FEDERAL SIGNAL
UPS
UNINTERRUPTIBLE POWER SUPPLY
OWNERS MANUAL
IMPORTANT SAVE THESE INSTRUCTIONS
PLEASE READ THIS MANUAL BEFORE USING EQUIPMENT
PUBLISHED DECEMBER, 2003
ALL RIGHTS RESERVED:
REPRODUCTION WITHOUT
PERMISSION IS PROHIBITED
REVISION : 1
PART # 109916
FEDERAL SIGNAL UPS
TABLE OF CONTENTS
PAGE
INTRODUCTION
1.1
1. GENERAL DESCRIPTION
General
Benefits of Owning and Using the UPS
Using Your Ups - How It Works
2. SPECIFICATIONS
1.1 - 1.2
1.3
1.4 - 1.5
2.1 - 2.2
3. SIZING THE UPS
Installation Considerations
3.1
4. INSTALLATION, SET-UP AND START-UP
Receiving your UPS
Removing the UPS from the Pallet
Cabinet Dimensions, Access and Clearances
Installation and Wiring
AC Input Breaker, Wiring and Amperage Matrix
Set-Up and Start-Up Procedures
Applying Power
Changing Input Power
AC Input and Output Wiring 3.5K, and 5 K
AC Input and Output Wiring 7.5K
Battery Installation
Customer Satisfaction Checklist
5. COMMUNICATIONS (Also See Options)
4.1
4.2
4.3 – 4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
5.1 - 5.4
6. PRODUCT SUPPORT SERVICES
Warranty Validation Form
6.1
FEDERAL SIGNAL UPS
TABLE OF CONTENTS
PAGE
7. MAINTENANCE PROCEDURE
General Maintenance
Complete Maintenance Check
UPS Function Test
UPS Generator Test
Performance Checklist
7.1
7.1
7.2
7.2
7.3
8. TROUBLE SHOOTING
General Trouble Shooting Guide
System Circuit Diagram
9. PARTS LISTS
8.1
8.2
9.1
10. OPTIONS WITH INSTALLATION INSTRUCTIONS
Plugs, Receptacles and Distribution Panels
Bypass Switches
Other Options
Remote Emergency Power Off Push Button
Monophone Automatic Phone Dialer
Remote Annunciator
4X Communication Port Expander
2X Communication Port Expander
UPS Component Locations and Options Installation Diagram
10.1
10.2
10.3
10.3
10.3
10.3
10.3
10.3
10.4
FEDERAL SIGNAL UPS
INTRODUCTION
The Federal Signal UPS is a single phase, continuous duty, line interactive, single conversion Uninterruptible
Power System (UPS) designed to supply reliable, clean, regulated power for critical loads. An efficient ferroresonant transformer, microprocessor controlled solid state pulse width modulation inverter and long lasting
battery pack provide immunity to all line disturbances and power interruptions with no break in AC output power.
When using the UPS you are assured the integrity of your systems will not be corrupted.
GENERAL OPERATION
The synchronous inverter produces a true uninterrupted output in any mode of operation.
A self-diagnostic monitoring alarm system keeps operators continuously advised of the system status.
A RS232 ASCII Communications port is standard and allows a computer or LAN System to communicate with the
UPS. The communications have many features including:
- Monitoring - Input voltage, output voltage, battery voltage, output current, percent load, watts, KVA,
power factor, frequency, number of outages, number of overloads, UPS on.
- Alarms - Low battery warning, on battery, overload, low output, high output, check battery,
frequency fault, overtemp.
- Set Points - You may customize the operation of the UPS for your special requirements.
- Auto Shutdown - Warns users of limited battery time and performs an orderly unattended shutdown.
- Alarm Contacts - UPS on, AC power failure, low battery, alarm, remote emergency power off.
CONSERVATIVELY RATED
The UPS is conservatively rated for non-linear loads with crest factors as high as 3:1 and 0.7 power factors.
FUZZY LOGIC AND ENVIRONMENTAL ADAPTIVE CONTROL
Fuzzy Logic is used to self-adjust to the incoming power and deliver exact output power to your systems without
wasting valuable battery time even during brownouts. Soft utility lines and engine generators produce severe
input voltage distortion that cause UPS detection circuits to misjudge real power failures. Environmental Adaptive
Control eliminates this problem by capturing the input voltage waveform and using artificial intelligence to make
detection decisions. This again preserves valuable battery time.
NORMAL OPERATION
The UPS is comprised of a microprocessor controlled PWM static inverter; highly filtered current and voltage
limited precision battery charger, diagnostic display and output power distribution.
Under normal operating conditions, the critical load is supported by AC power, filtered and regulated through a
ferro-resonant transformer. When AC power is present the battery charger maintains a ripple free float charge on
the batteries.
Page 1.1
EMERGENCY OPERATION
Upon failure of commercial AC power, battery power is converted by the PWM inverter and filtered through the
on-line power purification system. There is no interruption of regulated and conditioned power to the critical load
upon failure or restoration of the commercial AC power. The entire UPS operates from the front panel with status
signals available through a bi-directional RS232 port.
Battery sensory circuits warn you if your batteries are in need of attention and disconnect the batteries when
discharge reaches a critical level.
BATTERY AND CHARGER
The battery packs are pre-wired, pre-tested and are contained within the inverter cabinet. They are sealed no
maintenance recombinant lead acid batteries. Run time may be extended by adding Battery Extensions.
External battery cabinets are pre-wired and pre-tested, hook-up ready and match the inverter cabinet.
Precision controlled to 1%, highly filtered, current limited and voltage regulated battery charger sustains float
charge on the battery continuously affording maximum, battery life.
PROTECTION
INPUT - Integrally mounted molded case AC and DC circuit breaker protects against abnormal current overloads
and provides a convenient means of disconnecting utility or DC power.
OUTPUT - Ferro-resonant transformer, provides inherent overload protection. Output fuses or circuit breakers
are also utilized for added protection.
Page 1.2
BENEFITS OF OWNING AND USING THE UPS
* Environmental Adaptive Control
* True On-Line Protection
* Power Factor Correction
* Line Harmonic Filtering
* Small Physical Size
* Simple and Inexpensive Installation
* Highly Efficient
* Quiet Operation
* Low BTU Output
* Microprocessor Control and Diagnostics
* Automatic Synchronized Retransfer
* Multiple Input and Output Voltage Selection
* Casters Provide Simple Relocation and Installation
* Priced to be Affordable
* 200,000 Hour MTBF Transformer
* Extremely High Surge Capability
* 3:1 Crest Factor for Non Linear Loads
* Simple Operation
* Early Power Warning Communication for Unattended Computer Shutdowns
* Full RS232 Communication of Operating Parameters
* Input and DC Thermal Magnetic Circuit Breakers
* Nation Wide Customer Support Service
Page 1.3
USING YOUR UPS - HOW IT WORKS
1
FRONT VIEW OF UPS
2
3
4
5
6
1.
Input Volts- LED on indicates unit is monitoring the
input voltage via the digital display. This function is
activated by pushing the display select button.
2.
Output Volts- LED on indicates unit is monitoring the
output voltage via the digital display. This function is
activated by pushing the display select button.
3.
Percent Load- LED on indicates unit is monitoring
the output load capacity relative to maximum watts
via the digital display. This function is activated by
pushing the display.
4.
Percent Battery- LED on indicates unit is monitoring
the battery charger when UPS is on utility power.
Note: When UPS is on battery power the Percent
Battery monitors actual battery time left via the digital
display. This function is activated by pushing the
display select button.
