2 Remove and discard shipping support panel mounted in front of the battery trays 3 Inspect battery trays for signs of damage Verify that all terminal connections are sound 4 Use a voltmeter to verify that the battery string is above 420 VDC at the battery plug shown in figure 13 5 Verify that the positive red plug of the lower tray is connected to the negative black plug of the upper tray Form No 003 2287 Rev D 20 Emergency Lighting System A Never connect the positive red red plug to the negative black plug from the same tray Severe damage and injury could result 6 If the UPS has four battery trays also check the lower two battery trays ra Connect the external battery to the UPS using the procedure that follows Battery fuse DC input plug Black C Inverter fuse P al Battery plug j DEW 1 Blue plug La p F
11. TERMINAL TIGHTENING TORQUE 2 0 6 AWG 120 inch pounds 8 12 AWG 50 inch pounds Table 5 Ground Lugs GROUND LUGS TIGHTENING TORQUE 10 AWG 35 inch pounds 8 AWG 40 inch pounds 4 6 AWG 45 inch pounds 1 0 2 AWG 50 inch pounds Form No 003 2287 Rev D 13 Table 6 FirstLine UPS 8 12 16 KW Current Requirements Emergency Lighting System UPS Input Max Input Maximum Rating Voltage Current A Allowable Branch Allowed for Circuit Protection Specified A Branch Protector 8 KW 208 V 32 40 8 KW 480 V 14 20 12 KW 208 V 47 60 12 KW 480 V 21 30 16 KW 208 V 63 80 16 KW 480 V 28 35 UPS Output Rated Max Maximum Rating Voltage Output Current Allowable A Circuit Protection A 8 KW 208 V 22 note 1 8 KW 480 V 10 35 12 KW 208 V 33 note 1 12 KW 480 V 15 35 16 KW 208 V 44 note 1 16 KW 480 V 19 Note 1 Output circuit protection requirement determined by distribution circuit Form No 003 2287 Rev D Emergency Lighting System Wiring Specifications and Diagrams Note Unless the system is a I model with an input isolation transformer the input neutral must be wired for proper operation or the UPS will not start The o input neutral must be grounded at the source If an input isolation transformer is present the input neutral is not used and no input neutral wire needs to
12. be provided The neutral of the isolation transformer is bonded to ground at the UPS The UPS chassis must be grounded to the source via a grounding conductor per Table 7 Note Do not over tighten the screws be sure to use the specified tightening torque values shown in Table 4 Table 5 and Table 8 8KW 208V CAUTION to reduce the risk of fire connect only to a circuit provided with 40 amperes maximum branch circuit protection in accordance with the National Electrical Code ANSI NFPA 70 8 KW 480V CAUTION to reduce the risk of fire connect only to a circuit provided with 20 amperes maximum branch circuit protection in accordance with the National Electrical Code ANSI NFPA 70 12 KW 208V CAUTION to reduce the risk of fire connect only to a circuit provided with 60 amperes maximum branch circuit protection in accordance with the National Electrical Code ANSI NFPA 70 12KW 480V CAUTION to reduce the risk of fire connect only to a circuit provided with 30 amperes maximum branch circuit protection in accordance with the National Electrical Code ANSI NFPA 70 16 KW 208V CAUTION to reduce the risk of fire connect only to a circuit provided with 80 amperes maximum branch circuit protection in accordance with the National Electrical Code ANSI NFPA 70 16 KW 480V CAUTION to reduce the risk of fire connect only to a circuit provided with 35 amperes maximum branch circuit protection in accordance with the National Ele
13. is started Make sure that single phase loads are fairly evenly distributed across the three output phases Balanced operation maximizes efficiency and reliability Check the individual output phase currents when the UPS is operating Form No 003 2287 Rev D Emergency Lighting System CONTENTS SECUN Mearsi RP esprit SCTE ERE cte DEALS OUP PERE RE ELE ILLE ree ARE 1 AT GCL CT GIN eec ctc Sess ks le EEEE EER eti pudet de tu pere e dre de ded pure Me e Cu esas 1 FirstLine Emergency Lighting System Part Number Scheme eeeeussss 3 DECOM Z Sod D t d Adam heat DM A RA A Eu 4 Safety Warnings 93 4 5 50 efie ete eA sS S eL S 4 fidis p CR 6 UPS Sellipuc recepere ente ted ic eh tpm dedu ee partu dye Sete Spec ised pid te at ute met dE a 6 Inspecting the EdgBlpITighlk oso cicero a Re A e ena fem rm n s 6 NSt I c eee cun ED pM nup Pn er HIE 6 HOG LOA CING eq D a a aa a a aa a aE aaa 7 Unloading the Cablnel s uii eure o p Mete Raise AEE 8 PIAGING th CAO c a 10 SCHON Ai seni E i cn DNI DE D BI nM n t DI D rd 11 Electrical Installatori oh eee tad teed cds secede Ca eats cane ud o n dE UN US E EAR 11 MVE GP he ell Atl OMA ce cad vars gas oer Ee oer en e o e im dcn ov Ded eect 11 Wiring Installation PR E TE 13 Wiring Specifications and Diagrams sssesssssseeneeeennneeeeennnnnnneennnn 15 To begin wiring the Battery Cabinet S cccceeessssscceeeeeeeeeeeeeeeneeeeeeeeeeeeeeeesn
14. the event that the input fails The battery will automatically recharge during normal operation On Battery the input is outside of specified operating range and the battery is being used to power the load The Battery Indicator will be yellow Abnormal the system is running on bypass or there is a fault If neither the SYSTEM NORMAL nor the ON BATTERY condition exists then the system is ABNORMAL If the system is on bypass due to an output overload the overload must be eliminated before normal operation can be restored Use table 9 and table 10 as guides to obtain information to determine what fault might be present Form No 003 2287 Rev D 30 Emergency Lighting System The following table shows the indicator status and description Indicator Status Description Bypass Off Bypass input voltage or frequency not qualified Bypass Green Bypass input voltage or frequency qualified Bypass Yellow Inverter output not synchronized to bypass input Bypass Hed Bypass input voltage has incorrect phase sequence Input Off Rectifier input voltage or frequency not qualified Input Green Rectifier input voltage and frequency qualified Input Red Rectifier input voltage has incorrect phase sequence Rectifier Off System OFF or Rectifier input not qualified Rectifier Green Rectifier is running normally Rectifier Yellow Rectifier is running at input po
