American Power Conversion 1609 Power Supply User Manual
Contents
1. 127 VAC 133 VAC utility voltage is chronically high set the high 130 VAC 136 VAC transfer point higher if the connected 230 V models equipment can tolerate this condition 253 VAC e 253 VAC 261 VAC 257 VAC 265 VAC Low Transfer Point 120 V models To avoid unnecessary use of the battery where 106 VAC 97 VAC 103 VAC utility voltage is chronically low set the low e 100 VAC 106 VAC transfer point lower if the connected equipment 230 V models can tolerate this cen 208 VAC 196 VAC 204 VAC The 1609 US500E ships ready for 230 V 200 VA 208 VA sources When operating the UPS in 208 V C c applications the UPS low transfer voltage settings are adjusted through PowerChute software or the Network Management Card The proper setting for low transfer voltage is 196 V Refer to the PowerChute user guide or the Network Management Card instructions for setting adjustment details Output Voltage 230 V models only Sets the output voltage of 230 V models 230 VAC e 220 VAC 240 VAC the UPS while operating on battery e 230 VAC Storage Maintenance Transport Storage Maintenance Transport Storage Store the UPS covered in a cool dry location with the batteries fully charged At 5 to 86 F 15 to 30 C charge the UPS battery every six months At 86 to 113 F 30 to 45 C charge the UPS battery every three months Replacing the Battery Module This UPS has an easy to replace hot s2. is being used Refer to the PowerChute user manual on the CD shipped with the software 13 Service and Contact Information Service and Contact Information Service If the UPS requires service do not return it to the dealer Follow these steps 1 Review the problems discussed in Troubleshooting to eliminate common problems 2 If the problem persists contact Rockwell Automation Customer Support Ifthe product is determined to be defective contact the distributor for typical return procedures Retain the battery and the Network Management Card when available 3 Pack the UPS in its original packaging Pack the UPS properly to avoid damage in transit Never use Styrofoam beads for packaging Damage sustained in transit is not covered under warranty Always DISCONNECT THE BATTERY before shipping in compliance with U S Department of Transportation DOT and IATA regulations The battery may remain in the UPS Contact Rockwell Automation Refer to Rockwell Automation at 440 646 5800 14 Safety Information SAVE THIS GUIDE This Safety Guide contains important instructions that should be followed during installation and maintenance of the equipment and batteries It is intended for customers who setup install relocate or maintain equipment Changes and modifications to this unit not expressly approved could void the warranty Handling Safety he lt 18 kg lt 40 Ib sie 32 55 kg 70 120 Ib X
3. th 18 32 kg 40 70 Ib nan gt 55 kg gt 120 Ib ks gt 10 Z caution Electrical Safety Do not work alone under hazardous conditions High current through conductive materials could cause severe burns Check that the power cord s plug s and sockets are in good condition Use qualified service personnel to change the plug on the UPS and to install permanently wired equipment When grounding cannot be verified disconnect the equipment from the utility power outlet before installing or connecting to other equipment Reconnect the power cord only after all connections are made Do not handle any metallic connector before the power has been disconnected Connect the equipment to a three wire utility outlet two poles plus ground The receptacle must be connected to appropriate branch circuit mains protection fuse or circuit breaker Connection to any other type of receptacle may result in risk of electrical shock 230V models only In order to maintain compliance with the Electro Magnetic Compliance directive for products sold in Europe output cords attached to the UPS should not exceed 10 meters in length 230V models only Total leakage current from connected equipment and the UPS must not exceed 3 5 mA for a pluggable A Type UPS Z caution Deenergizing Safety If the UPS has an internal energy source battery the output may be energized when the unit is not connected to a utility power outlet To
4. deenergize a pluggable UPS press the OFF button or switch to shut the equipment off Unplug the UPS from the utility power outlet Disconnect the external batteries where applicable and disconnect the internal battery see User Manual Push the ON button to deenergize the capacitors To deenergize a permanently wired UPS press the OFF button or switch to shut the equipment off Switch off the utility circuit breaker that supplies power to the UPS Disconnect the external batteries where applicable and disconnect the internal battery see User Manual ZA warnine Battery Safety This equipment contains potentially hazardous voltages Do not attempt to disassemble the unit The only exception is for a UPS containing batteries Refer to the battery replacement procedures detailed in the User s Manual Except for the battery the unit contains no user serviceable parts Repairs are to be performed only by qualified service personnel e Do not dispose of batteries in a fire The batteries may explode e Do not open or mutilate batteries They contain an electrolyte that is toxic and harmful to the skin and eyes e To avoid personal injury due to energy hazard remove wrist watches and jewelry such as rings when replacing the batteries Use tools with insulated handles e Replace batteries with the same number and type of batteries as originally installed in the equipment Replacement and Recycling of Batteries See your dealer or contact Rockw
