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OWNER'S
OPERATING
MANUAL
SG Series UPS Plus
®
Uninterruptible Power Supply Models:
SG5K-1TX, SG5K-1TXC,
SG5K-2T. SG5K-2TC
SG5K-2TX, SG5K-2TXC
SG6K-1TX
SG6K-2T, SG6K-2TC
Detailed SG Series product specifications are available in PDF format at www.falconups.com
FALCON®Electric Inc., 5106 Azusa Canyon Rd., Irwindale, California 91706, (626) 962-7770, Fax 626-962-7720, Email: sales@falconups.com
2004 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. 2004-01-06
Falcon®, Falcon® Electric and UPS Plus logos are registered trademarks of Falcon Electric Inc.
OM48021-5-6K Rev. F
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TABLE OF CONTENTS
SG UPSFeatures. . . . . . . 1
SG Series Online UPS Block Diagram. . . . . . 1
Important Safety Instructions (READ FIRST) . . . . 2
Chapter 1.
SG Series UPS Overview . . . . . . 3
True Regenerative On-line Design . . . . . 3
Input Power Factor Correction . . . . . 3
Microprocessor Control . . . . . . 3
SNMP/HTTP Remote Management . . . . . 3
Extended Battery Bank Option . . . . . 3
Frequency Converter Option . . . . . 3
Chapter 2.
Installation Instructions (Common for all models). . . . 4
Output Voltage & Green Mode Switch Settings Diagrams . . 5
Floor Load Carrying Requirements.. . . . . 6
Lowering The Leveling Feet . . . . . 6
Installation Instructions for Hardwire Models . . . 7
Extended Battery Bank Installation, Hardwire Models . . . 10
Installation Instructions for All Models (Except Hardwire) . . 13
Extended Battery Bank Installation, All Models (Except Hardwire) . 16
Chapter 3.
Operation . . . . . . . 17
Front Panel Indicators & Function Key Diagram . . . 17
Front Panel Function Description . . . . . 17
Audible Alarms . . . . . . . 19
Maintenance Bypass Operating Instructions . . . . 20
Input Requirements . . . . . 7
Wire Gauge Chart . . . . . 7
Terminal Screw Torque Specifications . . . 7
Output Requirements . . . . . 8
Wiring Terminal Block Details . . . . 8
Internal UPS Diagram, SG5K-1TX(C) & SG6K-1TX . . 9
Internal UPS Diagram, SG5K-2T(C) & SG6K-2T(C) . . 9
Internal UPS Diagram, SG5K-2TX(C) & SG6K-2TX(C) . . 10
Floor Load Carrying Requirements . . . . 11
Extended Battery Bank Selection Guide . . . 11
SG5 & 6kVA Extended Battery Bank Rear Panel Details . 12
Output Details . . . . . . 13
Output Power Distributions Center . . . . 14
Optional Output Panel Configurations . . . 14
Typical SG 5 & 6Kva Rear Panel layout . . . 15
Extended Battery Bank Interconnection Diagram . . 16
Installation Procedure . . . . . 16
Category One Alarms . . . . . 19
Category Two Alarms . . . . . 19
Chapter 4.
Chapter 5.
Warranty . . . . . . . . 27
Specifications . . . . . . . . 28
Communications Interfaces. . . . . 21
RS-232 Interface (DB-9) . . . . . . 21
Communications Option Slot . . . . . 21
Contact Closure & Opto Interface Options . . . . 22
Maintenance & Technical Support . . . . . 24
Care & Maintenance . . . . . . 24
Battery Life vs. Temperature . . . . . 24
Battery Replacement . . . . . . 24
Storing the UPS and Batteries . . . . . 25
FCC Considerations . . . . . . 25
Technical Support & RMAProcedure . . . . 26
Requesting Technical Information or Support. . . . 26
FALCON Web Support . . . . . . 26
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SG SERIES UPS FEATURES
Models available with either 120V or 208-240Vac Input
True Double Conversion On-Line Design
Input Power Factor Correction
Dual Output Models Available with 120 & 208-240Vac
Wide Input Voltage Window
Pure Sinewave Output
Precision Output Voltage Regulation
Superior Brownout, Surge and Transient Protection
Internal System Bypass
Eliminates Generator Frequency & Voltage Drift
Microprocessor Control & RS-232 Communications
UPSILON®Monitoring & Shutdown Software
Optional Frequency Conversion
Optional Extended Battery Packs & Chargers
Optional External Maintenance Bypass Switch
Optional Internal SNMP/HTTP Interface Card
Two-Year Warranty
SG SERIES ON-LINE UPS SYSTEM BLOCK DIAGRAM
NOTE: All SG UPSs are constructed using metric screws, nuts and hardware.
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IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions which must be followed during the installation,
operation and maintenance of this UPS and its batteries. Please read all instructions before
operating this equipment and save this manual for future reference.
CAUTION
All of the models presented herein are designed for installation and use in a
temperature controlled environment, free of contamination.
CAUTION
This UPS utilizes voltage that may be hazardous. Do not attempt to disassemble.
This unit contains no user replaceable parts. Refer all servicing to Falcon
Electric, Inc.
THIS UPS IS NOT INTENDED TO BE USED IN CONJUNCTION WITH LIFE
SUPPORT OR OPERATING ROOM EQUIPMENT.
Always turn off the input and battery circuit beakers prior to cleaning and never
apply liquid or spray detergent on the UPS.
CAUTION
CAUTION
CAUTION
Never attempt to service batteries. High voltage exists within the unit, which
could cause electrical shock. Servicing of batteries should be performed or
supervised by personnel knowledgeable of batteries and the required precautions.
Keep unauthorized personnel away from batteries. When replacing the UPS
batteries, use the same number and type of batteries.
IMPORTANT
Allow at least 24 hours, after the UPS is first installed and turned on, to fully charge
the internal battery and assure the maximum backup time is available.
DO NOT
DO NOT connect the input of this UPS to its own output, as this may damage the
UPS.
DO NOT remove or unplug the UPS input when it is turned on. This removes the
safety ground from the UPS and the equipment connected to the UPS.
This UPS contains its own energy source (batteries). The output receptacles
may carry live voltage even when the UPS is not connected to an AC source.
CAUTION
CAUTION
IMPORTANT
Should the SG Series UPS unit be stored for more than two weeks, it is
mandatory that the battery circuit breaker be turned off prior to storage or
battery damage will result.
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CHAPTER 1
CHAPTER 1
SG Series UPS - Overview
True Regenerative On-Line Design
As new and innovative technologies have become the backbone of today's businesses, maximum system availability is critical and downtime is more expensive than ever. Increasingly, businesses need a UPS that not only protects against blackouts, but also virtually eliminates more
frequent and subtle power disturbances. Surges, sags, line noise and brownouts can disrupt
proper operation of sensitive equipment. These disturbances may also create unnecessary production, service, and data recovery costs.
A True Regenerative On-Line UPS provides the highest level of protection against the widest
spectrum of power problems. The incoming AC utility source is converted to a regulated DC
voltage. From this DC voltage, a new AC voltage is regenerated, providing continuous, clean,
tightly regulated power to your equipment. Line-interactive and Off-line designs leave your equipment connected directly to dirty utility power. They only provide minimal transient, voltage and
backup protection. If your equipment operation is "Mission Critical", a true double conversion
On-Line UPS, such as Falcon®Electric's SG SeriesTMUPS Plus®, is the only clear choice.
Input Power Factor Correction
All SG Series UPS Plus models include state-of-the-art Input Power Factor Correction. This
greatly reduces the amount of current demanded from your building wiring system, yielding a
highly efficient, "building friendly" UPS.
Microprocessor Control
Falcon Electric's SG Series UPS incorporates advanced microprocessor technology. This technology makes possible a high level of internal UPS control and management. With the supplied
UPSILON®software, all SG Series UPS models support unattended shutdown, management,
data logging, and self-diagnostics. The software supports MS Windows®95, 98, NT, 2000, 2000
Server, ME, XP, Novell Netware®5 & 6, LINUX and FreeBSD. UPSILON for UNIX may be
purchased seperately and supports most popular UNIX platforms and OS versions.
SNMP/HTTP Remote Management Support
Our SNMP/HTTP Agent board provides remote management and monitoring over any Ethernet
LAN, WAN or the Internet utilizing a 10BaseT-type connection. The optional SNMP/HTTP agent
installs via an option slot located behind a cover plate on the back panel of every SG Series
model.