15. FLU 10T 20 1 FLU 10T 20 1 I FLU 10T 20 1 I FLU 10T 42 1 FLU 10T 42 1 FLU 10T 42 1 I FLU 10T 42 1 I FLU 10T 44 1 FLU 10T 44 1 FLU 10T 44 1 1 FLU 10T 44 1 I FLU 15T 20 1 FLU 15T 20 1 FLU 15T 20 1 I FLU 15T 20 1 I FLU 15T 42 1 FLU 15T 42 1 FLU 15T 42 1 1 FLU 15T 42 1 I FLU 15T 44 1 FLU 15T 44 1 FLU 15T 44 1 I FLU 15T 44 1 I FLU 20T 20 2 FLU 20T 20 2 FLU 20T 20 1 I FLU 20T 20 1 I FLU 20T 42 1 FLU 20T 42 1 FLU 20T 42 1 I FLU 20T 42 1 I FLU 20T 44 1 FLU 20T 44 1 FLU 20T 44 1 I FLU 20T 44 1 I Battery Cabinet Part Number FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 3 N FLU BAT 20 3 B FLU BAT 20 3 N FLU BAT 20 3 B FLU BAT 20 3 N FLU BAT 20 3 B FLU BAT 20 3 N FLU BAT 20 3 B FLU BAT 20 3 N FLU BAT 20 3 B FLU BAT 20 3 N FLU BAT 20 3 B FLU BAT 20 3 N FLU BAT 20 3 B FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 2 N FLU BAT 20 2 B B signifies that the battery cabinets are equipped with a disconnect breaker N signifies that the battery cabinets are not equipped with a disconnect breaker and the breaker must be provided externally as part of the installation System Consists Of Second Battery Cabinet Part Number not required not required not required not requir
16. FLU924 16 20 B 208 120Y 208 120Y FLU924 16 42 N 480 277Y 208 120Y FLU924 16 42 B 480 277Y 208 120Y FLU924 16 42 N I 480 277Y 208 120Y FLU924 16 42 B 480 277Y 208 120Y FLU924 16 44 N 480 277Y 480 277Y FLU924 16 44 B 480 277Y 480 277Y FLU924 16 44 N I 480 277Y 480 277Y FLU924 16 44 B 480 277Y 480 277Y Lbs Lbs in Please note that there are two Battery Cabinets for all 16 kW Systems except the FLU924 16 20 N and the FLU924 16 20 B All other Systems use just one Battery Cabinet Refer to Table 1 Form No 003 2287 Rev D 7 Emergency Lighting System Unloading the Cabinet s The following tools are required for unloading the cabinet s gt Wrenches for 1 4 bolts and 1 2 nut gt Forklift CAUTION The UPS and Battery cabinets are heavy see Table 3 Unloading the cabinets JAN requires at least two people to safely remove the cabinets from the pallet To remove the UPS or Battery cabinets from the ship pallet 1 Remove all banding wrapping and foam protectors 2 Loosen the six 1 2 nuts and washers securing the shipping brackets to the pallet see Figures 3 and 4 3 Remove and discard the four 1 4 bolts and washers securing the shipping brackets to the cabinet side panels also remove the four 77 bolts and washers the brackets surrounds but does not touch Save these as they must be reinstalled later Pull the brackets away from the cabinet _ Forklift
17. Se Pre E DN ED ie eas aed 4 Table 3 Model Floor LoadiNgS suoi dendi Ema Rena eA ERERUMER A X2 R NC HERE B EN tenes X RE OE 7 Table 4 Input Output Termihalus as ecce Pure Ehe sehe t cues tae ere tah bee Ve Fieceuph prave te Sere AE eee 13 Table 5 Ground LUGS a 5 eoi Meester est reta buipet Aricia eese ets ra tei orsa iiri 13 Table 6 FirstLine UPS 8 12 16 KW Current Requirements seessesss 14 Table 7 Terminal Block Wiring iioc cepa tenet utente senda pueden ede tpi p dene piene 16 Table 8 Torque Values for TB1 2 3 4 esonxaes caca eap appa Ga EA D ELA LU ELA A EG e Rd 29 Table 9 Indicator Status and Description eeesssesssssesssseeeeeereeeeennn 31 Table 10 Menu Pap for Display Functions sssessseseeennemennnn 32 Table 11 Techrical SpecifIGatiOlis c tiet c ctc b bubo eteptus eund Muda iene 43 Form No 003 2287 Rev D Emergency Lighting System SECTION 1 Introduction The FirstLine UPS Emergency Lighting System is designed to provide power for maintaining critical lighting when utility power is not available The combination of the UPS uninterruptible power supply and external batteries provide rated power for up to 90 minutes of operation during utility power outages The true online double conversion three phase UPS provides clean well regulated sinusoidal voltage to the lighting loads Figure 1 shows the UPS cabinet dimensions Figure 2 shows the Battery C
18. User s Manual for The FIRSTLINE UPS EMERGENCY LIGHTING SYSTEM 8KW 12KW AND 16KW TACO NERGY PRODUCTS CO 301 Gaddis Boulevard Dayton Ohio 45403 U S Toll Free 866 261 1191 937 253 1191 Fax 937 253 1723 Web site www stacoenergy com Form No 003 2287 Rev D 09 4 2009 Emergency Lighting System Before Installing the Emergency Lighting Systems Read all safety and installation instructions Make sure that the System is the correct model for your application Verify that the available power source matches the input rating of the UPS Unless the UPS is equipped with a transformer option the source should be 120 volts line to neutral three phase ABC sequence with a grounded neutral Before starting the UPS Read all safety and operating instructions Verify that the UPS is installed in a clean temperature controlled area If the UPS is installed at an altitude above 1000 meters the output load capability must be de rated by 196 for each 100 meters above 1000 meters Verify that the installation includes an input breaker of the proper rating Verify that the wiring is correct and that all connections are neat and tight Verify that the internal batteries in the UPS have been connected Verify that the Extended Run Time Battery Cabinet is equipped with the optional breaker or that an external breaker has been provided as part of the installation The battery breaker should be closed before the UPS
19. abinet dimensions The 480 volt 16 kW model uses two battery cabinets all other systems consist of the UPS and one battery cabinet 32 38 822 4mm 14 23 00 584 2mm La 31 94 B11 2mm i 6 00 152 4mm MIN WALL CLEARANCE FOR VENTILATION i f 1 E m E j Es H l j Lc i 70 00 1778 0mm i i i i Y ug e INTAKE VENTILATION HOLES EXTERNAL BATTERY CONTROL CABLE ENTRY 2 25 57 2mm X 1 75 44 5mm EXTERNAL BATTERY POWER CABLE ENTRY 2 25 57 2mm X 1 75 44 5mm 2 SWIVEL CASTERS 4 LEVELING FEET 2 RIGID CASTERS K POWER CABLE ENTRY 7 25 184 2mm X 3 00 76 2mm Figure 1 The FirstLine UPS 8 16 KW Form No 003 2287 Rev D 1 Emergency Lighting System 22 31 566 7mm 31 94 811 2mm m 6 00 152 4mm MIN WALL CLEARANCE i A FOR VENTILATION I 70 00 1778 0mm n d n CUSTOMER CONNECTION TERMINAL ACCESS POWER CABLE ENTRY 3 25 82 6mm X 1 75 44 5mm 2 SWIVEL CASTERS 4 RIGID CASTERS 4 LEVELING FEET CONTROL CABLE ENTRY 2 25 57 2mm X 1 75 44 5mm Figure 2 The FirstLine Extended Run Time Battery Cabinet Form No 003 2287 Rev D 2 Emergency Lighting System FirstLine Emerg
20. access a from rear Pallet i SAK p CAEN Shipping bracket 1 this Bw up LA side and opposite side Figure 3 UPS on pallet Form No 003 2287 Rev D 8 Emergency Lighting System D Remove and discard p l J 1 4 bolt and washers S a P 4d 4 places i l i Remove 4 1 4 bolts j l P Reinstall after the unit is on the floor N A X Pull 2 shipping brackets NS A N away from cabinet EN P Loosen 3 1 2 nuts on each bracket Remove and discard Remove 4 1 4 bolts 1 4 bolt and washers Reinstall after the unit is on the floor 4 places Figure 4 Shipping Bracket Remove the front cover see Figure 12 before inserting the lifting forks Ensure that the four 4 leveling feet are raised so that they will not touch the floor when the cabinet is placed on the floor Lift the cabinet with a forklift from the rear of the unit one to two inches 1 2 2 5 5cm above the pallet see figure 5 Slide the pallet completely away from the raised cabinet Slowly lower the cabinet to the floor Reinstall the front cover and 4 4 bolts and washers see figure 4 Roll the cabinet to the desired location Do not move the cabinet to another location by forklift as the cabinets are heavy and may fall a ee mo ues ONLY MOVE THE CABINET VERTICALLY TO REMOVE THE PALLET FROM UNDER THE CABINET AN DO NOT ALLOW THE FORKLIFT TO MOVE WHILE THE CABINET IS RAISED Form No 003 2287 R