5. 1609 Industrial Uninterruptible Power Supply User Manual Featuring Industrial Technology Installation and Operation 41063 222 01 1 990 1868 12 2004 Mount the UPS This unit is designed to mount on a heavy duty DIN rail or on the back panel of an enclosure For details on DIN rail installation refer to the DIN rail installation guide included in the DIN rail package The DIN rail kit is not included When mounting on the back panel of an enclosure select screws that are appropriate for the weight of this unit and the mounting surface material Six screws must be used when mounting this unit in an enclosure Three screws in the top of the bracket and three screws in the bottom of the bracket Failure to follow these instructions may result in damage to the unit Battery Installation The UPS battery is shipped in a separate carton Refer to the installation guide included with the replacement battery for installation instructions Front Panel m 120 V model depicted o 0 f 3808080828080808080 E e 8 e e OBGZOLOLG80L68580868 Fal 8 e e 3 ele a e e BES B ze i i 3 I 2 o Connect Power and Equipment to the UPS Hardwiring should be performed by a qualified electrician Use appropriate size wires L 1 The UPS features a transient voltage surge suppression 7VSS screw located on th
6. al to the EPO terminal The EPO interface is a Safety Extra Low Voltage SELV circuit Connect it only to other SELV circuits The EPO interface monitors circuits that have no determined voltage potential Such closure circuits may be provided by a switch or relay properly isolated from the utility To avoid damage to the UPS do not connect the EPO interface to any circuit other than a closure type circuit Use one of the following cable types to connect the UPS to the EPO switch CL2 Class 2 cable for general use CL2P Plenum cable for use in ducts plenums and other spaces used for environmental air CL2R Riser cable for use in a vertical run in a floor to floor shaft CLEX Limited use cable for use in dwellings and for use in raceways For installation in Canada Use only CSA certified type ELC extra low voltage control cable For installation in other countries Use standard low voltage cable in accordance with national and local regulations Operation Operation UPS Display Panel 120 V 208 230 V 0 oO o o 0 Q e o models i models 230R amp 230R amp 9 9 aa NR Ge spams sco ANAT sant QUIET QIOIO QIOIO Display Panel Indicators and Function Buttons Indicator i lt i LED Indicator Title Description A On Line The UPS is supplying utility power to the connected equ
7. e UPS is wired to input utility power The UPS is shut down or the battery is discharged from an extended outage None The UPS will restart automatically when utility power is restored and the battery has a sufficient charge The UPS is overloaded The Overload LED is illuminated and the UPS emits a sustained alarm tone The connected equipment exceeds the specified maximum load as defined in Specifications listed on the rating label located on the UPS The alarm remains on until the overload is removed Disconnect nonessential equipment from the UPS to eliminate the overload condition The UPS continues to supply power as long as it is online and the circuit breaker does not trip the UPS will not provide power from batteries in the event of a utility voltage interruption The Replace Battery Battery Disconnected LED is illuminated The Replace Battery Battery Disconnected LED flashes and a short beep is emitted every two seconds to indicate the battery is disconnected Check that the battery connectors are fully engaged Weak battery Allow the battery to recharge for 24 hours and perform a self test If the problem persists after recharging replace the battery Failure of a battery self test Replace Battery Battery Disconnected LED illuminates and the UPS emits short beeps for one minute The UPS repeats the alarm every five hours Allow the battery to recharge for 24 hours Perform the self tes
8. e front panel The TVSS screw is used for connecting the ground lead on surge suppression devices such as telephone and network line protectors Prior to connecting the grounding cable ensure that the UPS is NOT connected to utility or battery power 2 Hardwire the UPS In 230 V applications the UPS must be protected with a circuit breaker that complies with European standards for branch rated protection per the country of installation In 208 V applications the 1609 U500E must be protected by a dual pole 10 A branch rated circuit breaker with UL489 rating The 120 V 1609 US500N has supplementary circuit breaker protection The unit should be protected by a single pole 15 A branch rated circuit breaker with a UL489 rating Allen Bradley part number 1492 MCAA115 is suggested Ensure that the branch circuit breaker is off prior to wiring the unit 120 V models 208 230 V models INPUT INPUT 208 220 240V 50 60Hz 7A MAX OUTPUT 208 220 240V 50 60Hz 7A MAX 230V 50 60Hz 500VA 325W 2 7A MAX 3 Connect equipment to the UPS 4 Add optional accessories to the SmartSlot located on the front panel 5 Turn on all connected equipment To use the UPS as a master on off switch be sure all connected equipment is switched on OU 230V 50 60Hz 500VA 325W 2 7A MAX TPUT izil 6 Press the button on the front panel to start the UPS The battery charges to 90 capacity d
9. ell Automation at 440 646 5800 for information on replacement battery kits and battery recycling Be sure to deliver the spent battery to a recycling facility in the replacement battery packing amp material Pa h