Extended Battery Bank Option
All SG Series models have a continuous duty inverter and support the addition of optional external battery/charger packs. Whether your application requires a few additional minutes or hours,
the SG Series will be ready. Falcon also offers optional battery charger upgrades for faster
recharging. Please specify your extended battery and charger requirements at the time of your
initial order.
Frequency Converter Option
With a factory modification at the time of order, any SG Series model can be configured for use
as an international frequency converter. This makes the SG Series UPS Plus an ideal choice for
worldwide power applications. Without this modification, all SG series models will detect the
incoming utility line frequency and automatically set its output frequency to match.
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CHAPTER 2
CHAPTER 2
INSTALLATION INSTRUCTIONS
General - Common for all models
1. Verify the following is included in the UPS shipping carton:
(1) UPS, (1) Software Diskette(s) & Manual, (1) Owners Manual & (1) UPS/Computer
Cable.
2. Verify the UPS unit is configured for the proper input/output voltage and frequency. This
information is stated on the nameplate label located on the rear or the side panel of the
unit. If any special input plug and output receptacle configurations were specified at the
time of order, verify for proper configuration.
3. Set the output voltage and green mode switches located on the UPS rear panel for the
nominal UPS output voltage desired. See the switch setting tables located on
page 5.
In most cases the nominal UPS output voltage should be set to match the incoming utility
voltage. This will assure a close matching voltage in the event the UPS is placed on
bypass. NOTE: Disregard the "ON" marking on the side of the actual dip switch
housing; use the tables in this manual or the silkscreen on the UPS rear panel only.
Dip switch 3 "enables" or "disables” the "Green Mode" function. The UPS is shipped
from the factory with the switch set in the "disabled" position (up). If SW3 is switched
down or to the "enabled" position, the Green Mode function is activated. When the
load connected to the output of the UPS drops to under 10% of the full rated UPS output
for 30 seconds, the UPS is automatically placed into bypass and the inverter is turned off.
NO BATTERY BACKUP IS PROVIDED AFTER THE GREEN MODE HAS ACTIVATED.
Dip switch settings must be made while the UPS is turned off. Any changes made while
the UPS is turned on will not take effect until the UPS is turn off and back on again since
the switch settings are read by the microprocessor only during initial UPS power up.
4. To prevent accelerated battery discharge during shipment, this UPS was shipped with the
battery circuit breaker turned off. TURN THE BATTERY DISCONNECT CIRCUIT
BREAKER ON PRIOR TO TURNING ON THE UPS INPUT CIRCUIT BREAKER.
CAUTION
NEVER TURN THE BATTERY CIRCUIT BREAKER OFF WHILE THE UPS AC CIRCUIT
BREAKER IS TURNED ON AND OPERATING FROM THE UTILITY VOLTAGE, OR UPS
DAMAGE MAY RESULT. UPS MUST BE COMPLETELY SHUT DOWN PRIOR TO
DISABLING THE INTERNAL BATTERY SUPPLY.
CAUTION
In the event this UPS is to be turned off or stored for more than two weeks, the battery
circuit breaker must be turned to the off position to prevent battery discharge. If placed in
long-term storage, every four months the UPS must be plugged in and turned on for 24
hours to allow the batteries to recharge and prevent battery damage. Failure to follow
these procedures will invalidate your warranty.
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DIP
SWITCHES
SELECTION
ON = 1
OFF = 0
VIEW OF OUTPUT VOLTAGE & GREEN MODE SELECT SWITCHES
(LOCATED ON THE UPS REAR PANEL)
Disregard
“ON” Designation
TABLE
SWITCH SETTINGS FOR ALL MODELS
SW2 SW1 OUTPUT VOLTAGE 1
(All models)
OUTPUT VOLTAGE 2
(-TX & -TXC models only)
Down Down 208 Vac 115 Vac
Down Up 220 Vac (default) 120 Vac
Up Down 230 Vac 125 Vac
Up Up 240 Vac 130 Vac
GREEN MODE SWITCH SETTINGS FOR ALL MODELS
SW3 FUNCTION
Down GREEN MODE ON
Up GREEN MODE OFF
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6. Select a suitable location for the UPS.
VERIFY THE FLOOR OR SURFACE SUPPORTING THE UPS WILL SUPPORT THE
WEIGHT OF THE UPS AND ANY OPTIONAL EXTENDED BATTERY BANKS.
SG5K-2T & SG6K-2T UPS MODELS = 216 lbs. (98 kg)
SG5K-2TC & SG6K-2TC UPS MODELS = 239 lbs. (108 kg)
SG5K-1TX, SG5K-2TX, SG6K-1TX, SG6K-2TX UPS MODELS = 299 lbs. (136 kg)
SG5K-1TXC, SG5K-2TXC, SG6K-2TXC UPS MODELS = 322 lbs. (146 kg)
FLOOR STANDING EXTENDED BATTERY BANKS = 363 lbs. (165 kg) MAX. (EACH BANK)
7. If extended battery banks are to be connected to the UPS, please refer to page 7 for
hardwire models and page 16 for all other models.
8. If unattended computer shutdown and monitoring are desired, connect the green
UPS/Computer cable to the DB-9 connector located on the UPS rear panel. Then
install the shutdown and monitoring software provided with the UPS. For your
reference, UNIX shutdown and monitoring software is available from Falcon Electric
at an additional cost.
9. Verify the location selected has adequate ventilation to allow for the proper cooling of
the UPS.
DO NOT BLOCK UPS FANS OR AIR VENTS. THE UPS MUST NOT BE
INSTALLED IN AN ENCLOSED AREA.
10. For further installation instructions covering hardwire models SG5K-1TX, SG5K-2T,
SG6K-1TX, SG6K-2T and SG6K-2TX, please refer to page 7.
11. Lower the leveling feet.
a. Verify the flooring at the UPS or battery bank installation location is rated for
the weight of the equipment.
b. Roll the UPS or extended battery bank to the final installation location.
c. Locate the position of the (4) levelling feet underneath the UPS near its four
corners. (see picture below).
d. Using your fingers and a 12mm open end wrench, screw the levelling feet in
a clockwise direction, lowering the feet until all four feet are securely
against the floor.
12. For further installation details covering the following models having a line cord and
PDU, please refer to page 13. Models SG5K-1TXC, SG5K-2TC, SG5K-2TXC,
SG6K-2TC and SG6K-2TXC.
Leveling Feet Adjustment
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Installation Instructions For Hardwire Models (see model numbers referenced below)
1.0 UPS Input & Output Requirements.
IMPORTANT
Note: All SG Series hardwire UPS models must be installed by a licensed
electrician, in accordance with the National Electrical Code (NEC) ANSI/NFPA70
and all local regulations. It is further required that the input of SG Series hardwire
UPS be wired to a building service panel incorporating a dedicated “branch
rated” circuit breaker of the proper rating.
INPUT REQUIREMENTS
MODEL REQUIRED INPUT
CIRCUIT BREAKER
SG5K-1TX:- 120Vac, 50/50Hz, 38.7A, 1 phase, 3 wire 50A
SG5K-2T - 208-240Vac, 50/60Hz, 19.5A, 1 phase, 3 wire 30A
SG5K-2TX - 208-240Vac, 50/60Hz, 20.3A, 1 phase, 3 wire 30A
SG6K-1TX - 120Vac, 50/60Hz, 46.6A, 1 phase, 3 wire 70A
SG6K-2T - 208-240Vac, 50/60Hz, 23.4A, 1 phase, 3 wire 30A
SG6K-2TX - 208-240Vac, 50/60Hz, 24.3A, 1 phase, 3 wire 30A
WIRE GAUGE CHART
MODEL AC INPUT
-1 = 120 Vac
-2 = 208-240 Vac
SG5K-1TX 8 Awg. 600V
75°C CU
SG5K-2T 12 Awg. 600V
75°C CU
SG5K-2TX 12 Awg. 600V 75°C
CU
SG6K-1TX 6 Awg. 600V
75°C CU
SG6K-2T 10 Awg. 600V
75°C CU
SG6K-2TX
External Battery &
Charger System
10 Awg. 600V 75°C
CU
16 Awg, 600V
75°C CU
AC OUTPUT(S)
120 Vac 208-240 Vac
10 Awg. 600V
75°C CU
N/A
10 Awg. 600V
75°C CU
8 Awg. 600V
75°C CU
N/A
8 Awg. 600V
75°C CU
N/A N/A
12 Awg. 600V
75°C CU
12 Awg. 600V
75°C CU
12 Awg. 600V
75°C CU
10 Awg. 600V
75°C CU
10 Awg. 600V
75°C CU
10 Awg. 600V
75°C CU
EXTERNAL
BATTERY
240 dc
10 Awg. 600V
75°C CU
10 Awg. 600V
75°C CU
10 Awg. 600V
75°C CU
10 Awg. 600V
75°C CU
10 Awg. 600V
75°C CU
10 Awg. 600V
75°C CU
10 Awg. 600V
75°C CU
ONLY USE WIRE WITH SOLID COPPER CONDUCTORS FOR ALL INPUT/OUTPUT/BATTERY WIRING
SCREW TORQUE SPECIFICATIONS FOR
INPUT/OUTPUT WIRING BLOCK
UPS & BATTERY BANK
Wire Gauge Torque
(inch pounds)
18 - 10 Awg. 20
8-6 Awg 25 - 30
CAUTION
To reduce the risk of fire, connect only to a circuit providing over-current protection incorporating the
specified "branch rated" over-current protection device in accordance with the National Electrical
Code, ANSI/NFPA 70.