21. alled where it will not readily be subjected to tampering by unauthorized personnel f The use of accessory equipment not recommended by the manufacturer may cause an unsafe condition g Do not use this equipment for other than intended use 2009 p Table 2 Symbols Danger Risk of Electric Shock Caution Risk of Explosion Note Ground Connection Electrostatic Sensitive Device oep 5 Form No 003 2287 Rev D 4 Emergency Lighting System This UPS contains LETHAL VOLTAGES All repairs and service should be performed by AUTHORIZED SERVICE PERSONNEL ONLY There are NO USER SERVICEABLE PARTS inside the UPS e This UPS contains its own energy source batteries The UPS output may carry live voltage even when the UPS is not connected to an AC supply e To reduce the risk of fire or electric shock install this UPS in a temperature and humidity controlled indoor environment free of conductive contaminants Do not operate near water or excessive humidity 95 maximum e Input and output over current protection and disconnect switches must be provided by others CAUTION Batteries can present a risk of electrical shock or burn from high short circuit current Observe proper precautions Servicing should be performed by qualified service personnel knowledgeable of batteries and required precautions Keep unauthorized personnel away from batteries Risk of explosion if batteri
22. and to scroll through the menu structure Press the button to enter a submenu Press the button to select an option Press the button to cancel or return to the previous menu The following table shows the basic menu structure Key A TE VPhA LL p VPhB_ LL VPhC_ LL V Form No 003 2287 Rev D Staco Energy Products Escape Bypass Input gt V Scroll Alarms Logs lt V Scroll Logs VPhA_ L L VPhB L L VPhC LL IPhA Amp IPhB Amp IPhc Amp Frequency Hz Table 10 Menu Pap for Display Functions m gt VPhA LL VPhB LL VPhC LL IPhA Amp IPhB Amp IPhC_ Amp Frequency Hz lt Battery gt Volts DC Amps DC 32 Emergency Lighting System SECTION 8 Initial Start Up To be performed by authorized service personnel 1 Inspect for damage Remove front cover panel inner front access panel front shipping support panel top cover and rear panel Look for signs of damage due to handling including bent supports loose components etc 2 Connect input power source and load to terminal blocks at rear of unit as described in Section 4 Before applying power to the UPS verify that the correct voltage is available and that the phase sequence is correct A B C 3 If an external bypass switch is to be used contact the factory for the correct method to interface contact sensing to the UPS 4 Double check that there is no visible damage to the battery
23. ction of the amount of energy used during the test so the battery time available will be reduced until sufficient charging has occurred The front panel display can be used to observe battery voltage and current during the discharge Multiplying the two numbers gives an approximation of the power supplied by the battery in watts ignore the sign of the answer since discharge is reported as negative current Manual Transfer to Bypass Verify that the bypass input is qualified by observing that the bypass indicator is green While holding down the ESC key press the up arrow key When the conditions are met for a transfer to bypass bypass input is qualified and inverter is synchronized to bypass the static switch will transfer the load to bypass After a few seconds the mimic display will update to show this Manual Transfer to Inverter This procedure enables an automatic transfer to inverter While holding down the ESC key press the down arrow key When the conditions are met for a transfer to inverter inverter is running and synchronized to bypass the static switch will transfer the load to inverter After a few seconds the mimic display will update to show this Form No 003 2287 Rev D 34 Emergency Lighting System External Bypass Arrangement If an external bypass arrangement is to be used with the UPS contact the factory for the proper method to interface auxiliary switches in the bypass arrangement with the UPS controls Pro
24. ctrical Code ANSI NFPA 70 Form No 003 2287 Rev D 15 Emergency Lighting System Table 7 Terminal Block Wiring UPS Voltage Input Phase Neutral Neutral Conductor with Ground Wire Rating Transformer Conductor Conductor non linear loads Min Max Type Min Max Min Max Min Max 10kva_ 208 120 NA 8 2 0 8 2 0 6 2 0 8 1 0 208 isolation 8 2 0 none none 8 1 0 480 277 auto 10 2 0 10 2 0 8 2 0 8 1 0 480 isolation 10 2 0 none none 8 1 0 15kva 208 120 NA 6 2 0 6 2 0 4 2 0 8 1 0 208 isolation 6 2 0 none none 8 1 0 480 277 auto 8 2 0 8 2 0 6 2 0 8 1 0 480 isolation 8 2 0 none none 8 1 0 20kva 208 120 NA 4 2 0 4 2 0 2 2 0 6 1 0 208 isolation 4 2 0 none none 6 1 0 480 277 auto 8 2 0 8 2 0 6 2 0 6 1 0 480 isolation 8 2 0 none none 6 1 0 OUTPUT Minimum wire size required to support rated load Smaller wire may be used if rated load current is not needed and the appropriate circuit protection is applied Output UPS Transformer Phase Neutral Neutral Conductor with Rating Voltage Type Conductor Conductor non linear loads Ground Wire 10 kVA 208 120 NA 10 10 8 8 1 0 480 277 auto 12 12 10 8 1 0 15 kVA 208 120 NA 8 8 6 8 1 0 480 277 auto 10 10 8 8 1 0 20 kVA 208 120 NA 6 6 4 6 1 0 480 277 auto 10 10 8 6 1 0 Note No output circuit prot
25. e Id DD reb Fou d Uum 35 Automatic Transfer to Inveltels a eee ee ede ex Denuo e Dex du ea lg 35 Over OAC UTE 35 FIGCUIIBI oon o Dc eu MIS p ele ole at soe 36 iE mcr 37 Battery Removal Installation and Service esssssssssssssesseees 37 Polarity Verification Proced re io cioe ordin e cr cun c eR C xU En Re ar ERR LOS 39 Stopping the Rectifier in the UPS ioco Eo rhone Eo EX ret EO Ee even Ere E DURER 40 To transfer to MBSi ceeeeeeceeeneee cece ee eeeeeeeeeaee eee eeeeeeeeeaaaaeeeeeeeeeeeeeceaaaaeeeeeeeeeeseeeeenueeeeeeess 41 UPS MAUS IAIN G ee 42 Form No 003 2287 Rev D Emergency Lighting System Section PO spp c E 43 FirstLine UPS Technical Specifications ccccececeeeeeeeeeeeeeeeneeeeeeeeeeeeeeeeneeeeeeeeeeeeeeeees 43 Figure T The FirstLine UPS 8 16 IW iiie inerte reste n Ee A Rex E cnet examen 1 Figure 2 The FirstLine Extended Run Time Battery Cabinet ssseesssssss 2 Figure 3 UPS on pallet usi ede bebo etre teed Na theta october ie bebe bed aeta s bebrbebrt iden bet aah 8 Figure 4 Shipplrig BFaeROL iie o v Pur UT USE Md utu DU um Uis 9 Figure 5 Lifting fork alae tne been reoc der nen re enc tete tena dene aene eg vae pe dp toned oud 10 Figure 6 Leveling foot being adjusted down to the floor seesssssesesssss 10 Figure 7 Bottom VIeWoe sets LL A A e de E AE E ot ae le 12 EIgure e Terminal IBIOCKS i2 e
