Falcon FN3KRM-2, FN6KRM-2TXI, FN6KRM-2TX, FN4KRM-2TX, FN6KRM-2 User Manual

OWNER'S

OPERATING

MANUAL

FN SeriesTMRackmount UPS Plus

®

Parallel or N+1 Redundant 3kVA to 24kVA

Hardwire models with a 208-240Vac Input and 120Vac & 240Vac Outputs

Uninterruptible Power Supply Models:

FN3KRM-2, -2TX & -2TXI
FN4KRM-2, -2TX & -2TXI

FN5KRM-2, -2TX, & -2TXI

FN6KRM-2, -2TX & -2TXI

FALCON®Electric, Inc., 5106 Azusa Canyon Rd., Irwindale, California 91706, [phone], Fax [phone], Email: [e-mail]

2009 Falcon®Electric Inc. All rights reserved.
All other brand names and trademarks are the property of their respective owners.
The information stated in this document is subject to change without notice. 2009-9-16
Falcon®, Falcon®Electric, FN and UPS Plus logos are registered trademarks of Falcon Electric, Inc.

FN Rackmount Series Parallelable and N+1 Redundant UPS Features.. . . . 3

FN -2TXI Double-Conversion On-line UPS Block Diagram. . . . . 3

Important Safety Instructions (READ FIRST) .... .4

Chapter 1. Introduction

1.1 Manual Overview. .... ..5

1.2 Brief FN Overview. .... ..5

Chapter 2. FN UPS Circuit Descriptions

Galvanically Isolated Output. . . . . . 6

Input & Power Factor Correction . . . . . 6

Power Factor Correction. . . . . . 6

DC/DC Converter. ..... ..6

DC/AC Inverter . . . . . . 6

Battery Packs ..... ..6

Internal Battery Charger .... ..6

Static Bypass Function. .... ..7

Automatic Bypass Transfers . . . . . 7

Output FIlter ..... ..7

Chapter 3. Unpacking the UPS and Battery Bank

3.1 Unpacking Instructions .... ..8

Chapter 4. Pre-installation Details

4.1 Floor Loading Requirements ...... 9

4.2 UPS Input Power Requirements. ......10

4.3 UPS Input/Output Requirements ......10

4.4 UPS Output Rating Details ......11

4.5 FN System Rear Panel Overview ......11

4.6 Hardwire Terminal Block Wiring Details .....12

4.7 UPS Rear Panel Details .......12

4.8 System Installation Wiring Diagram, Single UPS Unit ....13

4.9 System Installation Wiring Diagram, Multiple Parallel UPS Units. . . 13

4.10 UPS & Transformer Module Communications Bus Cabling.. ...13

4.11 External Battery Charger Option Installation ....14

Chapter 5. Displays & Controls

5.1 Control Button and LCD Locations . . . . . 15

5.2 Control Button Operation .... ..15

5.3 LED Display Modes ..... ..16

5.4 LCD Display Overview ..... ..17

5.5 LCD Icon Descriptions ..... ..17

5.6 Status & Error Code Descriptions .... ..17

Chapter 6. Operation

6.1 How to start up the UPS with utility power present. . . . . 19

6.2 How to start up the UPS without utility power present. . . . 21

6.3 How to turn off the UPS inverter and place the UPS into bypass mode . . 21

6.4 How to completely shutdown the UPS . . . . . 21

6.5 How to display Readings. .... ..22

6.6 How to display Programmed Settings . . . . . 24

6.7 How to change the Programmed Settings . . . . . 27

6.8 How to use the Maintenance Bypass Switch . . . . 31

Chapter 7. Communications

7.1 Advanced Communications Option Cards Available . . . . 32

7.2 RS-232 Port ...... ..32

7.3 Optional Remote Emergency Power Off . . . . . 33

7.4 Optional Communications Interface Board Details. . . . . 33

Chapter 8. Maintenance

1. UPS & Battery Care .... ..35

2. Storing the UPS and Batteries . . . . . 35

3. When to Replace Batteries . . . . . 35

Chapter 9. Parallel Mode Operation

9.1 How to configure FN models for Transformer Module, Parallel or N+1 Communications. . 36

9.2 How to connect the FNB Battery Module to the UPS Module . . . 37

Chapter 10. Environmental

10.1 Recycling the Used Battery Packs . . . . . 37

10.2 FCC Considerations ..... ..37

Chapter 11. Technical Support ..... ..38

Warranty ........ ..39

Specifications ....... ..40-43

TABLE OF CONTENTS

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FN SeriesTMParallelable and N+1 Redundant UPS Features