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2.0. UPS Output Requirements
Note: The outputs of SG 5 & 6kVA models are not configured for 208 or 240Vac
split-phase operation. Please reference the output configuration diagrams on pages
9-10 prior to making any wiring connections to the UPS. Should a 208 or 240Vac
split-phase output configuration be required, please contact the factory.
IMPORTANT
MODEL RECOMMENDED OUTPUT
SG5K-1TX:
Output 1: 208, 220, 230 or 240Vac selectable, 1 phase, 2 wire 30A
Output 2: 115, 120, 125 or 130Vac, 1 phase, 3 wire (follows output 1) 50A
SG5K-2T
Output 1: 208, 220, 230 or 240Vac selectable, 1 phase, 2 wire 30A
Output 2: None
SG5K-2TX
Output 1: 208, 220, 230 or 240Vac selectable, 1 phase, 2 wire 30A
Output 2: 115, 120, 125 or 130Vac, 1 phase, 3 wire (follows output 1) 50A
SG6K-1TX
Output 1: 208, 220, 230 or 240Vac selectable, 1 phase, 2 wire 30A
Output 2: 115, 120, 125 or 130Vac, 1 phase, 3 wire (follows output 1) 50A
SG6K-2T
Output 1: 208, 220, 230 or 240Vac selectable, 1 phase, 2 wire 30A
Output 2: None
SG6K-2TX
Output 1: 208, 220, 230 or 240Vac selectable, 1 phase, 2 wire 30A
Output 2: 115, 120, 125 or 130Vac, 1 phase, 3 wire (follows output 1) 50A
OUTPUT REQUIREMENTS
Terminal Designation Numbers
1 2 3 4 5 6 7 8 9 10
CIRCUIT BREAKER
View of the Input/Output Hardwire Terminal Block
This terminal block is located on the UPS rear panel and shown with the conduit mounting and
access cover plates removed.
Use only the lower terminals and wire securing screws when making wiring connections to
the UPS.
DO NOT USE THE UPPER TERMINAL CONNECTIONS
Refer to the Wire Gauge Table on Page 7 for recommended wire sizes.
Refer to the Torque Specification Table on Page 7 and tighten all 20 screws as specified.
Refer to Pages 9-10 for the terminal wiring designations for your specific SG UPS model.
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INTERNAL UPS DIAGRAM
SG5K-1TX(C) & SG6K-1TX
INPUT
RECTIFIER
Input
Auto-transformer
PFC
Battery
Charger
Chassis Ground (Input)
120Vac Input Line (Black Wire)
PWM
INVERTER
208-240Vac
Output
Internal UPS
Batteries (240Vdc)
+
+ External Battery (+240Vdc)
120Vac Input Neutral (White WIre)
Output 2 -120Vac Line (Black Wire)
- External Battery (- 240Vdc)
Output
Auto-transformer
Terminal #10Terminal #1
Output 2 - 120Vac Neutral (White WIre)
Output 1 - 208- 240VacL1
Chassis Ground (Output 1 & 2)
Output 1 - 208-240Vac L2 or Neutral
Terminal Block as Viewed Through
the Opening in the UPS Rear Panel
INPUT
RECTIFIER
INTERNAL UPS DIAGRAM
SG5K-2T(C) & SG6K-2T(C)
PFC
Battery
Charger
208-240Vac Input L1
Chassis Ground (Input)
PWM
INVERTER
Internal UPS
Batteries (240Vdc)
+
+ External Battery (+240Vdc)
208-240Vac Input L2 or Neutral
208-240Vac
Output
- External Battery (- 240Vdc)
Output 1 - 208- 240VacL1
NOT USED
Output 1 - 208-240Vac L2 or Neutral
NOT USED
Terminal #10Terminal #1
Chassis Ground (Output 1 & 2)
Terminal Block as Viewed Through
the Opening in the UPS Rear Panel
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INTERNAL UPS DIAGRAM
SG5K-2TX(C) & SG6K-2TX(C)
INPUT
RECTIFIER
PFC
Battery
Charger
208-240Vac Input L1
Chassis Ground (Input)
PWM
INVERTER
Internal UPS
Batteries (240Vdc)
+
+ External Battery (+240Vdc)
208-240Vac Input L2 or Neutral
208-240Vac
Output
Output 2 -120Vac Line (Black Wire)
- External Battery (- 240Vdc)
Isolated 120Vac
Output
New Derived
120Vac Neutral
Terminal #10Terminal #1
Output 2 - 120Vac Neutral (White WIre)
Output 1 - 208- 240VacL1
Chassis Ground (Output 1 & 2)
Output 1 - 208-240Vac L2 or Neutral
Terminal Block as Viewed Through
the Opening in the UPS Rear Panel
3.0. Extended Battery Bank Option Installation (hardwire models only)
Optional Extended Battery banks are available for the SG5 & 6kVA models
providing extended battery backup up to many hours. Each extended battery
is a completely self-contained battery system. If equipped with the optional battery
charger, it will require the additional connection to the utility source, incorporating
"branch rated" circuit breaker protection which can also be used as a disconnect for
the system. Hardwire model extended battery systems are not provided with an
input power switch or AC disconnect device. As the optional charger is designed to
maintain a continuous charge to the batteries, it must remained powered from the
utility source. A battery disconnect is provided on the rear panels of both the UPS
and battery bank and must be in the off position during installation or when the
system is being turned off or stored for more than two weeks.
Installation Instructions:
1. VERIFY THE BATTERY DISCONNECT CIRCUIT BREAKER IS IN THE “OFF”
POSITION PRIOR TOMAKING ANY WIRING CONNECTIONS.
2. Verify the Extended battery Bank is configured properly. Verify the input (models
with internal battery chargers only) and DC output voltage. All SG 5 & 6kVA models
require the use of an external battery bank with an output of 240Vdc @ 30A. This
information is stated on the nameplate label located on the rear or the side panel of
the unit.
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3. Select a suitable location for the the extended battery bank, preferably close to the
UPS to minimize the risk of DC voltage drop due to excessive long wiring runs. Use
10 Awg, 600V insulated wire for all hardwired DC connections between the UPS
and battery bank(s). See Wire Guage Chart of page 7.
VERIFY THE FLOOR OR SURFACE SUPPORTING THE UPS WILL SUPPORT
THE WEIGHT OF THE UPS AND ANY OPTIONAL EXTENDED BATTERY
BANKS.
FLOOR STANDING EXTENDED BATTERY BANKS = 363 lbs. (165 kg) MAX. (EACH BANK)
4. Remove the lower wiring access cover plate located on the rear panel of the battery
bank.
5. Remove the knock-outs from the conduit connector plate located above the previous
plate removed. Next, using conduit connectors, install the conduit between the UPS,
utility power source (models with battery chargers only) and any other extended
battery banks to be installed.
6. Install all of the required wiring. Reference the tables on page 7 for wire Gauge and
terminal block torque specifications.
7. Verify all wiring connection to the battery bank(s), UPS and utility sources prior to `
turning on any circuit beakers or equipment power switches.
8. ALWAYS TURN ON THE BATTERY BANK DC DISCONNECT(S)AND THE UPS
BATTERY CIRCUIT BREAKER PRIOR TO SWITCHING ON THE UPS AC INPUT
CIRCUIT BREAKER.