26. ection is required if the output conductor sizes are at least as large as the input conductors unless the UPS is equipped with an input isolation transformer If the UPS is equipped with an input isolation transformer the UPS is considered a separately derived source and circuit protection for the output conductors must be provided Use at least 75 C rated copper wire Minimum wire size is based on 120 208 full load ratings applied to NEC Code Table 310 16 Code may require a large AWG size than shown in this table because of temperature number of conductors in the conduit or long service runs Follow local requirements Form No 003 2287 Rev D 16 Emergency Lighting System Per NEC article 300 20 2 all three phase conductors must be run in the same conduit Neutral and ground must be run in the same conduit as the phase conductors Conduit to be sized to accommodate one neutral conductor the same size as the phase conductor and one ground conductor If two neutral conductors or an oversized neutral conductor are to be installed check the size of the conduit needed to accommodate the extra wire or size and use that conduit size in place of the conduit size listed Conduit sizes can be chosen from NEC Table C1 type letters RHH RHW RHW 2 TW THW THHW THW 2 u FEA r A v O OUTPUT i v
27. ed not required not required not required not required not required not required not required not required not required not required not required not required not required not required not required not required not required not required not required not required not required not required FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 2 N FLU BAT 20 2 B FLU BAT 20 2 N FLU BAT 20 2 B signifies that the UPS has an input isolation transformer and does not require an input neutral Form No 003 2287 Rev D Emergency Lighting System SECTION 2 Safety Warnings IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that you should follow during installation and maintenance of the UPS and batteries Please read all instructions before operating the equipment and save this manual for future reference READ AND FOLLOW ALL SAFETY INSTRUCTIONS Do not use outdoors Do not route wiring across or near hot surfaces Do not install near gas or electric heaters Use caution when servicing batteries Battery acid can cause burns to skin and eyes If acid is spilled on skin or in eyes flush acid with fresh water and contact a physician immediately Equipment should be inst
28. ed with a disconnect breaker an external one must be provided between the battery and the UPS 7 Repeat procedures 4 and 5 to the FirstLine UPS Extended Run Time Battery connector located in the right side of the UPS We recommend that the wires be marked as to which is positive and negative to ensure that the wires are not accidentally crossed See figure 15 Optional circuit breaker Optional battery breaker B units only f interface board Battery fuses 3e B units only J GV Ww ees epu y o O aialae ogogo a e le lle le ill all lle og ii d i h P3 d Ts ee USE E FOR AT PO INDER LOAD 9 O O O 9 9 amp O Eia Battery input connector Battery output connector GroundcoRsatiofi to next battery cabinet Figure 14 Input Output Panel Form No 003 2287 Rev D 22 Emergency Lighting System Never connect the positive to the negative Severe damage and injury could result BATTERY INPUT OUTPUT TERMINAL TIGHTENING TORQUE 2 3 AWG 50 inch pounds 4 6 AWG 45 inch pounds GROUND STUD TIGHTENING TORQUE Extended Run Time Battery Cabinet 100 inch pounds UPS Cabinet 55 inch pounds Form No 003 2287 Rev D 1 4 20 Ground terminal stud UPS extended run time battery cabinet connector Battery power cable conduit mounting plate Battery control cable conduit mounting plate Figure 15 UPS Connections 23
29. eeeaeeeeeees 18 Removing and Replacing the Front Panel eeeeeecceecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseaeaees 20 Check the Internal BARHEy es doe toe teet ette AL Le A d LE 20 Connecting the FirstLine Battery Cabinet to the UPS ssssssssseees 22 Miele H 25 Circuit breaker Inter TaCO s a intern tance gen tege obe depende die use epe deed ir 25 SOCOM Bou so MS LAU UM M a A PU ML A C AM PL C 27 Commu nicatlon cA I I M E 27 C stomet Interface setei ia audae dte bates tote bte re rettet 27 izle Nd ode Meteo tote 30 OperatioN e Aaii a E E E E I Ea 30 AAAA NO Mal Soa tes E N 30 Om Ball ioi Coes denn cos ES Once covet medcesdaneteres Conssuenwiscued ERUNI ARUM NUR cncteues RE RU ARE MERUE RUE PANE 30 jiener rri eee ee ee ee ee ee cere 30 IB To Ez UMC ONS RN E E TU 32 vip RTT EE eats tits 33 Initial SEQ ELID eai pte dac en e de cao ene dede d Dae tamea Cae tetra EP Mene bean 33 srinibge cie eu cT E 33 Testing the Emergency Lighting System 00 ceeeeceesccceeeeeeeeeeeeeeeeeeeeeeeeeeeeseeneaeeeeeeeees 34 Manual Transfer to Bypass ssssssssssssssssseeeeeeeeeeenene nennen nn nennmenrn nennen nnn 34 Manual Transfer to Myene sre Rod boo SU UE bo meer a brea 34 External Bypass Arrangement ssssssssssssssseeeeeeee eene nnne nnn nnn nnn 35 Automatic Transfer to BYPASS sss rasan tpe cis F
30. ency Lighting System Part Number Scheme Table 1 Part Numbering System System Part Number FLU924 8 20 N FLU924 8 20 B FLU924 8 20 N I FLU924 8 20 B I FLU924 8 42 N FLU924 8 42 B FLU924 8 42 N I FLU924 8 42 B I FLU924 8 44 N FLU924 8 44 B FLU924 8 44 N I FLU924 8 44 B I FLU924 12 20 N FLU924 12 20 B FLU924 12 20 N I FLU924 12 20 B I FLU924 12 42 N FLU924 12 42 B FLU924 12 42 N I FLU924 12 42 B I FLU924 12 44 N FLU924 12 44 B FLU924 12 44 N I FLU924 12 44 B I FLU924 16 20 N FLU924 16 20 B FLU924 16 20 N I FLU924 16 20 B I FLU924 16 42 N FLU924 16 42 B FLU924 16 42 N I FLU924 16 42 B I FLU924 16 44 N FLU924 16 44 B FLU924 16 44 N I FLU924 16 44 B I 208 120Y 208 120Y 208 Delta 208 Delta 480 277 Y 480 277 Y 480 Delta 480 Delta 480 277 Y 480 277Y 480 Delta 480 Delta 208 120Y 208 120Y 208 Delta 208 Delta 480 277 Y 480 277 Y 480 Delta 480 Delta 480 277 Y 480 277Y 480 Delta 480 Delta 208 120Y 208 120Y 208 Delta 208 Delta 480 277 Y 480 277 Y 480 Delta 480 Delta 480 277 Y 480 277 Y 480 Delta 480 Delta 208 120Y 208 120Y 208 120Y 208 120Y 208 120Y 208 120Y 208 120Y 208 120Y 480 277 Y 480 277Y 480 277Y 480 277Y 208 120Y 208 120Y 208 120Y 208 120Y 208 120Y 208 120Y 208 120Y 208 120Y 480 277Y 480 277 Y 480 277 Y 480 277Y 208 120Y 208 120Y 208 120Y 208 120Y 208 120Y 208 120Y 208 120Y 208 120Y 480 277 Y 480 277Y 480 277Y 480 277Y UPS Part Number FLU 10T 20 1