FN -2TXI Model Double Conversion On-line UPS Block Diagram

Parallel Mode and N+1 Redundant Mode Operation
True Double Conversion On-Line Sinewave Design
Output Galvanic Isolation
LCD Display with Advanced Monitoring
Remote Emergency Power Off (REPO) Option
Input Power Factor Correction
Wide Input Voltage Window
Precision Output Voltage Regulation
Superior Brownout, Surge and Transient Protection
Frequency Converter Operation
User-Replaceable and Hot-Swappable Battery Pack
Optional Extended Battery Banks & Chargers
RS-232, USB & Optional SNMP/HTTP Communications
UPSilon UPS Monitoring & Management Software
Two-Year Warranty

IMPORTANT SAFETY INSTRUCTIONS,

SAVE THESE INSTRUCTIONS

RETAIN THIS USER MANUAL!

This manual contains important instructions which must be followed during the installation, operation
and maintenance of the FN Series UPS, battery banks transformer box and options. Please read all

instructions before operating this equipment and save this manual for future reference.

All of the models presented herein are designed for installation and use in a temperature-controlled
environment, free of contamination.

This UPS operates from utility power and contains a number of high current back-up
batteries; this information is important to all personnel involved. Please read this manual first
before continuing to unpack, install or operate this UPS.

STORAGE AND TRANSPORTATION

This UPS must be handled with care and given special attention due to the high amount of energy
stored within its internal sealed, lead acid batteries. Please retain the UPS shipping container in the
event the UPS needs to be returned for service. It has been designed to ship the UPS safely,
without shipping damage.

INSTALLATION

This UPS must be installed in a clean environment, free from moisture, flammable gases or fumes
and corrosive substances. Operate the UPS in an indoor environment with an ambient temperature
range of 32ºF to +104ºF (0ºC to +40ºC).

This UPS is designed for use with industrial, scientific or data processing class equipment.

DO NOT USE TO POWER LIFE SUPPORT EQUIPMENT OR OTHER DESIGNATED
“LIFE CRITICAL” APPLICATIONS.

The maximum UPS output load (in watts) must never exceed that shown on the UPS rating
label. NEVER CONNECT equipment that could overload the UPS or demand half-wave
rectification from the UPS, for example: electric drills, vacuum cleaners or hair dryers.

Storing magnetic media on top of the UPS may result in data loss or corruption.

WARNING

This UPS must be installed according to the instructions in this manual. Failure to do so could result
in unsafe operation and could invalidate your warranty.

WARNING

Once batteries have reached the end of their life, ensure they are disposed of properly.

PLEASE REFER TO YOUR LOCAL LAWS AND REGULATIONS FOR BATTERY RECYCLING
REQUIREMENTS. NEVER DISPOSE OF BATTERIES IN A LAND FILL.

Do not dispose of battery pack or batteries in a fire. The battery may explode. Do not open
or mutilate the battery pack. Released electrolyte is harmful to skin and eyes. It may be toxic.

WARNING

A battery can present a risk of electrical shock and high short circuit current. The following
precautions should be observed when working on batteries:

* Remove watches, rings, and other metal objects.
* Use tools with insulated handles.

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1.0 INTRODUCTION

Manual Overview

This user manual has been written to provide basic information about Falcon FN Series -2TXI rackmount
models. The FN Series is a rugged, double conversion, "on-line" UPS. It has galvanic output isolation config­ured for single or dual voltage output(s). The FN Series provides continuous power conditioning and accepts
a wide range input voltage, while providing tight voltage regulation and a true sinewave output. The FN Series
UPS is specifically designed to protect sensitive computers, laboratory and industrial equipment against the
widest range of power problems. These problems include power failures, voltage sags, voltage surges,
brownouts, utility line noise, high voltage spikes, frequency variations, common mode noise, switching
transients, and harmonic distortion.

This manual also details unpacking, unit installation and the major features of the FN Series UPS, in addition
to detailed UPS operation, configuration and troubleshooting information.