EXTENDED BATTERY BANK SELECTION GUIDE
(Please specify a hardwire configuration at the time of order)
BATTERY OPTION
MODELS
W/O Charger
BATTERIES
BATTERIES IN UPS 20 each of 12V, 7AH
# of CASES
Inches
(mm)
RUN TIME @ 1000W 190 Min. 340 Min. 500 Min. 820 Min. 1400 Min.
RUN TIME @ 1750W 92 Min. 180 Min. 265 Min. 450 Min. 740 Min.
RUN TIME @ 2500W 60Min. 112 Min. 180 Min. 305 Min. 505 Min.
RUN TIME @ 3500W
5kVA Full Load
RUN TIME @ 4200W
6kVA Full Load
BATTERY OPTION
MODELS
With 120Vac Charger
BATTERY OPTION
MODELS
With 200-240Vac
Charger
CHARGER OUTPUT 275Vdc @ 1.3A 275Vdc @ 1.3A 275Vdc @ 1.3A 275Vdc @ 1.3A 275Vdc @ 1.3A
# OF CHARGERS
SGB2S7-6K6 SGB2S7 -6K6 SGB2S7-6K6 SGB2S7-6K6 SGB2S7 -6K6
40 Pieces 12V,
7AH
1 Floor Standing
32.1 x 10.2 x 21.8
(814 x 259 x 554)
37.5 Min. 78 Min. 120 Min. 210 Min. 340 Min.
29 Min. 60 Min. 92 Min. 165 Min. 270 Min.
SGB2S7-6K6-1 SGB2S7-6K6-1 SGB2S7-6K6-1 SGB2S7-6K6-1 SGB2S7-6K6-1
SGB2S7-6K6-2 SGB2S7-6K6-2 SGB2S7-6K6-2 SGB2S7-6K6-2 SGB2S7-6K6-2
1 2 3 4 8
80 Pieces 12V, 7AH 60 Pieces 12V,
2 Floor Standing
32.1 x 10.2 x 21.8
(814 x 259 x 554)
CHARGER OPTION INFORMATION
7AH
3 Floor Standing
32.1 x 10.2 x 21.8
(814 x 259 x 554) )
80 Pieces 12V, 7AH 160 Pieces 12V,
4 Floor Standing
32.1 x 10.2 x 21.8
(814 x 259 x 554)
7AH
8 Floor Standing
32.1 x 10.2 x 21.8
(814 x 259 x 554)
Battery run times are for reference only and may vary due to application, environment and the condition of the batteries.
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D
240 Vdc
UTILITY
INPUT
OUTPUT TO
NEXT BANK
BATTERY
Battery Disconnect &
Input/Battery
Reference the
Leveling
USE ONLY THE WIRE
For all Input/Output
AC
Input Voltage
---
208-240 Vac
SG5 & 6kVA Extended Battery Bank Rear Panel Details
(Hardwire Model Shown)
DO NOT BLOCK
wiring
USE COPPER
CONDUCTORS ONLY
GAUGE & TYPE
REFERENCED IN THE
PRECEEDING WIRING
TABLE
AC Input Current --- 4.5A max
Charger Current --- 3.9A
DC Output Voltage --- 240 Vdc
DC Output Current --- 30A
COOLING FAN
Circuit Breaker
Terminal Block
CAUTION
Reference the torque
specifications in this
manual prior to making
terminal block
Feet adjustment
procedure
+
G
N
Note: Input and output wiring must meet the National Electrical Code, ANSI/NFPA70. Please refer to the wire Gauge
table on page 6 for minimum wire gauge. THIS UNIT MUST BE INSTALLED BY A QUALIFIED ELECTRICIAN.
L
1
L
2
L
1
L
2
To reduce the risk of fire, connect only to a circuit provided with a "branch rated" over-current protection device in
accordance with the National Electrical Code, ANSI/NFPA 70.
CAUTION
12
Page 15
Installation Instructions for All Models Except Hardwire
1.0 UPS Input & Output Requirements.
Note: All SG Series UPS models, except Hardwire models, may be installed by
anyone providing the specified outlet, circuit and circuit protections are
available. Other plug and receptacle configurations are available, please
reference page 14 or contact the factory should an unlisted configuration e
required..
MODEL REQUIRED REQUIRED INPUT
RECEPTACLE CIRCUIT BREAKER
SG5K-1TXC - 120Vac, 50/50Hz, 38.7A, 1 phase, 3 wire L5-50R 50A
SG5K-2TC - 208-240Vac, 50/60Hz, 19.5A, 1 phase, 3 wire L6-30R 30A
SG5K-2TXC - 208-240Vac, 50/60Hz, 20.3A, 1 phase, 3 wire L6-30R 30A
SG6K-2TC - 208-240Vac, 50/60Hz, 23.4A, 1 phase, 3 wire L6-30R 30A
SG6K-2TXC - 208-240Vac, 50/60Hz, 24.3A, 1 phase, 3 wire L6-30R 30A
CAUTION
To reduce the risk of fire, connect only to a circuit providing over-current protection incorporating the
specified "branch rated" over current protection device in accordance with the National Electrical
Code, ANSI/NFPA 70.
2.0. UPS Output Details
Note: The outputs of the referenced SG 5 & 6kVA models are not configured for 208
or 240Vac split-phase operation. Output 1 (208-230Vac) is powered directly
from the UPS inverter while Output 2 (120Vac) is created from the inverter
output, through an isolation transformer. A new neutral for the 120Vac output
is derived at the output of the transformer. This configuration provides the
advantage of providing the full rated output of the UPS at output 1, output 2, or
a combination of both.
MODEL STANDARD OUTLET FUSES
SG5K-1TXC
Output 1: 208, 220, 230 or 240Vac selectable, 3500W* (1) L6-30R (2) KLKD 30
Output 2: 115, 120, 125 or 130Vac, (follows output 1), 3500W* (2) Duplex 5-20R (2) KLKD 20
SG5K-2TC
Output 1: 208, 220, 230 or 240Vac selectable, 3500W (1) L6-30R (2) KLKD 30
Output 2: None
SG5K-2TXC
Output 1: 208, 220, 230 or 240Vac selectable, 3500W* (1) L6-30R (2) KLKD 30
Output 2: 115, 120, 125 or 130Vac, (follows output 1) 3500W* (2) Duplex 5-20R (2) KLKD 20
SG6K-2TC
Output 1: 208, 220, 230 or 240Vac selectable, 4200W (1) L6-30R (2) KLKD 30
Output 2: None
SG6K-2TXC
Output 1: 208, 220, 230 or 240Vac selectable, 4200W* (1) L6-30R (2) KLKD 30
Output 2: 115, 120, 125 or 130Vac, (follows output 1) 4200W* (2) Duplex 5-20R (2) KLKD 20
* Maximum load at outputs 1 & 2.
All UPS outputs are protected by fuses. Always replace these fuses with the same
type and rating.
CONFIGURATION Class CC
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Page 16
2.1 Output Power Distribution Center
Optional SG 5 & 6kVA Output Panel Configurations
All models referenced on the previous page come equipped with a (4) bay power
distribution center mounted on the rear of the UPS. The Power Distribution
center is shown in the “standard” or “base” configuration. Custom configurations
are available; see the table below or contact the factory.
TYPICAL POWER DISTRIBUTION CENTER CONFIGURATION
120V FUSES
120V OUTPUT
RECEPTACLES
BAY 1
(full size)
BAY 2
(full size)
208-240V FUSES
BAY 3
(full size)
CAUTION
EXTERNAL BATTERY
208-240V OUTPUT
RECEPTACLE
BANK CONNECTOR
Red = +240Vdc
Black = - 240Vdc
Green = Chassis Ground
BAY 4
(half size)
LINE CORD
IMPORTANT
The configuration of the panels on the power distribution center are installed by the factory. Custom
configurations must be specified when the UPS order is placed.
Panel
Configuration
(2) 5-20R Duplex (1 fuse) Full SG5/6K-P1* 120 Vac
(1) L6-30R Outlet ( 2 fuses) Full SG5/6K-P2* 200-240 Vac
* Denotes the default factory configuration.