31. eries 2 to 5 years REPLACEMENT BATTERY Manufacturer Cat Number Quantity Required China Storage Battery HRL1280W 34 per string China Storage Battery HR1290W 34 per string All servicing should be performed by qualified service personnel Battery life is highly dependent on the ambient temperature and the number and depth of discharge cycles A discharged battery should be recharged as soon as possible If the battery is left in a discharged state irreversible sulfation occurs reducing the capacity run time of the battery Form No 003 2287 Rev D 42 Emergency Lighting System SECTION 10 FirstLine UPS Technical Specifications Table 11 Technical Specifications Input Voltage 208Y 480Y Three phase plus ground 208 Delta 480 Delta with optional isolation transformer I models Start up Range 10 10 From Nominal Operating Range 10 15 From Nominal Frequency 57 63 Hz Power Factor gt 0 98 At Full Load Current Distortion THD lt 5 At Full Load Input Current Nominal 28 40 52 at 208V Non Isolated Maximum 41 55 69 Input Current Inrush Walk In from 25 maximum to 100 full load rating in 5 seconds Output Voltage 208Y 480 Three Phase 4 wire plus ground Frequency 60 Hz 0 01 Voltage Regulation 1 balanced load 3 with 100 unbalanced load Voltage Transient Response lt 5 voltage change for 100 load step with rec
32. es are replaced by an incorrect type Replace with same type and rating only Proper disposal of batteries is required Refer to your local codes for disposal requirements Never dispose of batteries in a fire Batteries may explode when exposed to flame Form No 003 2287 Rev D 5 Emergency Lighting System SECTION 3 UPS Setup This section describes gt Equipment inspection gt Floor loading and clearances gt Removing and replacing the cabinet panels gt Unloading the cabinet s Inspecting the Equipment If any equipment has been damaged during shipment keep the shipping and packing materials for the carrier or place of purchase and file a claim for shipping damage If you discover damage after acceptance file a claim for concealed damage To file a claim for shipping damage or concealed damage 1 File with the carrier within 15 days of receipt of the equipment 2 Send a copy of the damage claim within 15 days to your service representative Clearances The following clearances are recommended for the FirstLine UPS From Front of Cabinet 36 91 4 cm working space From Back of Cabinet 6 15 2 cm From Side of Cabinet Minimum 24 61 cm The following clearances are recommended for the FirstLine Extended Run Time Battery Cabinet From Front of Cabinet 36 91 4 cm working space From Back of Cabinet 6 15 2 cm From Side of Cabinet to UPS Minimum 24 61 cm
33. ev D 9 Emergency Lighting System 10 00 254mm Max on Battery 4 13 00 330mm Max on UPS a im m 1 d Place forks in this area Leveling foot so as not to damage the leveling feet or casters Set forks to a maximum 13 inches at outside width on UPS cabinets amp 10 inches on battery cabinets Figure 5 Lifting fork area Placing the Cabinet Once the cabinet has been rolled into position remove the front panel to access the front leveling feet by pulling the panel outward at the bottom of the unit until it unsnaps and then lift up and off the cabinet see figure 9 Adjust the leveling feet as shown in figure 6 o r Lower the leveling foot to the floor to secure the UPS in position Figure 6 Leveling foot being adjusted down to the floor Form No 003 2287 Rev D 10 Emergency Lighting System SECTION 4 Electrical Installation The FirstLine has the following power connections gt 3 phase L1 L2 andL3 neutral and ground connection for rectifier oypass input gt 3 phase L1 L2 and L3 neutral and ground connection for load output The input neutral connection is not used when the UPS is equipped with the optional isolation transformer If the system is equipped with an isolation transformer the system part number will be FLU924 XX YY Z l where XX is 16 12 or 8 YY is 20 42 or 44 and Z is N or B That is the
34. ipped and connect all of the internal red and black power pole battery connectors in both battery cabinets 13 Install the internal covers on both battery cabinets and on the UPS Warning batteries must be connected to the UPS before the rectifier is started The rectifier starts automatically when the UPS is turned on All battery breakers must be closed prior to starting the UPS If a battery breaker is opened for any reason the UPS must be turned off before closing the breaker Refer to section 9 for additional information 14 Close the internal breakers and or external breakers for the battery cabinets 15 The UPS is now reagy to be started The outer covers can be installed as desired Form No 003 2287 Rev D 24 Emergency Lighting System SECTION 5 Circuit breaker interface Figure 16 shows the location of the optional circuit breaker interface connectors in the Battery Cabinet NOTE Wires to the battery breaker interface board must not enter the UPS or battery cabinet through the same port as the input output or battery power wires AUX SHUNT CONTACT TRIP j B BB n i i BATTERY BREAKER INTERFACE BOARD ASSY NO 825 0491 Input connector Output connector to next cabinet Figure 16 Battery Breaker Interface Board Assembly If the circuit breaker option is included in the battery cabinet attach one end of the provided 6 pin circular din molded cable to the input connector of the battery breake
35. is time If the UPS does not have an internal battery start by connecting the plug from the lowest battery string in the Extended Battery Cabinet to the plug from the input output panel If there is an external user supplied battery disconnect device it should be closed Measure the voltage at the external battery terminal block in the UPS with the positive lead of the meter on the left hand terminal and the negative lead of the meter on the right hand terminal The voltage measured should be positive If not the polarity of the connections is not correct If there is a second Extended Battery Cabinet measure the dc voltage in that cabinet from the left hand fuse positive lead of meter to the right hand fuse negative lead of meter The voltage measured should be positive If not the polarity of the connections is not correct Repeat this measurement for the third Extended Battery Cabinet if present The battery plugs for all strings in the Extended Battery Cabinet s can be connected at this time Stopping the Rectifier in the UPS Before connecting any batteries to the UPS the rectifier must be stopped The rectifier is stopped whenever the UPS is OFF The batteries are disconnected whenever the optional disconnect breaker s in the Extended Battery Cabinet s is are open or whenever the external user supplied battery disconnect device is open If the Extended Battery Cabinet s is are equipped with the optional disconnect breaker it i