10. ipment see Troubleshooting aa AVR Trim The UPS is compensating for a high utility voltage see Troubleshooting A AVR Boost The UPS is compensating for a low utility voltage see Troubleshooting On Battery The UPS is supplying battery power to the connected equipment Overload The connected equipment is drawing more than the UPS power rating allows ane see Troubleshooting Replace Battery Battery The battery is disconnected or must be replaced see Troubleshooting Disconnected Operation soy 2500 Diagnostic Utility The UPS has a diagnostic feature that indicates the utility voltage Voltage The UPS starts a self test as part of this procedure The self test does not 133 266 affect the voltage display 123 248 i ze Press and hold the button to view the utility voltage bar graph indicator 96 191 After a few seconds this five LED Battery Charge L indicator on the Battery right of the display panel will show the utility input voltage Charge Refer to the figure on the left for the voltage reading values are not listed on the UPS The indicator on the UPS shows the voltage is between the displayed value on the list and the next higher value see Troubleshooting Feature i Button Feature Title Function Power On Press this button to turn on the UPS Continue reading for additional capabilities Power Off Press this button to turn off the UPS Self Test Automatic The UPS perfor
11. ms a self test automatically when tuned on and every two weeks thereafter by default During the self test the UPS briefly operates the connected equipment on battery Manual Press and hold the button for a few seconds to initiate the self test Cold Start When there is no utility power and the UPS is off the cold start feature will switch the UPS and connected equipment onto battery power see Troubleshooting User Configurable Items User Configurable Items UPS settings Settings are adjusted through PowerChute software or optional Network Management Card Function Factory User Selectable Description Default Choices P Automatic Every 14 days e Every 7 days Set the interval at which the UPS will execute a Self Test 336 hours 168 hours self test On start up only e No self test UPS ID UPS_ IDEN Up to eight characters Uniquely identify the UPS i e server name or alphanumeric location for network management purposes Date of Last Manufacture mm dd yy Reset this date when you replace the battery Battery Date module Replacement Minimum Capacity 0 percent 0 60 Specify the percentage to which batteries will Before Return from 15 75 be charged following a low battery shutdown Shutdown 30 90 before powering connected equipment 45 Voltage Sensitivity High sensitivity High sensitivity The UPS detects and reacts to line voltage Medium sensitivity distortions by tran
12. pensive fuel powered generators may distort the voltage Test the input voltage with the utility voltage display see Operation If acceptable to the connected equipment reduce the UPS sensitivity Battery Charge and Load LEDs flash s imultaneously The UPS has shut down The internal temperature of the UPS has exceeded the allowable threshold for safe operation Check that the room temperature is within the specified limits for operation Check that the UPS is properly installed allowing for adequate ventilation Allow the UPS to cool down Restart the UPS If the problem persists contact Rockwell Automation at 440 646 5800 Diagnostic utility voltage All five LEDs are illuminated The line voltage is extremely high and should be checked by an electrician There is no LED illumination On Line LED Ifthe UPS is plugged into a properly functioning utility power outlet the line voltage is extremely low and should be checked by an electrician There is no LED illumination The LED is blinking The UPS is running on battery or it must be turned on The UPS is running an internal self test Software Network integration problem Network Management Card difficulties Refer to the Network Management Card user guide on the CD shipped with the Network Management Card Communication problems between the UPS and PowerChute software Ensure the correct communication cable 940 1524C
13. rnal fault Do not attempt to use the UPS Unplug the UPS and have it serviced immediately UPS beeps occasionally Normal UPS operation when running on battery None The UPS is protecting the connected equipment Press the button to silence this alarm UPS is not providing expected backup time The UPS battery s are weak due to a recent power outage or battery s are near the end of their service life Charge the battery s Batteries require recharging after extended outages Batteries can wear faster when put into service often or when operated at elevated temperatures If the battery s are near the end of their service life consider replacing the battery s even if the replace battery LED is not yet illuminated Left half Right half or Center section of front panel is flashing The UPS is experiencing an internal fault Do not attempt to use the UPS Unplug the UPS and have it serviced immediately All LEDs are illuminated and the UPS emits a constant beeping The UPS is experiencing an internal fault Do not attempt to use the UPS Unplug the UPS and have it serviced immediately Front panel LEDs flash sequentially The UPS has been shut down remotely through software or an optional accessory card None The UPS will restart automatically when utility power returns 11 Troubleshooting Problem and or Possible Cause Solution All LEDs are off and th