(1) L5-20R (1 fuse) Half SG5/6K-P3 120 Vac
(1) L5-30R (1 fuse) Half SG5/6K-P4 120 Vac
(1) L6-20R (2 fuses) Half SG5/6K-P5 208-240 Vac
SG5/6K-P6
(2) L5-20R (2 fuses) Full SG5/6K-P7 120 Vac
(2) L5-30R ( 2 fuses) Full SG5/6K-P8 120 Vac
(1) L5-20R (1 fuse)
(1) L5-30R (1 fuse)
(1) L6-20R (2 fuses)
(1) L6-30R (2 fuses)
(1) L5-20R (1 fuse)
(1) L6-20R (2 fuses)
(1)L5-30R (1 fuse)
(1) L6-30R (2 fuses)
(1) L5-30R (1 circuit breaker) Full SG5/6K-P13 120 Vac
(2) L5-15 Duplex (2 fuses) Full SG5/6K-P14 120 Vac
(1) L5-20R (1 circuit breaker) Full SG5/6K-P15 120Vac
(1) L6-20R (1 circuit breaker) Full SG5/6K-P16 208-240 Vac
(1) L6-30R (1 circuit breaker) Full SG5/6K-P17 208-240 Vac
Note: Other options available; please consult the factory.
Slot
Size
Full
Full
Full
Full
Option Panel
Designation
SG5/6K-P9
SG5/6K-P10
SG5/6K-P11 120 Vac
SG5/6K-P12 120 Vac
Nominal Output
Voltage
120 Vac
208-240 Vac
208-240 Vac
208-240 Vac
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Page 17
Typical SG5 & 6kVA Rear Panel Layout
(Shown with Power Distribution Center )
Output Voltage & Green Mode
Select Switches
RS-232 Computer Interface
Connector
COOLINGFANS
DO NOTBLOCK AIR FLOW
INPUT AC CIRCUIT BREAKER
ALWAYS TURN ON AFTER THE
BATTERY CIRCUITBREAKER
HAS BEEN TURNED ON
OUTPUT POWERDISTRIBUTION
CENTER
(see page 14)
Communications Option Slot
Cover Plate
MAINTENANCE BYPASS
SWITCH
REFER TO PAGE 20 FOR
OPERATINGINSTRUCTIONS
WARNING
NEVER TURN THIS SWITCH TO
THE ON POSITION UNLESS THE
UPS HAS BEEN PLACED INTO
MANUAL BYPASS, OR THE UPS
HAS BEEN TURNED OFF
BATTERY CIRCUIT BREAKER &
DISCONNECT
VERIFY THIS DISCONNECT IS IN
THE OFF POSITION WHEN:
* The UPS is being installed.
* The UPS is to be turned off or
stored for more than five days.
* Connecting external battery banks.
* Servicing the UPS.
WARNING
NEVER TURN OFF THIS
DISCONNECT WHILE THE UPSIS
OPERATING FROM UTILITY.
POWER OR DAMAGE MAY RESULT.
ALWAYS TURN OFFTHE UPS
FIRST.
IMPORTANT
TO TURN OFF THE UPS
SWITCH THE INPUT CIRCUIT BREAKER LOCATED ON THE UPS REAR PANEL TO THE “OFF” POSITION
AND PRESS THE ON/OFF BUTTON LOCATED ON THE UPS FRONT PANEL UNTIL THE UPS BEEPS. THE
UPS WILL RUN FOR ABOUT 30 SECONDS AND SHUT DOWN. DO NOT PRESS THE ON/OFF BUTTON
OR TURN THE CIRCUIT BREAKER ON AGAIN DURING THE SHUTDOWN PROCESS OR THE UPS WILL
GO TO AN ALARM CONDITION, WARNING THAT THE UPS WAS NOT SHUT DOWN PROPERLY. SHOULD
THIS OCCUR, TURN OFF THE INPUT CIRCUIT BREAKER AGAIN AND WAIT UNTIL THE UPS SHUTS
DOWN.
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Page 18
Please refer to the battery bank selection guide on page 11 for more model details.
EXTENDED BATTERY BANK DC INTERCONNECTION
(All models except hardwire)
1st Extended Battery
Bank
Connections
(Rear Panel View)
To UPS Battery Connector
(See Step 3 below)
RED KEY PIN
GREEN PIN IS Chassis Ground
Detailed
View
RED PIN IS +240Vdc
BLACK PIN IS THE 240Vdc Return
2nd Extended Battery
Bank
Connections
(Rear Panel View)
To the Battery Connector
on the second Battery Bank
To the Battery Connector on
the next Battery Bank
INSTALLATION PROCEDURE
1. Verify the battery disconnect circuit breaker on the UPS and all external battery banks
to be connected are in the off position.
2. Locate the battery interconnect cable(s).
3. Connect one end of the battery interconnect cable to the the UPS battery
connector located on the power distribution center (see page 14). Connect the other
end of the cable to the battery connector on the first battery bank as shown.
4. If a second battery bank is to be connected, connect the second battery interconnect
cable to the lower (second) battery connector on the first battery bank, and the other
end to the upper battery connector of the second battery bank. All subsequent battery
banks will be connected in the same manner.
5. Follow the instructions in the proceeding step for additional battery banks.
6. Turn the battery disconnect circuit breaker to the “on” position for the UPS and all
extended battery banks.
7. For all battery banks having the internal battery charger option installed from the
factory, perform the following:
a. Verify the battery charger circuit breaker is in the off (down) position.
b. On the battery bank nameplate label located on the rear panel, verify the
battery charger input voltage matches your utility source (120Vac or
230Vac).
c. Connect the input line cord(s) to the battery bank(s) power inlet.
d. Plug the other end of the power cord into a utility receptacle.
e. The batteries in the external battery banks are now being charged.
NOTE: Internal battery bank chargers do not charge the batteries inside the UPS.
NOTE: When the battery banks and UPS need to be shut down or stored for more than
two weeks, turn off the battery charger circuit breaker and turn off the UPS
battery circuit breaker, otherwise battery damage may occur due to excessive
discharge.
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Page 19
OPERATION
1 2 3 4
5 6 7
8 9 10
11
CHAPTER 3
CHAPTER 3
UPS FRONT PANEL INDICATOR AND FUNCTION KEYS
1. LOAD LEVEL INDICATOR LEDs
*The first or bottom LED is lit when the output load is greater than 25% of the `
rated output of the UPS.
*The second LED is lit when the output load is greater than 50% of the rated
output of the UPS.
*The third LED is lit when the output load is greater than 75% of the rated
output of the UPS.
2. BATTERY LEVEL INDICATOR LEDs
*The third or top LED is lit when the battery is fully charged.
*The second LED is lit when the battery level is above the low battery warning
level.led
*The first LED is lit when the battery level is above the battery cutoff voltage.
3. LINE / SITE WIRING FAULT INDICATOR LED
For models configured for standard 120 volt domestic usage, this LED is lit to a
steady “on” state when Utility voltage is present. However, should the led flash on
and off, it is an indication that the HOT and NEUTRAL wires are reversed some
where in the building wiring. (Typically at the wall outlet.)
4. BATTERY MODE INDICATOR LED
This LED is lit when the unit is operating from battery.
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Page 20
5. BYPASS INDICATOR LED
When this led is lit, the UPS bypass is active. Should the Alarm led be lit at the
same time, the UPS detected an internal failure and the UPS must be serviced.
6. INVERTER INDICATOR LED
When this led is lit, the UPS inverter is operating and powering the connected load.
7. GREEN MODE LED INDICATOR
This led is lit when the connected output load of the UPS drops to under 10% of
the full rated output of the UPS, providing SW3 is in the "down" position (Green
Mode Enabled) as shown on page 7. The UPS is automatically set to bypass mode
and the inverter is turned off, reducing the power requirement. NO BATTERY
BACKUP IS PROVIDED IN THIS MODE. (The UPS is shipped from the factory with
SW3 in the "up" or disabled position.)
8. OVER CREST INDICATOR LED
This led lights up when the connected load is close to the peak current rating of the
UPS.
9. ALARM INDICATOR LED
This led is lit during the following conditions:
a. The inverter voltage is too high or low.
b. UPS over-temperature condition.
c. The battery voltage is too high.
d. The internal DC Bus has an under or over voltage condition.
e. The internal microprocessor or memory failure.
10. ON / OFF BUTTON
The following describes the different modes of operation for this button:
a. Depressing this button when the UPS is off, and the utility voltage is not present,
or with the UPS input circuit breaker in the off position, will cause the UPS to DC
start and run on internal battery momentarily and shutdown.
b. Pressing this button while the UPS is on, and utility is present, will place the UPS
into bypass mode.
c. Pressing this button when the UPS input circuit breaker has been turned off, or
when the utility voltage is not present, will turn off the UPS.