36. mmodate bottom wire entry to the cabinet see figure 10 Remove plates and drill or punch hole to fit conduit bushing with Greenlee punch or similar device Make certain that the bushing will be clear in the opening in the base Mount bushing to plate and tighten to manufacturer s recommendations Replace the plates and mount conduit 7 00 177 8mm TYP POWER CABLE ENTRY SW jee An 3 25 82 6mm X 1 75 44 5mm p 2 12 54 0mm a E ee ee Due n Q NN 2 SWIVEL CASTERS 4 RIGID CASTERS ad i 4 LEVELING FEET o E CONTROL CABLE ENTRY 2 25 57 2mm X 1 75 44 5mm REAR Figure 11 Bottom View Battery Cabinet Form No 003 2287 Rev D 19 Emergency Lighting System Removing and Replacing the Front Panel JP Pull the top of the panel outward until the ball studs unsnap 2 Lift the panel up and off the cabinet To replace the panel f Lower the shoulder screws at the bottom of the panel into the keyhole slots on the cabinet 2 Press the panel inward until the ball studs snap into place KEYHOLE SLOT SHOULDER SCREW BALL STUD CATCH Figure 12 Removing the UPS Front Panel Check the Internal Battery To be performed by authorized service personnel 1
37. more Extended Battery Cabinets are connected to the UPS do not open the optional circuit breaker on any cabinet If the circuit breaker is open do not close the circuit breaker while the UPS is operating See Section 8 for the proper procedure to close the circuit breaker Testing the Emergency Lighting System This test must only be performed by authorized personnel Before testing the emergency lighting system verify that the system condition is normal The INVERTER indicator the INPUT indicator the Rectifier Indicator the Battery Indicator and the OUTPUT indicator should all be green The BYPASS indicator will also be green if the input is within specification for bypass operation Gain access to the circuit breaker that supplies the UPS Generally this breaker should have restricted access so that unauthorized personnel cannot disable the input to the emergency lighting system To initiate the test open the breaker The UPS should continue to operate but the Battery indicator on the front panel will change to yellow To terminate the test close the breaker that supplies power to the UPS The UPS will return to normal operation and the Battery indicator will change back to green The length of the test is up to the user A longer test gives additional confidence as to the condition of the battery but battery life is adversely affected by the number and depth of discharges Also the available battery run time is reduced as a fun
38. n the base Mount bushing to plate and tighten to manufacturers recommendations Replace the plate and mount conduit FRONT EXTERNAL BATTERY POWER EXTERNAL BATTERY CONTROL CABLE ENTRY CABLE ENTRY 2 25 57 2mm X 1 75 44 5mm 2 25 57 2mm X 1 75 44 5mm 4 75 120 7mm 4 755 120 7mm i L 2 12 54 0mm q Os Ki ver da LH q 2 SWIVEL CASTERS 2 RIGID CASTERS 4 LEVELING FEET se 81 20 6mm ug t T i POWER CABLE ENTRY p 4 75 120 7mm 7 25 184 2mm X 3 00 76 2mm REAR Figure 7 Bottom View Form No 003 2287 Rev D 12 Emergency Lighting System Wiring Installation Unscrew and remove the rear panel 2 Connect the input wires to the proper terminals shown in Figure 8 Insure proper phase rotation Connect the output wires to the proper terminals shown in Figure 8 Replace the rear panel mi od D m M D D NOTICE USE WIRI LEAST 75 C Figure 8 Terminal Blocks Table 4 Input Output Terminal INPUT OUTPUT
39. nal monitoring adaptor Form No 003 2287 Rev D 28 Emergency Lighting System Table 8 Torque Values for TB1 2 3 4 TORQUE VALUES FOR TERMINAL BLOCKS ON CUSTOMER INTERFACE BOARD 22 12 AWG 4 4 inch pounds Form No 003 2287 Rev D 29 Emergency Lighting System SECTION 7 Operation This Section contains information on how to use the FirstLine UPS including front panel operation UPS startup and shutdown Control Panel Functions The UPS has LCD with backlight It provides useful information about the UPS itself load status events measurements and setting see figure 21 p f Inverter Indicator Bypass Indicator Rectifier Indicator On Bypass Indicator gt en I DZ EY BET 9 9 Input Indicator Output Indicator Battery Indicator Alarm Indicator Figure 21 FirstLine Front Panel Display and Control Module To assure that the Emergency Lighting System is functioning properly observe the front panel display on the UPS There are three conditions that could exist System Normal everything is working as desired The INVERTER indicator the INPUT indicator the Rectifier Indicator the Battery Indicator and the OUTPUT indicator will all be green The BYPASS indicator will also be green if the input is within specification for bypass operation During normal operation the system will power the load with the inverter with the battery available in
40. oe on eme rro Era ee ro eR abe qr co ER pe mI A Es 13 Figure 9 Wiring Single Line DIagralri oio n D eoe oboe aspe cou d teet duxi is 17 Figure 10 Removing the Battery Cabinet Front Panel sssssssseeeeeee 18 Figure 11 Bottom View Battery Cabinet 19 Figure 12 Removing the UPS Front Panel uide deca einer a Lea chi ia Cu 20 Figure 13 Internal Batterie te te oe oa em em beoe matt 21 Figure 14 Input Output Panel esssssssssssseseeeeeneeenennn meer nnne nennen nnns 22 Figure 15 UPS COnhocllOnSs ias cen da cela coe nain nini cc cese due cadets nde qus i De Ra dude n nin edE 23 Figure 16 Battery Breaker Interface Board Assembly ssssssssssssss 25 Figure 17 Battery Breaker Gonfieolol uon Sr exc eoa rea o EE tou AX AR SABER Um AR ELIXUE 26 Figure 18 Communication Options and Control Terminals sesesesssss 27 Figure VON oo RIT Eo rrr rro 28 Figure 20 T4 uric suse tense LS SE Da dtque A eine i icta 28 Figure 21 FirstLine Front Panel Display and Control Module ssssssssss 30 Figure 22 Battery Tray sa desine erp Ie tomo tout ace ioi tdeductu noted det A mE 38 Figure 23 Battery Installation c cat oe m ducat qum iat sq aet du exei aeos iu eM D eM A E ELE 38 Table 1 Part Numbering System eeesssesessssssssssseeeeeennne eene nnnnnetennt nnn nnn 3 Table 2 SVmDOlS vocet det tetas ap Ir itte uec Sek sec tes esate doo