5.
Display Select- This pushbutton selects one of four
monitor functions mentioned above and displays the
results on the digital display. Also used for manual
restart after rundown.
6.
Digital Display- Three-digit display monitoring the
four functions mentioned above.
This display
monitors one function at a time and is selected by
the “Display Select” pushbutton.
7.
System On- LED on indicates the correct AC input
voltage is present. The units AC and DC circuit
breakers must be on. LED will remain on when unit
is on battery power.
7
8
9
10
12
11
13
8. System On Battery- LED on indicates the UPS is on battery power accompanied by an audible alarm. The UPS may switch to
battery power even when it appears there are not power outages. The reason is that the UPS detects input sags and surges
and does not necessarily require a total power loss to switch to battery power. The UPS will remain on battery power
for a few seconds after normal AC power is restored.
9. Low Battery- LED on indicates batteries are low and a total UPS shutdown is immanent unless AC power returns. This alarm set
point is user selectable via the communications port (see communications section) to turn on at a pre-determined percentage of
battery time remaining. Percentage is selectable from 10 % to 90% of battery remaining.
10. Alarm- LED on is accompanied by an audible alarm. For a number of alarm functions (see communications section). Alarm will
clear automatically once the alarm condition is resolved.
11. Battery Circuit Breaker- Connects or disconnects the battery pack.
12.
AC Circuit Breaker- Connects or disconnects the AC utility power.
13.
Stack Pack – Battery compartment.
Page 1.4
USING YOUR UPS - HOW IT WORKS
REAR VIEW OF UPS
1
2
5
1.
Mode selection switch:
Position 4- Audible Alarm-on/off.
Causes of alarm
-Loss of AC power
-Low battery warning
-Frequency Fault
-Check Battery
-Shorted SCR
-Low battery shutdown
3
Position 3- Automatic Restart- on/off.
(On = Auto Start)
-The UPS will automatically restart
When facility power is restored
following a power down caused by a
low battery condition. All other power
down conditions will require a manual
restart.
4
6
9
Position 2- Slew Rate Fast-on/off.
-For use with unstable line or
generators.
*Only 1 position (1) or (2) must be on
at one time. Do not change with UPS on.
7
Position 1- Normal Slew Rate-on/off.
-This is preset by the factory and need
not be changed unless the UPS will
be operated with rapid input
frequency variations, such as gas
driven engine generators.
8
2. J1 communication port.
3. Input voltage selection switch. Preset at the
factory. (See changing input power section
before changing this switch).
-Low Output
-High Output
-Overload
- Overtemp
4. Specification Tag:
KVA
Input Voltage
Input Current
5.
6.
7.
8.
9.
Output Voltage
Output Current
Cooling Fan
Input / Output Access Plate
Input / Output Terminal Block
Stack Pack – Battery compartment
Input Conduit Hole
Page 1.5
SPECIFICATIONS
INPUT
OUTPUT
KVA RATINGS
120 or 208 or 240 VAC at 50 or 60 Hz
Other voltages available
Sine wave voltage: Maximum 3%
Harmonic distortion, any single harmonic
Output is rated for computer-type
loads with switch mode power
supplies.
Operating rating: +10*% to -30% under a
typical load; +10% to -15% at full load
at 60Hz:
120VAC: 120/208 VAC:120/240 VAC
Frequency range: ± 2.5Hz
Power factor: self correcting to >0.95
(approaching unity)
at 50Hz
220VAC: 110/220VAC
Extended Emergency back up
available.
Crest factor: 3.5:1
Reflected Input harmonics: <3% THD
(total harmonic distortion)
K factor: 30 or better
Spike Attenuation: 3000:1
Power factor: 0.7 switch mode rated
Harmonic attenuation: load generated
harmonics are attenuated 400% at the
input
Line regulation: typically better than ±3%
Load regulation: typically better than ±3%
Note: Efficiency ratings for 3.5 KVA - 5 KVA is 89%, ratings for 7.5 KVA is 91%.
Note: Audible noise full load for 3.5 KVA - 5 KVA is 50 dBA, audible noise for 7.5 KVA is 51 dBA.
Federal Signal Model Number System
U35-30-120-S
KVA Size
Battery back-up
time in Minutes
Input Voltage
Cabinet Style
Page 2.1
BATTERY TIME, CABINET DIMENSIONS, AND WEIGHT
FS MODEL #
BACK UP TIME
(MINUTES)
DIMENSIONS
WEIGHT
U35-30-120-S
U35-60-120-S
U35-30-120-R
U35-60-120-R
U35-30-208-S
U35-60-208-S
U35-30-208-R
U35-60-208-R
U35-30-240-S
U35-60-240-S
U35-30-240-R
U35-60-240-R
U50-30-120-S
U50-60-120-S
U50-60-120-R
U50-60-120-R
U50-30-208-S
U50-60-208-S
U50-30-208-R
U50-60-208-R
U50-30-240-S
U50-60-240-S
U50-30-240-R
U50-60-240-R
U75-30-120-S
U75-60-120-S
U75-30-120-R
U75-60-120-R
U75-30-208-S
U75-60-208-S
U75-30-208-R
U75-60-208-R
U75-30-240-S
U75-60-240-S
U75-30-240-R
U75-60-240-R
30
60
30
60
30
60
30
60
30
60
30
60
30
60
30
60
30
60
30
60
30
60
30
60
30
60
30
60
30
60
30
60
30
60
30
60
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
19” x 29.81” x 36.44”
19” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
19” x 29.81” x 36.44”
19” x 29.81” x 36.44”
15” x 29.81” x 36.44”
15” x 29.81” x 36.44”
19” x 29.81” x 36.44”
19” x 29.81” x 36.44”
15” x 29.81” x 42.44”
15” x 29.81” x 42.44”
19” x 29.81” x 42.44”
23” x 29.81” x 42.44”
15” x 29.81” x 42.44”
15” x 29.81” x 42.44”
15” x 29.81” x 42.44”
23” x 29.81” x 42.44”
15” x 29.81” x 42.44”
15” x 29.81” x 42.44”
19” x 29.81” x 42.44”
23” x 29.81” x 42.44”
462
587
462
587
462
587
462
587
462
587
462
587
553
707
553
707
553
707
553
707
553
707
553
707
857
1151
857
1151
857
1151
857
1151
857
1151
857
1151
Page 2.2
SPECIFICATIONS
BATTERY
COMMUNICATIONS INTERFACE
Runtime listed at full and half load for each model number
with extended runtimes available beyond this standard
Status and alarm port: Used for network protection and
unattended, automatic shutdown for all LAN/WAN systems
such as Novell, LAN Manager, OS/2 and others including
UNIX and ZENIX operating systems.
Type: sealed, maintenance-free, gas recombinant, selfventing, suspended electrolyte with no gel contaminant
Charger: 3 amp, two stage, temperature compensated, not
to exceed 25% of the amp hour rating
Full duplex ASCII, RS/232 Serial port; this port provides over
50 operating, diagnostic and performance characteristics.