TO TURN UPS ON : CONNECT THE UPS TO UTILITY POWER AND TURN ON THE
BATTERY DISCONNECT CIRCUIT BREAKER FIRST, THEN TURN ON THE MAIN AC
CIRCUIT BREAKER LOCATED ON THE REAR PANEL. DO NOT PRESS THE “ON”
BUTTON LOCATED ON THE FRONT PANEL OR THE UPS WILL BE PLACED INTO
BYPASS MODE.
TO TURN UPS OFF: TURN OFF THE MAIN CIRCUIT BREAKER LOCATED ON THE
REAR PANEL AND DEPRESS THE "ON/OFF" BUTTON UNTIL THE UPS BEEPS AND
WAIT FOR THE UPS TO SHUT DOWN AND TURN OFF (ABOUT 30 SECONDS).
11. TEST BUTTON
The following describes the different modes of operation for this button:
a. Pressing the Test button while in Green Mode will disable Green Mode.
b. Pressing the Test button while utility is present will put the UPS through a self-test
diagnostic.
c. Pressing the Test button while in battery mode will turn the battery Audible alarm
off. Depressing it again will turn the Audible alarm back on.
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Page 21
AUDIBLE ALARMS
Audible alarm signals are divided into two different levels of alarm status. Category one
alarms represent normal or correctable operational alarms. Category two alarms are
sounded in the event of abnormal operation.
1. Category one alarms:
a. Two short beeps followed by three short beeps.
Notifies the user that the SG UPS is configured with the optional battery
pack and is in BATTERY MODE.
- - - - - = SG UPS IS IN BATTERY MODE
b. A continuous short beep.
The SG UPS is operating from battery and is in a LOW BATTERY operation.
- - - - - - - - = SG UPS IS IN A LOW BATTERY CONDITION
c. One long beep prior to a short beep.
The SG UPS is in an OVER LOADED, OVER CREST CONDITION. Remove
some load from the UPS output to correct this condition.
- = SG UPS IS IN OVERLOAD OR OVER CREST
d. One short beep is sounded when either the ON/OFF or TEST buttons are
pressed and held. This notifies the user the associated actions have been
initiated by the UPS.
- = WHEN SG UPS FRONT PANEL ON, OFF AND TEST BUTTONS ARE DEPRESSED.
2. Category two alarms:
a. Three short beeps indicate the SG UPS output voltage is out of proper
operating range.
- - - = SG UPS OUTPUT VOLTAGE IS OUT OF PROPER RANGE.
b. Four short beeps indicate the SG UPS output frequency is out of proper
operating range. The UPS must be repaired.
- - - - = SG UPS OUTPUT FREQUENCY IS OUT OF PROPER RANGE.
c. Five short beeps indicate the SG UPS is in an over-temperature condition.
Check for proper UPS cooling fan operation or blockage.
- - - - - = SG UPS INTERNAL TEMPERATURE IS TOO HIGH.
d. Should the internal POWER UP SELF-TEST fail, the SG UPS will sound the
following alarms denoting the failure mode:
* A continuous rapid beeping for about 5 seconds, then the SG UPS shuts
down - The UPS output voltage is out of range.
- - - - - - - - - - - - - - - - - - - - - - - - - = UPS OUTPUT VOLTAGE IS OF RANGE.
* A continuous rapid beeping for about 2 seconds and the SG UPS shuts
down - The SG UPS performed a DC start, but there is no output
frequency set in the UPS memory. Plug the UPS into your local utility
power and turn the UPS on to set it for your local utility power frequency.
- - - - - - - - - - = The SG UPS performed a DC start, but there is no output frequency set in
memory. Connect the UPS to your local utility power and turn on the UPS. Your local utility
frequency is now set into the UPS memory. The next time the UPS is DC Started, its output
frequency will be set automatically.
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Maintenance Bypass Operating Instructions
Unless configured as a frequency converter, SG 5 & 6kVA models are equipped with an
internal maintenance bypass switch. The switch is located on the rear panel of the UPS and is
clearly identified, See page 15. The maintenance bypass switch is a manual second bypass
primarily provided for service purposes and should not be confused with the internal UPS
static bypass. It provides a means of changing the internal UPS batteries while maintaining
power to the critical loads connected to the output of the UPS. It also can a provide method
of supplying power to the critical load around the UPS electronics in the event of a hard UPS
failure.
CAUTION
Improper use of the maintenance bypass switch will result in damage to the UPS.
The following procedures must be followed to assure proper UPS operation.
To place the UPS on Maintenance Bypass when the UPS is functioning normally perform the
following:
1. Place the UPS into internal bypass by depressing the multi-function “ON.OFF”
button located on the UPS front control panel. You can verify the UPS is in
internal bypass as the yellow “BYPASS” light will be illuminated.
Note: The UPS must be in the internal bypass mode prior to performing the next step.
2. The Maintenance Bypass switch may now be turned clockwise to the “Bypass”
position. The UPS is now operating directly from utility power.
When the UPS is off, the Maintenance Bypass switch may be turned to “Bypass” position and
the input AC circuit breaker turned on to power the loads connected to the UPS output.
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Page 23
COMMUNICATIONS INTERFACES
7 8 9
Location:
The RS-232 interface is standard on all SG series UPS models. The port is
located on the UPS rear panel, via a DB-9 female connector.
Supported Protocols
UPSILON 2000 & SEC SmartMon
BAUD RATE ------- 2400bps
DATA LENGTH---- 8 bits
STOP BIT----------- 1 bit
PARITY-------------- None
DB-9 Connector Pin Assignment
Pin # Function explanation I/O
9 RS 232 Rx INPUT
6 RS 232 Tx OUTPUT
7 Ground
CHAPTER 4
CHAPTER 4
RS-232 INTERFACE
1
2
3
4
5
6
TX
GND
GEN
RX
CAUTION
When making a connection between a computer and the UPS RS-232 port,
always use the green cable supplied with the UPS.
CAUTION
There are communications options that WILL DISABLE the RS-232 port and
render it inoperable. The options are as follows:
a. Internal SNMP/HTTP agent option installed into the UPS
communications option slot.
The following options WILL NOT affect the operation of the RS-232 port:
a. Falcon Opto Coupler based signal interface board installed in the
communications option slot.
b. Any Falcon relay-based, dry contact signal interface board
installed in the communications option slot.
CAUTION
DB-9 Signals are not isolated and intended for connection to like RS-232
interfaces. DO NOT APPLY ANY OTHER VOLTAGES TO THESE PINS!
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Page 24
DRY CONTACT & OPTO COUPLER INTERFACE BOARD OPTIONS
DB-9
PIN DESCRIPTION
9, pins six
DB-9F PIN
& JUMPER
ASSIGNMENTS
Typical Falcon Dry Contact Relay Board
JP1
JP2
JP3
J1
J2
J3
PIN & JUMPER ASSIGNMENT FOR THE FALCON
UA88374 RELAY OPTION BOARD
(no on-bypass signal)
1 Low Battery ( When UPS reaches low battery, contact activates)
(J1, 1-2 short = N.O) (J1, 2-3 short = N.C)
2 JP2 shorted = Low Battery common & all other shorted JP commons
JP2 open = common for low battery only
3 Utility Loss N.O. ( At loss of utility voltage, contact activates)
4 Utility Loss N.C. ( At loss of utility voltage, contact activates)
5 JP1 shorted = Utility Loss common & all other shorted JP commons
JP1 open = Utility Loss common only
6 Remote Shutdown common
7 Remote Shutdown
(J2, 1-2 short = outside power) (J2, 2-3 short = inside power)
1-2 shorted. Applying an external 12V signal across the DB-
and seven, while the UPS is on battery, will turn the UPS off.
2-3 shorted. Applying a short directly across the DB-9, pins six and
seven, while the UPS is on battery, will turn the UPS off.
8 Alarm (Upon a UPS fault or failure the contact activates)
(J3, 1-2 short = N.O.) (J3, 2-3 short = N.C.)
9 JP3 shorted = Alarm common & all other shorted JP commons
JP3 open = Alarm common only
PIN & JUMPER ASSIGNMENT FOR THE FALCON
UA88376 RELAY OPTION BOARD
(with on-bypass signal)
PIN DESCRIPTION
1 Low Battery ( When UPS reaches low battery, contact activates)
(J1, 1-2 short = N.O) (J1, 2-3 short = N.C)
2 JP2 shorted = Low Battery common & all other shorted JP commons
JP2 open = common for low battery only
3 Utility Loss N.O. ( At loss of utility voltage, contact activates)
4 Utility Loss N.C. ( At loss of utility voltage, contact activates)
5 JP1 shorted = Utility Loss common & all other shorted JP commons
JP1 open = Utility Loss common only
6 Remote Shutdown common
7 Remote Shutdown
(J2, 1-2 short = outside power) (J2, 2-3 short = inside power)
1-2 shorted. Applying an external 12V signal across the DB-9, pins six
and seven, while the UPS is on battery, will turn the UPS off.