41. overy to less than 2 in less than 1 cycle Voltage Distortion THD lt 2 with linear load lt 5 with 100 non linear load Inverter Overload 100 continuous 125 for 2 minutes 150 for 1 second Bypass Overload 110 continuous 125 for 2 minutes 150 for 10 seconds 700 for 5 cycles Output Current Amp s at 208V 22 33 44 Heat Rejection BTU Hr 6800 7500 8200 Battery Operation Run time on battery 90 minutes 90 minutes 90 minutes Rated recharge time 168 hours 168 hours 168 hours Typical recharge time 24 hours 24 hours 24 hours Environmental Altitude Derate load capability above 1000 meters 196 per 100 meters Maximum Operating Temperature 40 C Non Operating Temperature 20 to 60 C Exceeding 0 40 C will degrade battery life Dimensions and Weights mm Kg Refer to Figures 1 and 2 in Section 1 and Table 3 in Section 3 Standards 208V and 480V Models UPS UL listed to 1778 NEMA PE 1 ASME ASA C 39 1 1984 FCC Part 15 Subpart J Class B NEC OSHA IEEE587 ANSI C 62 41 1980 ISO9000 System listed to UL 924 Run time is approximate and depends on the battery state of charge age operating temperature and other conditions Form No 003 2287 Rev D 43
42. per interface is mandatory to prevent damage to the UPS Automatic Transfer to Bypass The static switch will automatically transfer the load to bypass if the bypass input is qualified and one of the following conditions applies 1 Initial start up of UPS 2 The inverter is unable to support the load due to a failure b overload c battery reaches end of discharge voltage 3 Loss of output voltage is detected Automatic Transfer to Inverter The static switch will automatically transfer the load to inverter if all of the following conditions are true T The inverter has been started and is running normally 2 The inverter is phase locked to the bypass input 3 There was no manual transfer to bypass 5 There is no overload present 6 There have not been more than three overload caused transfers to bypass in a one hour period Over Load Inverter Load Time Supported 10096 Continuous 11096 2 Minutes 12596 30 Seconds When the overload limits are exceeded while running on inverter an automatic transfer to bypass occurs When the overload clears an automatic transfer to inverter occurs unless there have been three overloads within one hour Inverter overload performance is not guaranteed while running on battery Form No 003 2287 Rev D 35 Emergency Lighting System Bypass Load Time Supported 110 Continuous 125 2 Minutes 150 10 Seconds 700 5 Cycles When the o
43. permit access to the battery to battery connections when the trays are withdrawn from the cabinet If batteries are being replaced only use the same manufacturer and battery type and rating as the battery removed It is very important that only one tray at a time be extended from the cabinet If more than one tray is extended the cabinet can become unstable and topple over After each tray is installed or serviced it must be fully inserted and secured using the supplied threaded fasteners before attempting to install or service another tray If the trays are to be removed always remove the highest tray first The battery trays are very heavy and it will be necessary to use a lifting device to support the trays as they are removed When the trays are to be reinstalled use the procedure in the following paragraph WARNING Never connect the two cables from a battery tray or from a battery string two trays together as severe damage will occur resulting in fire and or injury Battery connections should only be made by a person wearing eye protection It is advised that eye wash be available If there are any doubts about the proper connections do not proceed Form No 003 2287 Rev D 37 Emergency Lighting System Extension limit tab a Notch Battery tray A bs Tray mounting screw Battery shelf Cutaway side view of battery tray batteries not shown for clarity Figure 22 Battery Tray 1 4 20 Gro
44. r interface board see figure 16 Attach the opposite end of the cable to the J1 battery breaker connector cable located in the front lower left of the UPS see figure 17 If more than one battery cabinet is used connect the additional cable from the J2 output connector on the battery breaker interface board in the first cabinet to the J1 input connector in the second cabinet and so on Form No 003 2287 Rev D 25 Emergency Lighting System CAUTION The battery breaker interface board is an electrostatic sensitive MEAN device The user should be grounded when connecting to this assembly Battery breaker connector in the Firstline UPS Battery control cable conduit mounting plate Battery power cable conduit mounting plate Figure 17 Battery Breaker Connector CAUTION If the optional circuit breaker trips the internal batteries of the UPS are still connected and providing power to the UPS Form No 003 2287 Rev D 26 Emergency Lighting System SECTION 6 Communication Figure 18 shows the location of the communication options and terminals on the UPS TB2 Contact sensing inputs terminal block TB3 Form C contact outputs terminal block TB1 REPO Bypass terminal block 4 TB4 Opto isolated outputs ATTE ETTHETEETETEI See HUGHIEHGEHEHDHD HEHEHEHEHE terminal block Jo RS 232 Connector d 120V O
45. s possible for a breaker to be opened during operation which requires that the rectifier be stopped before closing the breaker If the external user supplied battery disconnect device is opened during operation it is necessary to stop the rectifier before closing the device All breakers should be closed when the UPS is started Generally the only reason to open any of the battery disconnect devices is to perform service which requires that the UPS be turned off It is best to close the disconnect devices before starting the UPS and leave them closed during operation In the event of an emergency condition that requires opening a disconnect device it will be necessary to stop the rectifier in order to restore the system to normal configuration The simplest way to stop the rectifier is to turn off the UPS by pressing the power line circle button on the front panel This will remove power from the load Once the battery breaker s has have been closed the UPS can be restarted by pressing the power button If the UPS is connected to the load using a Maintenance Bypass Switch MBS the load can be maintained when the UPS is turned OFF Form No 003 2287 Rev D 40 Emergency Lighting System To transfer to MBS 4 Verify that the bypass source is available Bypass lamp on UPS mimic display is green Perform a manual transfer to bypass mode on the UPS by pressing and holding the ESC key while simultaneously pressing the UP ARROW key