The specifications section at the end of this manual provides detailed operating parameters and general
information on approvals and certifications.

FN Rackmount Overview

The Falcon FN Series UPS system consists of (1) 2U Rackmount UPS module, (1) 3U rackmount battery
module and (1) 2U rackmount output isolation transformer module. An optional input isolation transformer
module is also available. The modules are designed to be easily installed in a standard 19” equipment rack.
The equipment rack must be equipped with hard mounted shelves to properly support the weight of the mod­ules. The modules do not support the mounting of equipment slide rails.

The FN Series front panel features a graphical LCD display, providing detailed operational information at a
glance. The display enables the user or field service engineer to easily monitor and troubleshoot localized
power problems, in addition to UPS operation. UPS control and programming are easily accessed using
pushbuttons located adjacent to the LCD display.

FN rackmount UPS, Battery and Transformer module rear panels have the following features and functions:

a. Circuit Breakers.
b. Hardwire input/output terminal blocks.
c. Maintenance Bypass Switch

The maintenance bypass switch is located behind a protective cover plate on the transformer box rear panel.
The UPS must be placed into manual static bypass mode prior to switching the maintenance bypass switch.

d. RS-232 Port - This port may be used to provide communications between the UPS and a network server

or other computer system. When used in conjunction with the supplied UPSilon software, remote UPS
monitoring and control are facilitated. The software will automatically save all open computer files and initiate
an unattended, orderly operating system shutdown in the event of a utility power outage. UPSilon supports
most MS Windows and Linux operating systems. An optional UNIX version is available through Falcon at an
additional cost.

e. Two Communications Option Board Expansion Slots - The slots support the installation of an

optional SNMP/HTTP Agent or contact closure interface boards. The SNMP/HTTP Agent board is a TCP-IP
addressable solution to remote UPS monitoring and management via LAN, WAN or the Internet. The agent
board is supplied with client software that will remotely shut down multiple servers or computers through the
Ethernet LAN. A CD containing software clients and a SNMP MIB II compliant MIB is provided that supports
most popular operations systems.

f. Two RJ45 connectors for connection of UPS parallel operation or remote maintenance

bypass interface cables.

Used when UPS and transformer modules, or multiple UPS systems are

connected in parallel.

WARNING: Only FN rackmount models of identical power ratings may be connected in parallel. For example, a
FN3KRM-2TXI may only be connected in parallel with another FN3KRM-2TXI unit. The FN5KRM-2TXI may only be
connected in parallel with another FN5KRM-2TXI. The same is true for the FN6KRM-2TXI model.

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g. One Local Maintenance Bypass Switch. The switch is located on the transformer module rear panel

and provides a manual means of placing the UPS into bypass mode to allow for servicing to be performed on
the UPS and battery modules.

2.0 FN RACKMOUNT UPS CIRCUIT DESCRIPTIONS

Galvanically Isolated Output

The FN -2TXI output isolation transformer module provides a galvanically isolated, 120/240Vac, hardwire out­put. To meet UL and code requirements, a dedicated electrical panel should be provided by your electrical
contractor or electrician. The FN -2TXI output configuration can be configured for a 120Vac, 208, 220, 230, or
240Vac output. It may also be configured for a dual voltage or 120/240Vac split-phase hardwire output. This
configuration allows for the use of a standard electrical panel and readily available branch rated circuit break­ers It also simplifies the distribution to 240Vac and 120Vac loads. The outputs of up to four FN -2TXI units
may be connected in parallel. Please refer to pages 12-13 of this manual for wiring details.

Additionally, the FN galvanic output isolation in conjunction with a derived neutral greatly reduces common
mode noise and ground loops.

Input & Power Factor Correction

All FN rackmount models require a 2 wire plus ground type 208-240Vac power source, at 50 or 60Hz. Each
UPS module input must be connected to a dedicated circuit having a branch rated circuit breaker. If multiple
FN units are to be connected in parallel, care must be taken to verify the source electrical panel has enough
capacity. It must be rated to supply the total input power requirements of all FN Series units being connected,
including all optional extended battery chargers, in addition to any other circuits that may be connected to the
panel. Please have your electrical contractor review the FN datasheet located at the end of this manual and
perform a site survey several weeks in advance of the installation date.