Recharge time: typically 3 hours to full charge
ENVIRONMENTAL
Buss voltage: 48 volts dc, 3.5 – 5 KVA; float 2.27 vdc - final
1.75 vpc, 96 volts dc 7.5 KVA
Isolation: NEC article 250 -5d; complies with this standard
that specifies a separately derived power source
Factory tested with specific inverter before shipping
Operating temperature: 0 (32) to 40 (105) degrees Celsius
(F) without derating in any mode
Projected life: 5 years service
Capacity: batteries are sized with the inverter to support the
load at rated KVA with a 0.7 power factor
PERFORMANCE
Storage temperature: -20 to 50 degrees Celsius
Relative humidity: 95% non-condensing
Elevation: 5,000 feet, 1500 meters
Overload capacity: 125% for ten minutes
MTBF
Surge Capability: 150% of rated output without need of
static bypass
Total system - 100,000 hours MIL Spec standard 217E
Frequency stability: ± 0.2 Hz
Transformer - 200,000 hours
Inner winding capacitance: 0.01 pico farads (primary to
secondary coupling)
Mean time to repair - less than one hour
Common mode: 120 dB (106 : 1 ground noise attenuation)
(-3 dB at 1 kHz; -20 dB per decade)
SAFETY
Reactive power correction: load at .6 pF corrected to > .95 at
input (automatically self-correcting)
UL Listed 1778 standard for UPS equipment
CSA certified
Fuzzy Rangingtm Human-like decision making to optimize
useable input line voltage without use of batteries. Range
without battery consumption to 61% of nominal input
voltage.
FCC article 15, section J, Class A means it will not interfere
with any other electronic device, including your computer or
phone.
DISPLAY MONITORS AND DIAGNOSITCS
AGENCIES
Digital, 3 digit, bright LED providing system parameters:
IEEE 587 category B guide for surge suppression, exceeds
by 33%
• Input Voltage
• Percent of Load • Percent of Battery Charger
• Output Voltage • Percent of Battery Capacity
LED indicators providing system status:
System On (Green)
System On Battery (Yellow)
Low Battery Warning (Red)
The following are accessible through the J1 port:
• Low Output
• Over temperature
• Output Shutdown
• High Output
• Shorted SCR Shutdown
• Inverter On
• Overload
• Low Battery Shutdown
• Low Battery
• Frequency Fault
• Weak Battery
• Remote/Emergency Power Off Shutdown
Audible Alarm:
• Switch Selectable
•
ANSI/IEEE C62.41 and .45 category A and B
FAA - G - 201e power factor specifications
CBEMA and ANSI C84.1 - exceeds specifications and
recommendations
IEEE 519
Federal Signal reserves the right to change specifications and design without notice as part of our policy of continual
improvement of products and technology.
Page 2.3
SIZING THE UPS
When sizing the UPS, be sure to take into consideration all loads and circuits the UPS is to supply. A good way
to insure that the UPS is sized properly is to use the following guide lines.
- List each piece of equipment, include Model, Voltage, Current and KVA.
- Gather the data by reading the spec plate of the equipment you plan on backing up. Make sure your
equipment's input voltage matches the UPS output voltage.
- Consult the vendor of the computer equipment to supply you with the information you need.
- Add up the total KVA of the equipment and make sure it does not exceed the UPS KVA rating.
INSTALLATION CONSIDERATIONS
Prior to installing the UPS be sure to take into consideration the site you have selected. UPS systems produce
heat and therefore require ventilation as well as accessibility. Consider these factors.
- Ventilation
- Input Source Voltage
- Size of the UPS
- Receiving Facilities
- Weight Load
- Available Single Phase KVA
- Noise Requirements
- Room Temperature
- Audible
- Distance of Inverter to Critical Load
- Clearances
- Accessibility
- Excessively Long Power Runs
- Proper Ground Techniques
- Generator Applications
- Distribution of Power
- Communications (i.e. Early Power Warning Feature)
- Remote Emergency Power Off (REPO)
- Monitors
- Extended Battery Run Times
- Options
Page 3.1
RECEIVING THE UPS
*** INSPECTION, PLACEMENT, INSTALLATION, SET-UP ***
AND START-UP SHOULD BE PERFORMED
BY QUALIFIED PERSONNEL
*** WARNING ***
HIGH VOLTAGE EXISTS, CAUTION MUST BE TAKEN
WHEN WORKING NEAR THE BATTERY TERMINALS.
POWER IS SUPPLIED BY MORE THAN ONE SOURCE.
MAKE SURE BOTH AC AND DC CIRCUIT BREAKERS
ARE OFF BEFORE INSTALLING OR SERVICING THE UPS
INSPECTION
Upon receipt of your UPS visually inspect the unit for shipping damage. If shipping damage has occurred the
purchaser should promptly notify the carrier and file a claim with the carrier. Federal Signal should be notified if
the damages may impair the operation of the unit.
Call 1-708-534-4756
Note: Be sure to remove the cover and inspect inside the unit for shipping damage.
STORAGE
If it is necessary to store the unit be sure to place it in a clean dry area. It is advisable to protect the unit by
replacing it in the original container. For extended storage the battery must be charged for 24 hours every 6
months. This is accomplished by hooking up and turning the UPS on. Make sure proper ventilation is available
anytime the UPS is on.
PLACEMENT
The portability of the system allows the unit to be rolled into a convenient location. The minimum spacing
required for service, ventilation, and accessibility to the circuit breakers is (2) two feet at the left, rear and front
side of the cabinet.
If flexible conduit is used for input power and distribution, the rear clearance can be reduced to ten inches.
Allowance must be made in the length of the cable so that the unit can be rolled out forward for service.
Page 4.1
THE FEDERAL SIGNAL UPS
REMOVING THE UPS FROM THE PALLET
TOOLS REQUIRED.
1/2” Wrench
Hammer
STEPS TO REMOVE THE CABINET
1.
2.
3.
4.
5.
Check to make sure the casters are locked.
Remove the bolts holding the brackets to the skid with a 1/2” Wrench.
Remove the brackets
With a hammer, knock out one end of the skid as shown below.
Unlock the casters and carefully roll the unit down the ramp.
Page 4.2
THE FEDERAL SIGNAL UPS
CABINET DIMENSIONS, ACCESS AND CLEARANCES
Page 4.3
THE FEDERAL SIGNAL UPS
CABINET DIMENSIONS, ACCESS AND CLEARANCES
Page 4.4
THE FEDERAL SIGNAL UPS
CABINET DIMENSIONS, ACCESS AND CLEARANCES
Page 4.5
THE FEDERAL SIGNAL UPS
CABINET DIMENSIONS, ACCESS AND CLEARANCES
Page 4.6
THE FEDERAL SIGNAL UPS
CABINET DIMENSIONS, ACCESS AND CLEARANCES
Page 4.7
THE FEDERAL SIGNAL UPS
INSTALLATION AND WIRING
TOOLS REQUIRED AND INSTALLATION CHECKLIST
_______ Flat Head and Phillips Head Screw Driver
_______ The AC input breaker, wiring and amperage matrix defines the proper AC breaker size for the
appropriate KVA. Refer only to the matrix for the service panel AC breaker size. The UPS comes
standard with terminals for hard wire installation.
For Input Wiring, Refer To the Section "AC Input Breaker,
Wiring and Ampereage Matrix” Page 4.9.
_______ All 208/240 VAC UPS systems will operate without the neutral wire at the input of the
system, however, the neutral wire is required when bypassing the system without the use of the VPXT
(Voltage and Phase Correction Transformer) option.
_______ Do not attempt to change the plug supplied with the equipment. Federal Signal offers
receptacle/plug converters that will allow you to match most standard receptacles.
_______ All the UPS requires a ground wire. The ground wire should be the same size as the input
feed wires. The ground that feeds the UPS should be of good integrity and dedicated to the UPS. The
run should be as short as possible. Conduit cannot be used for the grounding of the circuit.