14. sferring to battery operation es to protect the connected equipment Low sensitivity nie i In situations of poor power quality the UPS may frequently transfer to battery operation If the connected equipment can operate normally under such conditions reduce the sensitivity setting to conserve battery capacity and service life Alarm Delay Enable Enable Mute ongoing alarms or disable all alarms Control e Mute permanently e Disable Shutdown Delay 90 seconds Os e 360s Set the interval between the time when the UPS 90s 4505 receives a shutdown command and actual 180s 540s shutdown e 270s e 630s User Configurable Items Factory User Selectable MST Function Default Choices Description Low Battery 2 minutes 2 5 8 11 14 PowerChute software interface provides Warning 17 20 23 minutes automatic unattended shutdown when approximately two minutes of battery operated run time remains The low battery warning beeps are continuous when two minutes of run time remain Change the low battery warning interval setting to the time that the operating system or system software requires to safely shut down Synchronized 0 seconds 0s e 240s Specify the time the UPS will wait after the Turn on Delay 60s 3005s return of utility power before start up to avoid 120s e 3605 branch circuit overload e 180s e 420s High Transfer Point 120 V models To avoid unnecessary use of the battery where 127 VAC
15. t procedure to confirm the replace battery condition The alarm stops and the LED clears if the battery passes the self test If the battery fails again it must be replaced The connected equipment is unaffected The input circuit breaker trips The connected equipment exceeds the specified maximum load as defined in Specifications listed on the rating label located on the UPS Unplug all nonessential equipment from the UPS Reset the circuit breaker The AVR Boost or AVR Trim LEDs are illuminated The system is experiencing very high or low utility voltage Have a qualified service personnel check your facility for electrical problems If the problem persists contact the utility company for further assistance 12 Troubleshooting Problem and or Possible Cause Solution There is no utility power There is no utility power and the UPS is off Use the cold start feature to supply power to the connected equipment from the UPS battery s Press and hold the button The unit will emit two beeps one short beep and one long beep Release the button during the second beep UPS operates on battery although line voltage exists The UPS input circuit breaker trips Unplug all nonessential equipment from the UPS Reset the circuit breaker Your system is experiencing very high low or distorted line voltage Move the UPS to a different outlet on a different circuit Inex
16. uring the first four hours of normal operation Do not expect full battery run capability during this initial charge period 7 For optimal computer system security install PowerChute monitoring software included with the UPS Connectors Communication Port A standard serial interface cable is incompatible with the UPS Use the cable supplied with the unit SERIAL PORT Contact Closure Port j mien The relays are connected from the common COM to the normally rill 7 com ON closed NC pins When the unit enters a low battery or on battery state ci enc BATTERY the appropriate relay will transition and connect the common COM to F No EOW the normally open NO pin lanc BATTERY The Contact Closure Port connection will automatically disable when a ae COM Network Management Card or the Serial Port connection are used Output Contact Ratings Parameter Value nominal switching capacity 1 A 30 VDC maximum switching power 30 W maximum switching voltage 60 VDC maximum switching current 2 ADC maximum carrying current 2 ADC surge ratings 2 kV per Bellcore TA NWT 001089 1 5 kV per FCC part 68 Emergency Power Off The emergency power off EPO feature is user configurable EPO provides immediate de energizing of connected equipment from a remote location without switching to battery operation Use a normally open contact to connect the EPO COM termin
17. wappable battery module Replacement is a safe procedure isolated from electrical hazards You may leave the UPS and connected equipment on during the replacement procedure Ensure battery replacement every 2 4 years Standard 40C battery Allen Bradley catalog number 1609 500SBAT High Temperature 50C battery Allen Bradley catalog number 1609 SOOHBAT Once the batteries are disconnected the connected equipment is not protected from power outages Refer to the appropriate replacement battery installation guide for battery module installation instructions See your dealer or contact Rockwell Automation at 440 646 5800 for information on replacement battery modules amp Be sure to deliver the spent battery s to a recycling facility or ship it to the address specified in the replacement battery literature Troubleshooting Troubleshooting Use this chart to solve minor installation and operation problems Refer to Rockwell Automation Tech Support at 440 646 5800 for further support Problem and or Possible Cause Solution UPS will not turn on The battery is not connected properly Check that the battery connector is fully engaged button not pushed The UPS is not connected to utility power supply a Press the Wst button once to power up the UPS and connected equipment Check that the UPS is properly connected to utility power UPS will not turn off The UPS is experiencing an inte
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