While the FN Series UPS is operating from the utility power, it’s internal power factor correction circuit
converts utility AC power into regulated DC power for inverter use. The circuit also corrects the input current
to maintain the phase relationships between both current and voltage sine waveforms. this also minimize the
amount of current distortion that is reflected back to the utility line.

DC/DC Converter

The DC/DC converter utilizes energy from the batteries and boosts up the DC voltage to a level required by
the inverter. This allows the inverter to operate continuously at optimum efficiency and voltage. The converter
incorporates a patented circuit which reduces the amount of ripple current and EMI interference to the battery,
increasing the overall battery life.

DC/AC Inverter

In utility mode operation, the inverter utilizes the regulated DC output and converts it back into clean,
regulated sinewave AC power. When utility power fails, the inverter will receive its energy from the battery
through the DC/DC converter. In both modes of operation, the UPS inverter is online and continuously
generates clean, regulated AC output power to the load. The IGBT, PWM inverter is of a very robust design
and produces a pure sinewave output with a +/-2% voltage regulation. Having a very low output impedance, it
can supply the high current demands of high inrush and non-linear loads.

Battery Packs

FN rackmount battery modules utilize flame retardant batteries. They consist of (20) 12V, 7AH valve-regulat­ed, sealed lead acid (VRLA) batteries in each module (Yuasa NP7-12). See replacement instructions on page

34.

To maintain the optimum battery life, the UPS should be installed in an environment with an ambient
temperature of 68ºF to 77ºF (20ºC to 25ºC). Due to the battery manufacturer specification, the FN Series UPS
batteries may be operated at 32ºF to 104ºF (0ºC - 40ºC) , but battery life will be substantially reduced if con­tinuously operated at the higher temperature levels. Optional extended battery modules and external battery
charger modules are available through Falcon to extend the amount of battery runtime.

Internal Battery Charger

The internal battery charger located inside the UPS module utilizes energy from the utility power source to
continuously charge the UPS batteries. The charger operates in "constant power" mode. The UPS batteries
are being charged whenever the UPS is plugged in, turned on and operating from utility power. The internal
UPS battery charger output is rated at 1.9 amps.

Static Bypass Function

NOTE: Bypass power will only be available If the bypass input is connected at the time of UPS
installation.

A manual static bypass pushbutton is located on the FN front control panel. When the UPS is operating from
utility in the normal utility mode on-line state, depressing this button will cause the UPS to transfer to bypass.
Depressing the bypass button again will return the UPS to normal inverter operation.

Automatic Bypass Transfers

The FN Series UPS module will automatically switch to bypass mode under the following conditions: To
energize the connected load when the UPS is first turned on; encounters an overload; encounters an over
temperature condition; or upon a UPS failure condition. Should any of these events occur, the UPS will
automatically transfer to bypass mode, sound an audible alarm and provide a "bypass" indication on the UPS
module LCD display.

Output Filter

As with the input filter stage, the output filter maintains conducted (EMC) and RFI levels below FCC Class A
limits.

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3.0 UNPACKING THE UPS AND BATTERY BANK

Due to their size and weight the FN rackmount UPS, battery and transformer modules are packaged inside
shipping cartons that are secured to a shipping pallet. Removal of the UPS, transformer and battery bank
modules should never be attempted by one person.

Upon unpacking the UPS, transformer or battery bank, verify the following items were shipped. Should you
have not received any of the items listed below, please contact Falcon Electric Customer Service at 1-800­842-6940.

FN Rackmount UPS Module FNBRM-1S7 Battery Module

Shipping pallet contents: Shipping pallet contents:

(1) FN Rackmount UPS (verify model shipped) (1) FN Extended Battery Bank
(1) RS-232 Cable (1) Interface Cable
(1) UPSilon Software CD (1) Installation Kit
(1) Software Interface Cable
(1) Owner’s Manual
(1) Installation Kit

FNITRM-2 Rackmount Output Transformer Module

(1) Installation kit
(2) UPS Communications Interface Cables

NOTE: If multiple FN UPS units were received for connection in parallel, please verify

that one parallel interface cable kit has been received for each FN Rackmount
system unit received.

3.1 Unpacking Instructions

1. Cut the bands securing the protective carton and lift it off of the UPS, Transformer and battery
modules in their shipping cartons. Due to the weight of the units, a second person will be required.