Reference: NEC 250-5 and 250-6
_______ Systems using the VPXT option, do not require the neutral from the AC source panel. The VPXT
recreates the neutral and generates a new neutral ground bond in accordance with the National Electric
Code.
_______ The System is designed to operate on the primary power you select. Verify that the available power
source meets the voltage and current requirements. Under no circumstances should the primary not
conform to the UPS operating voltage you have selected.
_______ If this voltage is not correct for your application refer to section "Changing Input Voltage." Page 4.12.
_______ The input plug is 120 or 240 volts unless tagged for 208 volts.
Page 4.8
THE FEDERAL SIGNAL UPS
AC INPUT BREAKER, WIRING AND AMPERAGE MATRIX
KVA
KW
AC LINE
VOLTAGE
SERVICE
PANEL AC
BREAKER
NO. OF
INPUT
WIRES
REG.
OUTPUT
VOLTAGE
OUTPUT
CURRENT
3.5
3.5
3.5
5
5
5
7.5
7.5
7.5
2.5
2.5
2.5
3.5
3.5
3.5
5.3
5.3
5.3
120
208
240
120
208
240
120
208
240
40
25
20
50
30
30
80
50
50
3W
4W
4W
3W
4W
4W
3W
4W
4W
120 / 240
120 / 240
120 / 240
120 / 240
120 / 240
120 / 240
120 / 240
120 / 240
120 / 240
29
16.8
14.6
41.7
24
20.8
62
36
31
NOTE: Output currents at 120 volts (from 3.5K to 7.5K) are derived from the addition of two line to neutral loads.
Page 4.9
THE FEDERAL SIGNAL UPS
SET-UP AND START-UP PROCEDURES
*** DO NOT ATTEMPT TO OPERATE THE ***
UNIT UNTIL THE FOLLOWING STEPS HAVE
BEEN COMPLETED
_______ Prior to turning on the power and starting the UPS, it is very important to check out the mode in which
you intend to operate the system.
_______ All operating parameters are factory set to standard operating modes.
_______ Selector switch S1 and S2 at the rear of the UPS allows you to change the mode operation that best
suits your specific needs.
SELECTOR SWITCH S1 (DIP SWITCH SELECTING)
Operating Mode
Position 1 - Slew Rate Normal (factory set to normal). Do not change switch with UPS on.
*Position 2 -Slew Rate Fast - This selection is typically used when the UPS must follow a rapidly changing input
frequency. I.E.....engine generators. Do not change switch with UPS on. NOTE: Only one switch
must be on at a time for Positions #1 and #2..
Position 3 - Manual or Automatic Restart - (Automatic Restart - following a power down caused by depleting the
battery power, the UPS will automatically start upon restoration of utility power). This selection can be
changed with the UPS on. Manual restart requires pushbutton at front of unit to be reset. ON = Auto
Restart, OFF = Manual Restart.
Position 4 - Audible Alarm - (Off to silence audible alarm). This selection can be changed with the UPS on.
* DEFAULT
SELECTOR SWITCH S2 (DIP SWITCH SELECTING)
Input Voltage
Do not change this setting without changing or verifying that the input wiring matches the input voltage selection.
(See Changing Input Voltage on Page 4.12).
Page 4.10
THE FEDERAL SIGNAL UPS
APPLYING POWER
_______ Re-install all panels that may have been removed during installation.
_______ Verify the input voltage matches the UPS input volts and the UPS output voltage matches your
equipment’s input voltage.
_______ Turn off all loads attached to the UPS.
_______ Using the line cord and plug supplied, plug in the UPS or for hardwire installation turn on the input
service breaker.
NOTE: Batteries require charging for 6 to 8 hours. Backup time is reduced until batteries are fully
charged.
_______ Turn on the battery and utility breaker. There will be a few seconds delay as the unit comes on. The
digital display and "System On" LED will illuminate. Scroll to the "Output Volts" function and make sure
the output voltage is correct.
_______ Verify the output voltage on the UPS matches the load requirement. Do not plug your equipment in if
output voltage is out of spec, contact factory.
_______ Simulate a power loss by turning off the UTILITY BREAKER ONLY, located on the front of the UPS. An
"Audible Alarm" will sound and the following LED's will illuminate.
- System On
- System on Battery
- Alarm
_______ While on inverter, verify the output voltage on the UPS matches the load requirement while on batteries.
Do not plug your equipment in if output voltage is out of spec, contact factory.
_______ Turn on the Utility breaker and the UPS will return to utility power.
_______ With the UPS running and “System On” LED illuminated, turn on the output circuit breakers and loads.
_______ Some loads start hard and may cause the UPS to display a temporary overload. This is normal and in
no way damage the UPS.
_______ If the overload (typically to much equipment connected to the UPS) persists and is in excess of 150%
the UPS will shut off within one minute. If the unit is overloaded , some equipment will have to be
removed or the UPS must be expanded.
Call Customer Support for any questions during start up at 1-708-534-4756.
Page 4.11
THE FEDERAL SIGNAL UPS
CHANGING INPUT VOLTAGE
CAUTION: HIGH VOLTAGES - ONLY QUALIFIED ELECTRICIANS SHOULD SERVICE.
_______ Turn off all power (open AC and DC breaker on the front of the unit) and unplug the UPS prior to
performing the following steps.
_______ Locate the input terminal strip through the rear access of the UPS.
_______ The illustrations on Page 4.13 and 4.14 display the method in which the wiring at the input terminal
must be connected for your selected voltage.
*** IMPORTANT ***
_______ Selector Switch 2, at the rear of the UPS, must match the input voltage selection.
* No transformer tap is provided in standard unit. Consult factory for applications of this voltage.
*** CAUTION ***
When using bypass switches, changing the input voltage may negate the bypass function. Be sure that
the input and output of the UPS are the same. Contact the Customer Support Department at Federal
Signal at 1-708-534-4756 if you have any questions.
Page 4.12
THE FEDERAL SIGNAL UPS
AC INPUT AND OUTPUT WIRING FOR 3.5 KVA AND 5 KVA
Note: To change output voltage a pre-wired output connector and receptacle
panel is required. Contact factory.
*** WARNING ***
CAUTION RISK OF ELECTRICAL SHOCK. THE UPS
RECEIVES POWER FROM MORE THAN ONE SOURCE.
BE SURE BOTH UTILITY AND BATTERY CIRCUIT
BREAKERS ARE IN THE OFF POSITION BEFORE SERVICING
Page 4.13
THE FEDERAL SIGNAL UPS
AC INPUT AND OUTPUT WIRING FOR 7.5 KVA
*** WARNING ***
CAUTION RISK OF ELECTRICAL SHOCK. THE UPS
RECEIVES POWER FROM MORE THAN ONE SOURCE.
BE SURE BOTH UTILITY AND BATTERY CIRCUIT
BREAKERS ARE IN THE OFF POSITION BEFORE SERVICING.
Page 4.14
THE FEDERAL SIGNAL UPS
BATTERY INSTALLATION
**** WARNING ****
CAUTION RISK OF ELECTRICAL SHOCK. THE UPS
RECEIVES POWER FROM MORE THAN ONE SOURCE.
BE SURE BOTH UTILITY AND BATTERY CIRCUIT
BREAKERS ARE IN THE OFF POSITION BEFORE
SERVICING.