2-3 shorted. Applying a short directly across the DB-9, pins six and
seven, while the UPS is on battery, will turn the UPS off.
8 On Bypass or Alarm (Upon the UPS going to bypass or a UPS failure
the contact activates)
(J3, 1-2 short = N.O.) (J3, 2-3 short = N.C.)
9 JP3 shorted = On bypass, Alarm common & all other shorted JP
commons
JP3 open = On bypass, Alarm common only
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Typical Falcon Opto-coupler Interface Card
PIN ASSIGNMENT FOR THE FALCON
UA88373 OPTO-COUPLER OPTION BOARD
(no-bypass signal)
PIN DESCRIPTION
1 Not Used
2 Utility Loss (N.O.) (Closes upon utility loss)
3 Utility Loss (N.C.) (Opens upon utility loss)
4 Common for pins 2, 3 & 5
5 Low Battery (N.O.) (Closes at low battery)
6 Remote Shutdown
Applying a +5-+12Vdc voltage level for >500ms,
while the UPS is on battery will shutdown the
UPS
7 Not Used
8 Not Used
9 Not Used
To CPU
Alarm Signal
(C)
(E)
OPTO Board Internal Circuitry
(K)(B)
(A)
Utility Loss
6
7
8
DB-9
2
3
4
5
Low Battery Signal
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Page 26
CHAPTER 5
CHAPTER 5
Maintenance & Technical Support
1. Care & Maintenance
FALCON®SG Series UPSs are designed to be maintenance-free. They can be
cleaned with a damp cloth or non-abrasive cleanser, providing the UPS is
turned off and the input plug is disconnected from the utility source.
On a regular basis, check the vents to make sure they are kept free from
accumulation of dust, dirt or lint.
2. Battery Life vs. Temperature
For full battery life, keep the UPS close to an ambient temperature of 77ºF.
The batteries should never be exposed to temperatures below 40ºF and above
104ºF.
.
3. Battery Replacement
This UPS contains sealed maintenance-free batteries (VRLA). When situated in
a typical office environment, with the proper charging and limited cycling, the
batteries can last many years. In home, office or computer room
environments, the batteries should be replaced every three to five years.
Battery Replacement Must Be Performed by Qualified Personnel.
WARNING
Never attempt to service batteries. High voltage exists within the unit, which
could cause electrical shock. Servicing of batteries should be performed or
supervised by personnel knowledgeable of batteries and the required
precautions. Keep unauthorized personnel away from batteries.
When replacing the UPS batteries, use the same number and type of batteries.
NEVER
A. NEVER dispose of batteries in a fire, as batteries will explode.
B. NEVER dispose of used batteries or the UPS in the trash or landfill as it is
against federal and state laws. The UPS and Batteries must be recycled.
For UPS and battery recycling information, please contact our service
department for the name and address of the nearest battery recycling facility.
CAUTION
A. Do not open or mutilate the battery or batteries. Released electrolyte is
harmful to the skin and eyes. It may be toxic.
B. A battery can present a risk of electrical shock and has a high short circuit
current.
REFER ALL BATTERY SERVICING OR REPLACEMENT TO A
QUALIFIED SERVICE TECHNICIAN. NEVER ATTEMPT TO
REPLACE THE BATTERIES YOURSELF.
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Page 27
The following precautions should be observed by a qualified technician when
working with batteries.
1. Remove watches, rings, or other metal objects.
2. Use tools with insulated handles.
3. Wear rubber gloves and boots.
4. Do not lay tools or metal parts on top of batteries.
4. Storing the UPS and Batteries
Should you need to store the UPS for a long period, fully recharge the battery
just prior to storage and recharge the battery every 4 months by plugging the
UPS into a power outlet. It is recommended that the batteries charge for 24
hours after long-term storage.
5. FCC Considerations
This equipment generates and uses radio frequency energy and if not installed
and used properly in strict accordance with the manufacturer's instructions,
may cause interference to radio and television reception. All models covered in
this manual have been tested and found to comply with the limits for a Class A
computing device, in accordance with the specifications in FCC regulations,
Part 15, Subpart J, which are designed to provide reasonable protection
against such interference.
If this equipment does cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and on, the
user is encouraged to try to correct the interference by one or more of the
following measures:
a. Reorient or relocate the receiving antenna.
b. Increase the separation between the equipment and the receiver.
c. Connect the equipment into an outlet on a circuit different from that to
which the receiver is connected.
d. Consult the dealer or an experienced radio/television technician for
assistance.
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6. Technical Support
Your FALCON®Electric SG Series UPS is backed by one of the finest customer
service teams assembled. Write, call, fax or email should you require
technical assistance or service.
Please have your UPS model, serial numbers and date of purchase on hand
prior to your call. The model & serial numer information is located on labels
located on the rear panel of the unit. This information is essential in retrieving
your unit’s historical records. Should our service department determine service
is required, you will be given a Return Material Authorization number (RMA)
along with return shipping instructions.
Falcon Electric, Inc.
5106 Azusa Canyon Road
Irwindale, CA. 91706
Service 800.842.6940
Voice 626.962.7770
Fax 626.962.7720
Email: service@falconups.com
WWW.FALCONUPS.COM
The RMA number issued must appear on the outside of the shipping carton.
The original shipping container must be used when returning any SG Series
product. Falcon®Electric will not assume any responsibility for shipping
damage. In the event of shipping damage, you will be notified of the damage
and be instructed to file a claim with the freight carrier. You will be billed for all
repairs caused by the shipping damage. You must submit a copy of our repair
invoice to the carrier for reimbursement.
All units must be returned prepaid. The address and shipping instructions will
be given to you at the time the RMA is issued.
7. Requesting Technical Information or Support
You may request technical information or support by email or telephone.
Please send your technical or support questions by email to:
SUPPORT@FALCONUPS.COM
You may contact a FALCON support engineer directly by calling the FALCON
support line between 9:00 am and 4:00 pm PST.
800.842.6940
8. FALCON Web Support
Product data sheets, specifications and owner’s manuals are available in
Adobe®Acrobat .PDF format on our corporate website.
WWW.FALCONUPS.COM
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WARRANTY
GENERAL PROVISIONS
FALCON® ELECTRIC INC., hereby warrants product shipped under this agreement to be free from defective workmanship for a period of two years
following date of shipment. This Limited New Product Warranty Agreement only applies to covered repairs to the product occurring within the United
States and Canada.
EXCLUSIONS:
The following are not covered by the Falcon Electric Limited New Product Warranty:
1. DAMAGE DUE TO ACCIDENTS, FRAUD, INTENTIONAL NEGLIGENCE, MISUSE, IMPROPER INSTALLATION,
UNAUTHORIZED ADJUSTMENTS, MODIFICATIONS, ALTERATIONS, DISCONNECTION, TAMPERING: Accidents or acts of
nature or other events beyond the control of Falcon Electric, damage from impact, contaminants, fire, or water, misuse of the
product such as sustained overloading, improper installation or operation, operation in an uncontrolled environment.
2. DAMAGE DUE TO IMPROPER INSTALLATION OR LACK OF MAINTENANCE: Lack of proper maintenance as outlined in the
owner's manual.
3. NORMAL MAINTENANCE: Cleaning, replacement of leaking or outdated batteries.
4. DAMAGE DUE TO ALTERATIONS: Alterations by changing or adding to the product by any unauthorized personnel or service
organization.
5. DAMAGE CAUSED BY OTHER THAN ORIGINAL EQUIPMENT PARTS. Any malfunctions caused by the use of other than Falcon
Electric original equipment parts such as batteries, line cords and plugs, output receptacles, or any other part.
6. BROKEN OR TAMPERED WARRANTY SEALS: Falcon Electric will deem all warranties null and void in the event warranty seals
are broken or show signs of removal or tampering.
7. CONSEQUENTIAL DAMAGES: This Limited New Product Warranty does not cover any consequential or secondary damages that
may be suffered as a result of usage of the product or the need to repair or replace a warranted part except to the extent coverage
of such damage is required by the state whose law governs the Falcon Electric Limited New Product Warranty.