46. to the left hand terminal and the negative wire goes to the right hand terminal If additional cabinets are to be added run the three wires from the first cabinet to the second using the right hand terminal block in the first cabinet and the left hand terminal block in the second cabinet If a third cabinet is present run the three wires from the second cabinet to the third using the right hand terminal block in the second cabinet and the left hand terminal block in the third cabinet Polarity Verification Procedure Check to make sure that all wiring is proper and secure and that all personnel are clear of hazardous circuits For this procedure the UPS should be off with no power applied Form No 003 2287 Rev D 39 Emergency Lighting System If the UPS has an internal battery connect it to the DC input connector If there is an external user supplied battery disconnect device it should be closed At the external battery cabinet measure the dc voltage from the left hand fuse positive lead of meter to the right hand fuse negative lead of meter The voltage measured should be positive If not the polarity of the connections is not correct The voltage measured during this procedure should be in the range of 400 to 445 Vdc depending on the state of charge of the battery Repeat this measurement for the other Extended Battery Cabinets if present The battery plugs for all strings in the Extended Battery Cabinet s can be connected at th
47. und terminal stud UPS extended run time battery cabinet connector Tray mounting screw A Bs Battery tray f assemblies Figure 23 Battery Installation Form No 003 2287 Rev D 38 Emergency Lighting System Special Considerations for Connection Batteries to the FirstLine UPS including Extended Run Time Battery Cabinets It is never safe to work within either the UPS or the extended battery cabinet while the UPS is powered The battery produces a lethal voltage whether or not the UPS is powered or running Always work with extreme caution No service work should be performed unless the personnel are properly trained and appropriate tools and equipment are available All batteries must be connected to the UPS prior to starting the rectifier The rectifier runs whenever the UPS is on If a battery is disconnected while the rectifier is running for example if the optional breaker on an extended battery cabinet is opened while the UPS is running it must not be closed without first stopping the rectifier This same precaution applies to opening the external user supplied battery disconnect device If one is present Connecting a battery while the rectifier is running will cause equipment damage that is not covered by the equipment warranty See the procedure below for stopping the rectifier It is essential that the Extended Battery Cabinet be connected with the proper polarity
48. utput receptacle EEHERERERH a fuse d IB 120V Output duplex receptacle L m C b IB REAR VIEW Figure 18 Communication Options and Control Terminals 120 Volt Output Duplex Receptacle The 120 volt receptacle is only to be used to power Staco supplied communications equipment It is imperative that no other loads be connected to this receptacle Note TB1 TB2 TB3 TB4 plug in terminal blocks fuse and fuse cap are shipped in the zip lock bag with this manual Install them before powering the UPS Customer Interface The Customer Interface is located on the rear cover of the UPS There are seven dry contact inputs that function as follows gt TB1 terminals 1 and 2 Remote Emergency Power Off REPO contact closure causes immediate shutdown of the UPS Contact the factory if a normally closed REPO switch is required gt TB1 terminals 3 and 4 Bypass Switch Sensing For future use Form No 003 2287 Rev D 27 Emergency Lighting System TB2 terminals 1 and 2 Battery Charge Inhibit For future use TB2 terminals 3 and 4 Reduced Current Operation For future use TB2 terminals 5 and 6 Automaitc Restart Inhibit For future use TB2 terminals 7 and 8 not defined YYY V V WV TB2 terminal 9 and 10 not defined There are five sets of form C dry contact available as outputs They are capable of switching up to 30 volts AC or DC at up to 1 amp Listed in order of NO
49. verload limits are exceeded while on bypass the static switch will turn off Note that external circuit protection devices may operate during overload conditions Rectifier The rectifier is microprocessor controlled using algorithms that limit the input current to levels that protect the rectifier components If the inverter requires more current than the rectifier can provide the battery will supply current as needed Thus the rectifier will supply as much energy as is available from the rectifier input At 80 input voltage the rectifier can support the rated inverter load but does not have any extra capacity to charge the battery At higher line voltages there is enough capacity to charge the battery while supporting rated load The rectifier uses an advanced high frequency Pulse Width Modulated design that presents low current distortion to the input power source Its high power factor means that maximum power is obtained for a given input current Form No 003 2287 Rev D 36 Emergency Lighting System SECTION 9 Battery Removal Installation and Service The batteries must only be serviced by authorized service personnel Before any battery service is attempted the batteries must be disconnected by unplugging the cables to the battery trays Before unplugging the cables the connections should be marked in a way that no confusion will exist when it is time to reconnect the cables The batteries are mounted in slide out trays that
50. wer limit Rectifier Red Rectifier failure or DC Bus Fault call for Service Battery Off System OFF Battery Green Battery is being charged or is at full charge Battery Yellow Battery is discharging Battery Red Battery fault or no battery present Inverter Off System OFF or on Bypass Inverter Green Running ON INVERTER normal mode Inverter Yellow Bus voltage out of range or tripped on over current Inverter Red Inverter failure call for service On Bypass Off System OFF or not on Bypass normal mode On Bypass Green ON Bypass On Bypass On Bypass overload present reduce load before system Yellow shuts down On Bypass Red Static Switch Failure Do Not Operate UPS call for Service Output Off System off Output Green Output is present On Inverter or on Bypass Output Yellow Output is overloaded reduce load before system shuts down Output Red Output failed or EPO was activated or REPO was activated Alarm Off No alarms are present Alarm Yellow An alarm is present Table 9 Indicator Status and Description Form No 003 2287 Rev D 31 Display Functions Emergency Lighting System As the default or after 15 minutes of inactivity the LCD displays the selectable startup screen The default is the Staco Energy Products Co logo and can be changed to the Mimic screen in the User Settings menu The backlit LCD automatically dims after a long period of inactivity Press any button to restore the screen Use the two middle buttons f

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