KVA
3.5
5
7.5
DC/BUS
48
48
96
Page 4.15
FEDERAL SIGNAL UPS
CUSTOMER SATISFACTION CHECKLIST
The employees at Federal Signal strive to produce and maintain quality UPS’s. All facets from installation
through to operation are reviewed so that the unit is the easiest to install and operate. We listen to our customers
suggestions and recommendations. This insures that you receive equipment with the most current technology
and functionality.
We value your suggestions and recommendations. Please take the time to fill out the following form. Your
comments allow Federal Signal to better serve you.
SATISFACTORY TO POOR
How was the unit upon arrival?
Was the installation simple?
Was the start-up simple?
Do you find the UPS easy to operate?
Is the information clear and concise?
Does the UPS meet your expectations?
Do you feel the UPS has enough capacity to fulfill your growth needs?
Are the ergonomics of the UPS satisfactory?
How was the communications with the factory or the representative?
1
2
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
_____
3
_____
_____
_____
_____
_____
_____
_____
_____
_____
4
_____
_____
_____
_____
_____
_____
_____
_____
_____
CIRCLE ONE
Did the UPS solve a previous power problem?
Do you have future applications?
Do you have any other UPS needs?
Is the UPS located in a computer room?
Is the UPS maintained under a service contract?
Would you like information on our Customer Support Plan?
Would you recommend Controlled Power to others?
Yes
Yes
Yes
Yes
Yes
Yes
Yes
or
or
or
or
or
or
or
No
No
No
No
No
No
No
What type and model of equipment is the UPS supporting?
__________________________________________________________________________________________
__________________________________________________________________________________________
Comments
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
Complete and return to: Federal Signal
Integrated Systems Group
2645 Federal Signal Drive
University Park, IL 60466
Phone 1-708-534-4756
Page 4.16
COMMUNICATIONS
The UPS provides complete diagnostic and operating status. The signals are available through a DB 25 Pin
Female connector labeled J1 on the rear of the unit.
Three methods can be used to communicate with the UPS:
- Direct connect to a terminal.
- Direct connect to a PC that is operating as a terminal emulator or a communication software
that will emulate a terminal.
- Modem operation.
Once the communication link is established, system set points, system parameters, system status and memory
modification is attainable.
Any system status change will automatically cause the UPS to send an alert warning signal. The signal sent is
"?". User software can be written to identify this signal and initiate automatic unattended action.
J1 PORT - DB25 PIN FUNCTION
Pin #
1
2
3
6
7
8
11
14
18
Name
UPS On (Battery Operation)
Receive Data
Transmit Data
+ 12 VDC Supply
Signal Ground
UPS On (Ready)
Low Battery Alarm (Shutdown Pending)
General Alarm
Remote Emergency Power Off
20
21
23
+ 12 VDC Supply
-12 VDC Supply
Remote Emergency Power Off
25
12, 13
Signal to ground
Bypass On
Description
Closes when on battery operation.
RS/232
RS/232
Limited to 1 ma
Communication signal ground.
Closes when UPS output power is present.
Closes when low battery.
Closes on alarm condition.
Contact closure with reference to ground
shuts unit down.
Limited to 1 ma
Limited to 1 ma
Positive DC input w/reference to ground shuts
unit down.
Communication signal ground.
Closes when switch is on Bypass
Pins 8, 1, 11 and 14 are normally open cold contacts that change state as described. The contacts are
referenced to pins 7 or 25 which is chassis ground. Contact Rating: AC/DC 24 volts .5 amps.
Pins 12 and 13 are totally isolated cold contacts rated: AC/DC 24 volts .5 amp.
Pin 23 requires a high input limited to 20 VDC with respect to pin 7 and 25 or the +12 VDC signal at pin 6 may be
utilized with an external contact.
RS232 TECHNICAL SPECIFICATION SUMMARY
Connector
Format
Baud Rate
Parity
Duplex
Delimiters
Flow Control
25 Pin, Type D, Female
ASCII 8 Bit, One Start Bit, One Stop Bit
Default 1200
None
Full
Carriage Return per Block
XON / XOFF
Page 5.1
COMMUNICATIONS CON'T
SYSTEM PARAMETERS
To attain System Parameters and Status send the lower case "s" to the UPS from the terminal.
Description
AC Volts In
AC Volts Out
Battery Volts
AC Amps Out
Percent of Full
Load
Watts Out
Volts Amps Out
Power Factor
Incoming Line
Frequency
Outages
Overloads
Response
Sample Display
Explanation
Input Voltage = 240
The voltage the UPS is receiving.
Output Voltage = 240
The voltage the UPS is delivering to the load.
Battery Voltage (%) = 98
Percent of full charge of the battery.
Output Current = 2.4
Amperage the load draws from the UPS.
Load (%) = 90
The percentage of total capacity that the load
is using.
KW = .54
The total real power the UPS is delivering to
the load.
KVA = .77
The total apparent power the UPS is
delivering to the load.
Power Factors = 0.70
The power factor of the computer load
(KW/KVA).
Frequency = 60.0
Displays input frequency when on line, output
frequency when on inverter.
Number of Outages = xx
The number of outages recorded from the last
clear function.
Number of Overloads = xx The number of overloads from the last clear
function.
Status
Description
Synchronization
Sample Display
Synchronization
UPS On
Low Battery Warning
UPS On
Low Battery Warning
On Battery
On Inverter
Overload Alarm
Overload Alarm
Low Output
Low Output
High Output
High Output
Weak Battery
Weak Battery
Frequency Fault
Frequency Fault
Over temp Warning
Over temp Warning
Shorted SCR
Shutdown
Low Battery
Shutdown
Output Shutdown
Shorted SCR
Shutdown
Low Battery
Shutdown
Output Shutdown
Explanation
When the UPS is in sync with the line
frequency.
When the UPS is producing an output voltage.
When the battery level reaches the preset value
of alarm condition.
When the UPS is supplying output power from
the batteries.
When the UPS is supplying more power than its
rated capacity.
When the output voltage goes lower than the
preset alarm condition.
When the output voltage exceeds the preset
alarm condition.
When the batteries discharge rate is greater
than normal.
When the fault exceeds the preset range of the
alarm conditions.
When the UPS temperature reaches a critical
level. Shutdown 2 minutes after warning.
When the power electronic switch is shorted.
When the batteries are depleted the UPS shuts
off.
If selected, the UPS will shutdown when the
output exceeds set points.
Page 5.2
COMMUNICATIONS CON'T
SYSTEM SET POINTS
To attain System Set Points send the lower case "p" to the UPS from the terminal. Note: This allows monitoring
of system set points only. To modify set points see page 5.4.
Description
Minimum AC Start
Voltage
Maximum AC Start
Voltage
Low Output Alarm Set
Point
High Output Alarm Set
Point
Low Battery Warning
Set Point
High Battery Warning
Set Point
Low Frequency Alarm
Set Point
High Frequency Alarm
Set Point
Over Temperature Set
Point
Nominal Input Voltage
Response
Sample Display
Password
min AC start = 204
Required
max AC start = 264
Required
low output = 210
Required
high output = 264
Required
low battery (%) =
040
high battery (%) =
105
low frequency = 59
Required
No Access
high frequency = 61
Required
over temperature =
160
input nominal = 240
No Access
Nominal Output
Voltage
output nominal =
240
Required
Maximum KVA Rating
Low Line Switch Point
Note: If using Fuzzy
Logic enter as shown.