8. REPAIRS BY UNAUTHORIZED SERVICE ORGANIZATIONS OR PERSONNEL: Otherwise covered repairs when the prescribed
repair is not performed by the Falcon Electric Service Center or by a Falcon Electric authorized third party service organization.
9. LIABILITY FROM USE OF THE PRODUCT: Liability for damage to property or injury or death of any person arising out of the
operation, maintenance, or use of the product weather.
10. Warranty void if the battery is allowed to discharge below the minimum battery cutoff point. To prevent such discharge, remove the
battery fuse, or switch the battery disconnect to the off position when the unit is to be stored without the AC power being supplied
to the UPS for more than two days. The battery must be recharged every three to four months when not in use.
11. This product is not recommended, and Falcon Electric Inc. will not knowingly sell this product, for use with life support and other
designated “critical devices". ANY SUCH USE BY A USER AUTOMATICALLY VOIDS AND DISCLAIMS ANY AND ALL
WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY, IMPLIED WARRANTY OF FITNESS FOR A
PARTICULAR PURPOSE, AND EXPRESS WARRANTIES THAT THIS PRODUCT WILL CONFORM TO ANY AFFIRMATION OR
PROMISE, FOR THIS PRODUCT AND THE USER AGREES THAT IN NO EVENT SHALL FALCON ELECTRIC INC. BE LIABLE
FOR CONSEQUENTIAL OR INDIRECT DAMAGES.
LIMITS OF LIABILITY:
TRANSFER:
This Falcon Electric Limited New Product Warranty is not transferable in the event of the product ownership being transferred during the warranty coverage period.
ITEM COVERAGE:
LIMITATION OF LIABILITY: THERE IS NO LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL LOSS OR DAMAGE UNDER THESE
WARRANTIES INCLUDING BUT NOT LIMITED TO, LIABILITY FOR INJURY, LOSS OF LIFE, PROPERTY DAMAGE, LOSS OF USE, LOSS
OF DATA, LOSS OF TIME, INCONVENIENCE OR COMMERCIAL LOSS, OR BREACH OF IMPLIED OR EXPRESSED WARRANTIES. ANY
AND ALL SUCH LIABILITY IS EXPRESSLY EXCLUDED. IN NO EVENT SHALL FALCON ELECTRIC BE RESPONSIBLE FOR ANY
AMOUNT EXCEEDING THE ACTUAL MARKET VALUE OF THE PRODUCT. Some states do not permit the exclusions of limitations of
incIdental or consequential damages, so these limitations may not apply to you.
Effective January 1, 2000, FALCON® ELECTRIC hereby warrants product shipped under this Agreement to be free from defective workman
ship for a period of two years following date of shipment. Coverage under this Falcon Electric New Product Warranty Agreement commences
with the date of shipment defined as the date on the Bill of Lading. If no Bill of Lading is issued, the date of shipment shall be shown on
seller's shipping document. The Falcon Electric Limited New Product Warranties expire two years from the aforementioned commencement
date. Falcon Electric Inc. reserves the right to make changes, additions, and/or other improvements in its products without incurring any
obligation to install them on its products previously sold. This Warranty is valid for product as sold.
1. For product located in the continental United States and Canada deemed by Falcon Electric to be covered under this warranty,
Falcon Electric will pay shipping costs associated with the return and repair of product under the following conditions only:
a. Falcon Electric will pay shipping costs both to and from our U.S. Service Center for the first 30 days from the original
date of invoice. During this 30 day period, Falcon Electric may elect to ship a new unit to replace the defective product.
b. After the first 30 days and up to 90 days from the original date of invoice, the end-user is responsible for shipping costs
associated with sending the defective unit to the Falcon Electric U.S. Service Center. Falcon Electric will pay shipping
costs associated with returning the repaired product to the end-user. During this 60 day period Falcon Electric may elect
to offer a loaner unit, providing the end-user agrees to pay for all shipping costs associated with transportation of the
loaner unit both from and return to the Falcon Electric U.S. Service Center.
c. All shipping costs for product submitted beyond 90 days of the original date of invoice is the responsibility of the end-
user.
27
Page 30
SG Series
TM
UPS PLUS
®
5-6kVA MODELS
Model Number
Nominal VA 5000 5000 5000 6000 6000 6000
Electrical Input
SG5K-1TX & -
-1TXC
SG5K-2TX &
-2TXC
SG5K-2T
& -2TC
SG6K-1TX SG6K-2TX &
-2TXC
SG6K-2T
& -2TC
Nominal AC Voltage 120V 230V 230V 120V 230V 230V
AC Voltage Range 87-140V 170-275V 170-275V 87-140V 170-275V 170-275V
Current-Amps
Frequency 50/60 Hz ±5%
38.7 20.3 19.5 46.6 24.3 23.4
Efficiency (Typical) > 79% > 82% > 79% > 82%
Power Factor Correction > 0.95
Electrical Output
Watts 3500 4200
AC Voltage
(Switchable except where noted)
120 & 208V or
120 & 220V or
120 & 240V
(No Switching)
(1)
120V
(1)
(1)
208V
220V
230V
240V
208V
220V
230V
240V
120 & 208V or
120 & 220V or
120 & 240V
(No Switching
(1)
120V
(1)
)
(1)
208V
220V
230V
240V
208V
220V
230V
240V
Isolation Transformer No Yes No No No Yes No No
Frequency 60Hz 50/60Hz 50/60Hz 50/60Hz 60Hz 50/60Hz 50/60Hz 50/60Hz
Voltage Regulation
Frequency Stability
Step Load Change
±
4%
±
3%
±
0.3% (Battery Mode)
±
7% for 100% load variation
±
4%
±
3%
THD – Linear Loads < 3%
THD – Non-Linear Loads < 7% <5% < 7% <5%
Overload 105% for 50 Seconds
Crest Ratio 3:1
(1) Contact the factory for output settings.
.
Battery
DC Voltage
Type
Back Up Time @ Full Load
@ 1/2 Load
Recharge Time
Battery times are approximate.
Electrical Connections Input
Electrical Connections Output
Contact the factory for other input/output options.
Environmental
9 Minutes
28 Minutes
12V, 7AH Sealed Lead Acid Maintenance-Free
-1TX
-1TXC
-2T
-2TC
-2TX
-2TXC
-1TX
-1TXC
-2T
-2TC
-2TX
-2TXC
Hardwire Hardwire
L5-50P
Hardwire Hardwire
(2) duplex
5-20R &
(1) L6 -30R
Hardwire Hardwire
L6-30P
Hardwire Hardwire
(2) duplex
5-20R &
(1) L6-30R
(1) L6 -30R
240V
7 Minutes
18 Minutes
10 Hours to 90%
Hardwire Hardwire
L6-30P
Hardwire Hardwire
L6-30P
(2) duplex
5-20R &
(1) L6 -30R
L6-30P
(1) L6-30R
Operating Temperature 0º C to 35º C (32º F to 95º F)
Humidity 10% to 95% Non – Condensing
Altitude 7,000 Feet
Cooling Low Velocity Forced Air Fans
Audible Noise @ 1 Meter < 55dBA
Controls and Indicators
LED Line, Inverter, Battery Reserve, Load, Bypass, Alarm, Crest, Battery & Load Capacity Level
Audible Alarms DC Mode, Low Battery, Over/Under Voltage, Over/Under Frequency, High Temp., Over Load, Fault Alarm
Communications RS-232 Serial Port (Bundled UPSilon 2000 Software)
Mechanical
Dimensions H x W x D inches
(mm)
Weight lb. (kg) T
Agency Listing
Hardwired Models
Receptacle Models
TX
TC
TXC
UL1778, CUL,
FCC Class A
32.1 x 10.2 x 27.0 (815.3 x 259.0 x 685.8)
-2T: UL1778, CUL, FCC Class A, CE
All others: UL1778, CUL, FCC Class A
216 (98)
299 (136)
239 (108)
322 (146)
UL1778, CUL,
FCC Class A
32.1 x 10.2 x 21.8 (815.3 x 259.0 x 553.7)
-2T: UL1778, CUL, FCC Class A, CE
All others: UL1778, CUL, FCC Class A
Available Options: Extended Run Time Battery Packs, Make-Before-Break Maintenance Bypass, SNMP/HTTP Network Card,
Frequency & Voltage Conversion.
©
2004 Falcon®Electric, Inc. All rights reserved. Falcon®and the Falcon Electric logo are registered trademarks of Falcon Electric, Inc.
All other brand names and trademarks are the property of their respective owners.
The information and specifications stated in this document are subject to change without notice.
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