2. Remove the Individual modules from their shipping cartons. Take care to remove separate
cables, software, hardware packages and any other items shipped with the modules.

Note: The UPS or extended battery bank weighs over 100 pounds. It is not

recommended that you attempt to lift and remove them from the shipping pallet
without the proper equipment.

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4.0 PRE-INSTALLATION DETAILS

Falcon Electric, Inc. is not responsible for shipping damage or for filing shipping damage claims. Visually
inspect the equipment for freight damage. If any equipment has been damaged during shipment, retain the
shipping pallet and packing materials for inspection by the carrier, and immediately file a claim for “shipping
damage” with the carrier. If you discover damage after acceptance, file a claim for “concealed damage”.

To file a claim for shipping damage or concealed damage:

a. YOU MUST file with the carrier within 15 days of receipt of the equipment;
b. YOU MUST send a copy of the damage claim within 15 days to Falcon Electric, Inc.

WARNING

The UPS, Transformer and Battery Modules are very heavy. Use the proper lifting equipment and take the
proper precautions when lifting or moving them.

1. Always install the FN system indoors in a controlled environment.

2. Install the FN modules in a location with unrestricted airflow around the front and rear sides of the modules,

away from water, flammable liquids, gases, corrosive, and conductive contaminants.

3. Maintain a minimum clearance of 4 inches in the front and rear of the UPS.

4. Maintain an ambient temperature range of 32ºF to 104ºF (0ºC to 40ºC). To assure the maximum life of the

batteries, operation in an ambient temperature of 68ºF to 77ºF (20ºC to 25ºC) is recommended.

OPERATION IN TEMPERATURES ABOVE 77ºF (25ºC) WILL REDUCE BATTERY LIFE.

5. The FN Series Rackmount system modules must be installed in a standard 19” equipment rack having hard

mounted shelves under the modules to properly support their weight.

6. When selecting a suitable rack location for the UPS, Transformer and battery bank(s) always verify the
floor loading capabilities:

4.1 Floor Loading Requirements

a. VERIFY THE FLOOR OR SUPPORTING SURFACE UNDER THE EQUIPMENT RACK IS RATED TO SUPPORT
THE WEIGHT OF THE TOTAL WEIGHT OF THE RACK, THE FN MODULES AND ALL OTHER EQUIPMENT INSIDE
THE RACK.

UPS Module:

(1) FN3KRM-2TXI or FN4KRM-2TXI or FN5KRM-2TXI or FN6KRM-2TXI = 53 lbs. (24 kg)
(2) FN3KRM-2TXI or FN4KRM-2TXI or FN5KRM-2TXI or FN6KRM-2TXI = 106 lbs. (48 kg)
(3) FN3KRM-2TXI or FN4KRM-2TXI or FN5KRM-2TXI or FN6KRM-2TXI = 159 lbs. (72 kg)
(4) FN3KRM-2TXI or FN4KRM-2TXI or FN5KRM-2TXI or FN6KRM-2TXI = 212 lbs. (96 kg)

Battery Bank Modules (for all FN Rackmount models)

(1) FNBRM-1S7 = 150 lbs. (68 kg)
(2) FNBRM-1S7 = 300 lbs. (136 kg)
(3) FNBRM-1S7 = 450 lbs. (204 kg)
(4) FNBRM-1S7 = 600 lbs. (272 kg)

Output Transformer Module (for all FN Rackmount models)
(1) FNITRM-2 = 91 lbs. (41 kg)
(2) FNITRM-2= 181 lbs. (82 kg)
(3) FNITRM-2= 272 lbs. (123 kg)
(4) FNITRM-2= 362 lbs. (164 kg)

4.2 UPS Input Power Requirements

a. VERIFY THE PROPER UPS INPUT POWER IS AVAILABLE (for each UPS installed)

FN3KRM-2TXI Input -- Hardwire, 208-240Vac, 50/60Hz, 20A, single-phase, 2 wire plus ground
FN4KRM-2TXI Input -- Hardwire, 208-240Vac, 50/60Hz, 30A, single-phase, 2 wire plus ground
FN5KRM-2TXI Input -- Hardwire, 208-240Vac, 50/60Hz, 30A, single-phase, 2 wire plus ground
FN6KRM-2TXI Input -- Hardwire, 208-240Vac, 50/60Hz, 40A, single-phase, 2 wire plus ground