High Line Switch Point
output KVA = 5000
sag switch point (%)
= 85. Fuzzy logic =
00.
surge switch point
(%) = 110
Required
Required
Low Line Sample
Accumulation Buffer
sensitivity (1-2) = 1
Required
Frequency
Accumulation Buffer
frequency delay
(2-9) = 8
Required
Power Grid Stability
Check
transfer delay
(sec) = 10
No Access
System ID Number
system ID = units 8
digit serial #.
output shutdown
enable (1/0) = 0
Required
System Shutdown
Enable
Required
Required
Required
Required
Explanation
Minimum AC voltage required
before the UPS will start.
If the input voltage exceeds this
value, the UPS will not start.
Alarm or shutdown if the output
voltage dips to this set value.
Alarm or shutdown if the output
voltage reaches this set value.
Percent of battery capacity alarm
set value.
Manufacturer set point for
diagnostics and charger control.
Alarm or shutdown if the output
frequency dips to this set value.
Alarm or shutdown if the output
frequency reaches this set value.
Manufacturer set point.
Nominal input voltage. Switch set
points are calculated from this
value.
Nominal output voltage. Value
from which other calculations are
derived.
Maximum KVA rating of the UPS.
Percent below nominal AC input
when the UPS will switch to battery
operation.
Percent above nominal AC input
when the UPS will switch to battery
operation.
Averaging factor for low line
voltage. 1 = least averaging
(greater sensitivity).
Number of AC cycles required to
be out of set frequency range prior
to switching to inverter mode.
Amount of time in seconds the UPS
will wait before accepting the AC
input.
System identification serial number.
If enable set = 1, the UPS will shutdown when alarm set points are
exceeded. 0 = audible alarm only.
Page 5.3
COMMUNICATIONS CON'T
There are alarm and operation set points that will alter the behavior of the UPS. It is not recommended that these
be modified without a complete understanding of the function. For added security, a password will be required to
continue into the memory modification group.
* Consult Customer Support at 1-708-534-4756 prior to modifying set points.
To enter into the memory modification group send the lower case "m" from the terminal to the UPS.
The response will be:
PASSWORD=
(consult factory)
Upon entering the correct password, one line item will be displayed, i.e.,
Min AC Start = 204
Min AC Start =
* If the value is to remain unchanged press
ENTER or else type the new value.
To end the process type the lower case "e".
Other interactive signals can be sent that will place the UPS in the inverter operation mode and/or shut the UPS
down.
The following functions require the password.
Testing the UPS inverter send SHIFT I. This will cause the UPS to run on battery power for a few seconds and
then return to normal.
To remotely shutdown the UPS from the communication link send SHIFT D. You cannot restart the UPS from the
communication line.
To clear the log send lower case "c".
SYSTEM SET POINTS - FACTORY PRESET LEVELS
Description
Value Entered w/Nominal Input
Voltage = 120
Value Entered
w/Nominal Input
Voltage = 208
= 177
= 229
= 208
Same
= 182
= 229
Same
Value Entered
w/Nominal Input
Voltage = 240
= 204
= 264
= 240
Same
= 210
= 264
Same
Minimum AC Start Voltage
Maximum AC Start Voltage
Nominal Input Voltage
Nominal Output Voltage
Low Output Alarm Set Points
High Output Alarm Set Points
Low Line Switch Point. Note:
Fuzzy Logic is entered as shown.
High Line Switch Point
Low Battery Warning Set Point
Low Output Frequency Alarm Set
Point
High Output Frequency Alarm Set
Point
Low Line Sample Accumulation
Set Point
Frequency Accumulation Buffer
System Shutdown Enable
Maximum KVA Rating
= 102
= 132
= 120
Refer to units spec tag.
= 105
= 132
Low Line Switch % = 85. Fuzzy
Logic = 00.
% = 110
% = 040
=059
Same
Same
Same
Same
Same
Same
= 061
Same
Same
Available (1-2) = 1
Same
Same
Available (2-9) = 8
Audible Only = 0
Enter Actual KVA Rating – See
units spec tag.
Same
Same
Same
Same
Same
Same
Page 5.4
FEDERAL SIGNAL UPS
WARRANTY
***Warranty void unless this form is completed and returned to ***
Federal Signal
Federal Signal warrants that the UPS and its components will remain free from defects in material and
workmanship for the period of 18 months from the date of delivery and agrees to replace, F.O.B. it's factory, any
part which fault through defect in material or workmanship during such period.
This Warranty applies only to the original purchaser who must properly register the product within (10) days of
receipt.
1. The Warranty shall be effective only if and so long as the system is installed and operated in the manner
specified in this manual which accompanied the UPS and operated within the ratings on the nameplate of the
system.
2. The Warranty shall be void if any alteration is made to the system or any of its components are altered by
anyone other than an authorized Federal Signal Power Service Personnel without the written permission of
Federal Signal.
3. The Warranty shall be effective provided the purchaser pays the cost of transporting the questionable
component to and from the Federal Signal factory at his own expense. The cost of installation of
the defective component is the responsibility of the purchaser. Factory servicemen are not included in this
warranty. If the component fault has been caused by misuse or abnormal conditions in the judgment of
Federal Signal, after inspection at our plant, the customer will be charged for repairs based on
parts and labor required.
4. This Warranty is in lieu of all other warranties, expressed or implied. Federal Signal neither
assumes nor authorizes any person to assume for it, any liability other than that specifically set forth in this
Warranty. Except for its obligations, Federal Signal assumes no responsibility for consequential or other
damages resulting from defects in or failure of the system or any component.
System #_______________________________ Model #____________________________________
Date___________________________ Application__________________________________________
Company___________________________________________________________________________
Address____________________________________________________________________________
City/State/Zip________________________________________________________________________
Contact______________________________________ Phone #_______________________________
Start-Up Organization_________________________________________________________________
Please complete and return to : Federal Signal
Integrated Systems Group
2645 Federal Signal Drive
University Park, IL 60466
Phone 1-708-534-4756
Page 6.1
THE FEDERAL SIGNAL UPS
MAINTENANCE PROCEDURE
WARNING: ONLY QUALIFIED ELECTRICAL PERSONNEL SHOULD MAINTAIN THIS
EQUIPMENT.
*** DANGER HIGH VOLTAGE ***
GENERAL MAINTENANCE
The best preventive maintenance is to operate the UPS in a clean environment with proper ventilation and no
restrictions on air intakes and cooling fan outputs.
Battery connections should be tightened annually by qualified electrical personnel. Batteries should be replaced
every 5 years.
The UPS should be checked monthly on battery operation. Take precautions to have computers in a mode that
could tolerate a shut down. To simulate a utility power loss, simply turn off the AC circuit breaker located on the
UPS. Observe the battery display. A properly functioning system will show 90 - 100% on the battery display and
should decrement slowly.
COMPLETE MAINTENANCE CHECK
PREPARATION
A shutdown period must be scheduled to perform maintenance unless the system is equipped with a
"Maintenance Bypass" switch. A computer load should be available to test the UPS with a loss of power
simulation.
EQUIPMENT
Digital multimeter, wire brush or other cleaning device (for battery connections), insulated tools (for battery
connections) and safety glasses.
SYSTEM OPERATION
1. With power on, check display functions of unit for proper operation.
2. Turn AC and DC breakers off.
VISUAL INSPECTION
1. Remove top panel.
2. Remove any load from units output.
3. Check for burnt, frayed, broken or loose connections. Look closely in the following areas: Inverter
components, power semi-conductors, input, output connections, circuit breakers, transformer connections,
capacitors, fans, bypass switch and electronic circuit boards.
4. Correct any loose connections, replace any physically burned or broken components. Use extreme care
when replacing components to assure correct installation.
NOTE: Note check off all items on the Performance Checklist.
Page 7.1
BATTERY CHECKS
*** WARNING DANGER HIGH VOLTAGE ***
Batteries have high voltage present. Accidental shorts may cause severe arching, burning or battery explosion wear eye protection and use insulated tools when servicing batteries. Remove all jewelry.
NOTE: Never mix batteries with a different brand or size. Never mix old and new batteries. Dispose of
batteries properly. Do not open, mutilate or dispose in a fire.
1. Visually inspect all battery connections,. If there is any sign of corrosion - disconnect that battery and clean
with wire brush. Tighten all other battery connections. Make sure batteries are not swollen or cracked.
If they are, contact factory.
2. Turn AC and DC breakers on. Let unit run for a minute.
3. Verify battery float voltage in table A after following these steps. Place DC voltmeter on millivolt scale and
measure across resistor R5 on switch mode board #406242 This signal limits at 75 millivolts when
batteries require a full charge. If this condition exists allow batteries to charge until signal is 15 millivolts or
less.
4. Place voltmeter across K1 connector on switch mode board wires V2 (common) and V1. Adjust P2 float
voltage as shown in Table A.
TABLE A
UNIT SIZE
3.5 - 5 KVA
7.5 KVA
NUMBER OF
BATTERIES
4
8
FLOAT VOLTAGE
54.5 VDC
109 VDC
5.
Turn AC input breaker off only, unit should invert. Note the percentage of battery time remaining. The rate
at which the batteries decrease is related to the actual load on the output and battery backup time. If
back-up time is extremely short, contact factory.
6.
Complete a NO LOAD INVERTER test and record readings on Performance Checklist.
7.
Turn AC breaker on, unit will return to line power, complete a NO LOAD ON LINE test and record readings
on Performance Checklist.
8.
Check any emergency power off devices and any options - bypass switch, REPO, remote monitor,
computer interface, etc.....
9.
Test unit ON LINE with load and record readings on Performance Checklist.
10. Invert unit with loads and record readings on Performance Checklist.
NOTE: Observe the percentage of battery time remaining. The rate at which the display decreases is
related to output load and battery back-up time. If battery back-up time is very short, contact factory.
GENERATOR TEST
1.
If generator is backing the UPS, check to be sure the UPS operates properly with the generator.
A. Check generator operation with no load. Unit should switch to inverter when generator kicks on. After a
minute or so the UPS should switch back to normal mode and run off the generator. Record UPS
output voltage on Performance Checklist.
B. Check generator with customers loads. Follow same steps stated above and record readings on
Performance Checklist.
Page 7.2
THE UPS PERFORMANCE CHECKLIST
COMPANY:____________________________ MODEL #:_________________ SERIAL :________________
DATE:______________________
1. Comments or problems with UPS ___________________________________________________________
2. Display functions_________________________
Cooling Fans (3)_________________________
3. Electrically wired properly i.e.. Bypass switch, breakers, ground ______________________
4.
Verify input and output voltage. Compare with spec tag _________________________
5. Test any emergency shutoff devices _____________________________________
6.
Check tightness of electrical connections - Bypass switch ____________ Input connections __________
Output
connections __________ Heatsink assembly __________ Main battery connector __________
Circuit board connections _________ Resonant capacitors __________ Battery connections __________
Fan Motor _________
7. UPS environment clean and dust free
Yes ______
No ______
8. Charger output voltage __________ VDC Charger current shunt __________ Milli VDC
9. NO LOAD ON LINE
AVAILABLE LOAD ON LINE
Input voltage ________ VAC
Output voltage L1 to L2 __________ VAC
L1 to N ________ VAC L2 to N ________ VAC
L3 to N ________ VAC L1 to L2 ________ VAC
10. INVERTER NO LOAD TEST
INVERTER FULL LOAD TEST
Output voltage L1 to L2 ________ VAC
L1 to N ________ VAC L2 to N ________ VAC
L1 to L3 _______ VAC L3 to N ________ VAC
11. BATTERY VOLTAGE
1.
2.
3
4.
5.
6.
7.
8.
9.
10.
11.
12.
Input voltage ________ VAC
Output Voltage L1 to L2 ________VAC
L1 to L3 ________ VAC
Input Current ________ Amps
Output Current _______ Amps
Output voltage L1 to L2 ________ VAC
L1 to N ________ L2 to N ________ VAC
L3 to N ________ L1 to L3 ________ VAC
Output Current _____________ Amps
(Record actual voltage of each battery)
No Load
With Load
No Load
With Load
No Load
With Load
________
________
________
________
________
________
________
________
________
________
________
________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
________
________
________
________
________
________
________
________
________
________
________
________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
________
________
________
________
________
________
________
________
________
________
________
________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
14. Generator check A. No load on GEN-Output =_______VAC. B. Invert on GEN-Output = _______ VAC.
Does UPS return to normal when on generator ______ yes ______ no.
Page 7.3
THE UPS GENERAL TROUBLE SHOOTING GUIDE
PROBLEM
NO OUTPUT WHEN
UTILITY POWER
FAILS
UPS SHUTS OFF
OR
OVERTEMPS
PROBABLE CAUSE
A. DEFECTIVE CONTROL CIRCUITS
B. DEFECTIVE BATTERY OR ASSOCIATED
WIRING
C. UNIT IN BY PASS MODE
D. DC BREAKER TRIPPED
E. BATTERIES WEAK
A. CONTACT FACTORY
B. CHECK WIRING AND TEST BATTERIES
REFER TO MAINTENANCE PROCEDURES
C. CHECK BY PASS SWITCH
D. RESET DC BREAKER
E. ALLOW BATTERIES TO CHARGE 24 HOURS AND
TEST UPS
A. AIR INTAKE BLOCKED
B. EXHAUST FANS BLOCKED
A. CLEAN INTAKES
B. CHECK FOR PROPER CLEARANCE, CLEAN
EXHAUST
C. REPLACE DEFECTIVE FANS
D. CHECK OPERATING SPECIFICATIONS
E. VERIFY OUTPUT RATINGS
C. DEFECTIVE FANS
D. ROOM TEMPERATURE TO HOT
E. UNIT OVERLOADED
NO OUTPUT AT
START UP
A. OUTPUT BREAKER OPEN OR OUTPUT
FUSE OPEN
B. WRONG INPUT VOLTAGE
C. NO INPUT VOLTAGE
D. DEFECTIVE BATTERY
E.
F.
G.
H.