4.3 UPS Input/Output Requirements

a. VERIFY THE INPUT AND OUTPUT WIRING REQUIREMENTS

FN3KRM-2TXI Wiring Type -- THHN, 600V, insulated solid copper wire

Gage -- Input, 12 awg. - Output, 10 awg.
Terminal Block Screw Torque -- 20 inch-pounds
Required Branch Rated input circuit breaker -- 20A (40A with 3 external battery charger module

options installed)

Required Branch Rated output circuit breaker -- 20A

FN4KRM-2TXI Wiring Type -- THHN, 600V, insulated solid copper wire

Gage -- Input, 10 awg. - Output, 8 awg.
Terminal Block Screw Torque -- 20 inch-pounds
Required Branch Rated input circuit breaker -- 30A (50A with 3 external battery charger module

options installed)

Required Branch Rated output circuit breaker -- 30A

FN5KRM-2TXI Wiring Type -- THHN, 600V, insulated solid copper wire

Gage -- Input, 10 awg. - Output, 8 awg.
Terminal Block Screw Torque -- 20 inch-pounds
Required Branch Rated input circuit breaker -- 30A (50A with 3 external battery charger module

options installed)

Required Branch Rated output circuit breaker -- 30A

FN6KRM-2TXI Wiring Type -- THHN, 600V, insulated solid copper wire

Gage -- Input, 8 awg. - Output, 4 awg.
Terminal Block Screw Torque -- 25-30 inch-pounds
Required Branch Rated input circuit breaker -- 40A (60A with 3 external battery charger module

options installed)

Required Branch Rated output circuit breaker -- 40A

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4.4 UPS Output Rating Details

a. VERIFY THE LOAD TO BE CONNECTED DOES NOT EXCEED THE UPS OUTPUT

RATING for the single or combined paralleled UPS units.

(1) FN3KRM-2TXI Not N+1 Hardwire, 120/240Vac, 2,100W, split-phase, 3 wire plus ground
(2) FN3KRM-2TXI Not N+1 4,200W

N+1 2,100W

(3) FN3KRM-2TXI Not N+1 6,300W

N+1 4,200W

(4) FN3KRM-2TXI Not N+1 8,400W

N+1 6,300W

1) FN4KRM-2TXI Not N+1 Hardwire, 120/240Vac, 2,800W, split-phase, 3 wire plus ground
(2) FN4KRM-2TXI Not N+1 5,600W

N+1 2,800W

(3) FN4KRM-2TXI Not N+1 8,400W

N+1 5,600W

(4) FN4KRM-2TXI Not N+1 11,200W

N+1 8,400W

(1) FN5KRM-2TXI Not N+1 Hardwire, 120/240Vac, 3,500W, split-phase, 3 wire plus ground
(2) FN5KRM-2TXI Not N+1 7,000W

N+1 3,500W

(3) FN5KRM-2TXI Not N+1 10,500W

N+1 7,000W

(4) FN5KRM-2TXI Not N+1 14,000W

N+1 10,500W

(1) FN6KRM-2TXI Not N+1 Hardwire, 120/240Vac, 4,200W, split-phase, 3 wire plus ground
(2) FN6KRM-2TXI Not N+1 8,400W

N+1 4,200W

(3) FN6KRM-2TXI Not N+1 12,600W

N+1 8,400W

(4) FN6KRM-2TXI Not N+1 16,800W

N+1 12,600W

4.5 FN Rackmount System Rear Panel Overview

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4.6 Output Transformer Module Hardwire Terminal Block Wiring Details

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4.7 UPS Module Hardwire Terminal Block Wiring Details

4.8 System Installation Wiring Diagram (single rackmount UPS system)

4.9 System Installation Wiring Diagram (typical multiple parallel UPS units, Rackmount)

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4.10 UPS & Transformer Modules Communications Bus Cabling

Use one UA88385 parallel communications bus cabling kit for each UPS to be connected to the system output trans­former module or to paralleled UPS systems. Connect the supplied cables as shown below. Note the first and last con­nectors on the first and last UPS are connected using the longer of the supplied cables. Switch on the termination resis­tor dip switch next to the long cable. For the transformer module, daisy chain the cables from the UPS to the transformer
module in a similar manner using the communications connectors located on the transformer module rear panel.