UPS WILL NOT
RETURN
TO UTILITY POWER
SHORTED OUTPUT
DEFECTIVE INVERTER COMPONENTS
DEFECTIVE CONTROL CIRCUITS
AC OR DC BREAKER OFF
A. INPUT VOLTAGE OR FREQUENCY OUT
OF SPEC (GENERATOR APPLICATION)
B. DEFECTIVE CONTROL CIRCUITS
C. INADEQUATE SOURCE
D. AC BREAKER TRIPPED
SHORT BATTERY
BACK UP TIME
A. BATTERY DISCONNECTED
B. BATTERY NOT CHARGING
C. OPEN CHARGER FUSE
D. DEFECTIVE BATTERY
E. BATTERY NOT CHARGED
F. UNIT OVERLOADED
UPS ALARMS
OCCASIONALLY
A. NORMAL
B. INTERMITTENT ALARM
UNIT OPERATES
BUT
DROPS LOAD
SOLUTION
A. COMMUNICATIONS ERROR
B. OUTPUT BREAKER TRIPPED OR FUSE
OPEN
C. UNIT OVERLOADED
A. CHECK BREAKER OPERATION AND TEST OR
REPLACE FUSE
B. VERIFY INPUT VOLTAGE AND SELECTOR
SWITCH SW2
C. VERIFY SOURCE FEEDING THE UPS
D. TEST BATTERIES
REFER TO MAINTENANCE PROCEDURES
E. DISCONNECT OUTPUTS AND RESTART UNIT
F. CONTACT FACTORY
G. CONTACT FACTORY
H. TURN ON BOTH AC AND DC BREAKERS
A. VERIFY INPUT SPECS, SELECT DIFFERENT
SLEW RATE (REFER TO SET UP PROCEDURES
IN INSTALLATION SECTION)
B. CONTACT FACTORY
C. VERIFY SOURCE FEEDING UPS IS ADEQUATE
D. RESET AC BREAKER
A. CHECK BATTERY CONNECTIONS (REFER TO
MAINTENANCE PROCEDURES)
B. CHECK BATTERY FLOAT VOLTAGE
REFER TO MAINTENANCE PROCEDURES
C. CHECK FUSE F1 ON CHARGER BOARD
D. TEST BATTERIES
REFER TO MAINTENANCE PROCEDURES
E. ALLOW BATTERIES TO CHARGE 24 HOURS
F. CHECK % LOAD DISPLAY AND REDUCE LOAD
A. UPS IS PROTECTING YOUR EQUIPMENT
FROM MOMENTARY SAGS AND SURGES
B. MONITOR TYPE AND FREQUENCY OF ALARM,
TAKE ACTION ON PARTICULAR ALARM.
A. CHECK INTERFACE CABLES FOR CONTINUITY
TEST COMMUNICATION SIGNALS
B. RESET OUTPUT BREAKER AND TEST OUTPUT
FUSE
C. CHECK % LOAD DISPLAY AND REDUCE LOAD
NOTE; The UPS has two shutdown levels, the first one releases the load, and the second shutdown will disable the internal circuitry after a
period of time, before the batteries get too low. If this situation occurs, both breakers on the UPS must be opened for a couple minutes and
then closed, at which point the unit should power up.
Page 8.1
Page 8.2
3.5 - 7.5 KVA PARTS LIST
PRINTED CIRCUIT BOARDS
PART NUMBER
IS-415336
IS-406242
IS-28056
IS-28556
IS-28295
IS-28917
DESCRIPTION
Control Board
Power Supply
Snubber Board
Display Board
E.M.I. Filter Board
SCR DV/DT Board
all units
all units
all units
all units
all units
all units
Transistor
Diode SKKT 81/04
Diode DD-89N-12K
Relay (solid state)
all units
all units
all units
all units
INVERTER COMPONENTS
IS-19183
IS-19884
IS-104561
IS-104562
MISCELLANEOUS (FUSES, CAPACITORS, ETC...)
IS-103391
IS-16120
IS-19188
IS-13576
IS-16123
IS-18271
IS-13577
IS-13695
IS-109218
IS-104435
IS-13319
IS-18385
IS-18386
Capacitor, DC
Input Capacitor
Capacitor, DC
Ferro Capacitor
Ferro Capacitor
Ferro Capacitor
Ferro Capacitor
Fan Motor
High Speed Fan Motor
Caster
Thermal Sensor
Fuse, 1A
Fuse, 3/4A
3.5K - 5K
all units
7.5K
all units
all units
all units
all units
all units
all units
all units
all units
all units
all units.
Page 9.1
PLUGS, RECEPTACLES AND DISTRIBUTION PANELS
CAUTION: RISK OF ELECTRICAL SHOCK. THE UPS
RECEIVES POWER FROM MORE THAN ONE SOURCE.
BE SURE BOTH UTILITY AND BATTERY CIRCUIT
BREAKERS ARE IN THE OFF POSITION BEFORE
SERVICING.
The following is a list of receptacles available that may be configured onto a distribution panel and plugged into
the output of your UPS. Input plugs are also available in these configurations.
INSTALLATION
CHANGING POWER DISTRIBUTION PANELS
________Refer to figure
________Turn off both utility and battery breaker.
________Unplug all items supplying power to the
UPS and battery.
________Remove the four screws that hold the output
distribution panel in place.
________Unplug the output connector and disconnect
the green ground wire from the ground lug.
________Replace the patch panel with new patch
panel.
________Be sure to re-install the ground wire.
________Re-attach all panels.
________Apply power and verify output receptacles
have proper voltage before plugging in
critical loads.
Page 10.1
.
BYPASS SWITCHES
IMBB
Internal make before break switch. This switch bypasses battery backup capability of the UPS, but still utilizes
the power purification transformer to provide clean power to your computers in the event of a battery or inverter
failure.
CAUTION: This is not a "Maintenance" bypass switch. The UPS must be completely shutdown to perform
service on the UPS. You may operate this switch with no interruption to critical loads.
WARNING: Do not operate this switch while on battery power.
Page 10.2
OTHER OPTIONS
REMOTE EMERGENCY POWER OFF PUSH-BUTTON
This option allows you to completely disable the UPS, which is required by many local safety codes. The pushbutton may mount near an entrance or exit and comes standard with 50 feet of cable terminated with a 4 pin
connector. The 4 pin connector is used in conjunction with a DB25 gender changer that plugs into the UPS.
(See Page 10.4 for installation diagram.)
MONOPHONE AUTOMATIC PHONE DIALER
Monitors when UPS is on battery power, when the batteries are low and the room temperature. Each of these
conditions will automatically dial up to four preprogrammed phone numbers and delivers a voice synthesized
warning message. The monophone will continue to call until the message is acknowledged. Warning features
may be added which are - moisture detection, unauthorized access and alarms pertinent to heating and cooling
systems.
The "call in" feature allows you to call in from any outside telephone. You receive a report on monitored
conditions and may listen for unusual sounds in the room.
It is recommended to plug the monophone into the UPS so you are assured the monophone is working during
power outages. The monophone has it's own battery and may be plugged into any 120 volt AC outlet, but the
battery is not rechargeable and must be replaced annually. This option comes with 50 feet of cable terminated
with a DB25 connector and a 10 foot telephone cord.
NOTE: All auxiliary conditions are contact closure inputs. (See Page 10.4 for installation diagram.)
REMOTE ANNUNCIATOR
This option provides a remote emergency power off push button and remotely monitors the UPS status with
incandescent bulbs. The monitor function includes UPS On, System on Battery, Impending Shutdown, and ByPass Active. The option comes with 50 feet of cable terminated with a DB25 connector and a 24 volt power
supply that plugs into the output of the UPS. (See Page 10.4 for installation diagram.)
NOTE: If a 4X port expander is used the 24 volt power supply is not required. Remote annunciator may be
connected directly to 4X expander.
4X COMMUNICATIONS PORT EXPANDER
This option allows communication to the UPS by up to four separate peripherals. All ports are isolated eliminating
mixed ground problems or incompatibility of signal style. The 4X Expander must be plugged into the UPS and
comes with a interconnecting cable for the J1 port on the UPS. (See Page 10.4 for installation diagram.)
2X COMMUNICATIONS PORT EXPANDER
(Option # 103934)
This option allows communication to the UPS by up to two separate peripherals. The option has one male DB25
connector and two female DB25 connectors one foot long.
Note: There is NO isolation between the two female connectors.
Page 10.3
UPS COMPONENT LOCATIONS AND OPTIONS
INSTALLATION DIAGRAM
Page 10.4