Falcon SG800-1T User Manual

OWNER'S

OPERATING

MANUAL

SG SeriesTMUPS Plus

®

Uninterruptible Power Supply Models:

SG800-1T, SG800-2T

SG1K-1T, SG1K-2T, SG1.5K-1T & SG1.5K-2T
SG2K-1T, SG2K-2T, SG2K-1TX & SG2K-2TX & SG2K-1TXI & SG2K-2TXI
SG3K-1T, SG3K-2T, SG3K-1TX & SG3K-2TX & SG3K-1TXI & SG3K-2TXI

Detailed SG Series product specifications are available in PDF format at www.falconups.com

FALCON®Electric Inc., 5116 Azusa Canyon Rd., Irwindale, California 91706, [phone], Fax [phone], Email: [e-mail]

2011 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. 2011-09-15
Falcon®, Falcon®Electric and UPS Plus®logos are registered trademarks of Falcon Electric, Inc.
OM48021-1-3K Rev. H

-1TX & -2TX & -1TXI & -2TXI

-1T & -2T Models

SG UPS Features. ...... 1

SG Series On-line 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 ..... 4

Dip Switch Settings DIagrams .... 6

Extended Battery Bank Interconnection . . . 7
Extended Battery Bank Installation Procedure . . 8
Extended Battery Bank Selection Guide . . . 8

Chapter 3.

Operation ....... 9

Front Panel Indicators & Function Key Diagram . . 9

Front Panel Function Description .... 9

Audible Alarms ......11

Category One Alarms .....11

Category Two Alarms .....11

Chapter 4.

Rear Panel Details ......12

SG800-1T & SG1K-1T Rear Panel ...12
SG800-2T & SG1K-2T Rear Panel ...12
SG1.5K-1T, SG2K-1T & SG3K-1T Rear Panel . . 13
SG1.5K-2T, SG2K-2T & SG3K-2T Rear Panel . . 13
SG2K-xTX & TXI & SG3K-xTX & TXI Rear Panel . 14

Chapter 5.

Communications Interfaces. ....15

RS-232 Interface (DB-9) .....15

Communications Option Slot .....15

Contact Closure & Opto Interface Options ...16

Chapter 6.

Maintenance & Technical Support ....19

Care & Maintenance ......19

Battery Life vs. Temperature .....19

Battery Replacement ......19

Storing the UPS and Batteries.....20

FCC Considerations ......20

Technical Support & RMA Procedure ....21

Requesting Technical Information or Support. . . 21

FALCON Web Support ......21

Warranty ........22

Specifications ........23

SG800VA - SG1.5KVA ......23

SG2KVA - SG3KVA -1TX, -1TXI. ....24

SG2KVA - SG3KVA all other models. ....25

TABLE OF CONTENTS

SG SERIES UPS FEATURES

SG SERIES ON-LINE UPS SYSTEM BLOCK DIAGRAM

True Double Conversion On-Line Design

Input Power Factor Correction
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

1

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.

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

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 unplug this UPS and remove the UPS battery fuse prior to cleaning and never apply liquid or spray
detergent on the UPS.

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.

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 plug this UPS into its own output as this may damage the UPS. 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. Never connect surge protected plug strips to the UPS output.

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. Never connect surge protected plug strips to the
UPS output.

DO NOT remove or unplug the input cord when the UPS 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

CAUTION

CAUTION

CAUTION

IMPORTANT

DO NOT

CAUTION

CAUTION

IMPORTANT

2

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 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.

3

CHAPTER 2

CHAPTER 2

INSTALLATION INSTRUCTIONS

1. Verify the following is included in the UPS shipping carton:
(1) UPS, (1) Software Diskette(s) & Manual, (1) Power Cord (800VA-1KVA models only),
(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 dip switches located on the UPS rear panel for the nominal UPS output
voltage desired. See the dip switch setting tables located on page 6.

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, the 1-3kVA models have had
the battery fuse removed. INSTALL THE BATTERY FUSE PRIOR TO TURNING ON THE
UPS INPUT CIRCUIT BREAKER OR PLUGGING IN THE UPS. Prior to installing the

battery fuse, depress the battery pre-charge button located on the UPS rear panel
for two seconds prior to inserting the battery fuse. Not applicable to 1kVA models.

NEVER REMOVE THE BATTERY FUSE WHILE THE UPS AC CIRCUIT BREAKER IS
TURNED ON AND OPERATING FROM THE UTILITY VOLTAGE OR UPS DAMAGE
MAY RESULT. THE UPS MUST BE COMPLETELY SHUT DOWN PRIOR TO DISABLING
THE INTERNAL BATTERY SUPPLY.

In the event this UPS is to be turned off or stored for more than four weeks, the battery
fuse must be removed to prevent excessive 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 due to the normal battery
self-discharge asociated with sealed lead-acid batteries. Failure to follow these procedures
may cause battery damage and invalidate your warranty.

CAUTION

CAUTION

4

5. For SG800VA - SG1kVA and 208-240V models, connect the power cord to the UPS
inlet located on the UPS rear panel. On SG1.5K - SG3K 120V models the line cord is
permanently attached to the UPS.

6. Select a suitable location for the UPS, near enough to the computer or equipment to
to be protected. Connect the power cord(s) for the equipment to be protected to the
UPS output receptacles.

VERIFY THE TABLE OR SURFACE SUPPORTING THE UPS WILL SUPPORT THE
WEIGHT OF THE UPS AND ANY OPTIONAL EXTENDED BATTERY BANKS.

800VA-1KVA UPS MODELS = 33 lbs. (14.9 kg)

1.5KVA- 2KVA UPS MODELS = 68.4 lbs. (31 kg)
3KVA UPS MODELS = 81.4 lbs. (37 kg)
2 & 3kVA-1TX, -1TXI, -2TX & -2TXI models = 150 lbs. (68 kg)
MINI-TOWER EXTENDED BATTERY BANKS = 123 lbs. (55.8 kg) MAX. (EACH BANK)
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 8 for
further instructions.

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. Plug the UPS power cord into the nearest grounded wall outlet. SG1K-2T 208-240V
models will automatically turn on since they do not have an input circuit breaker. For
all other SG models, go to step 12.

11. Turn the input circuit breaker located on the UPS rear panel to the “on” position. The
internal UPS fan and front panel "line" indicator should turn on, followed by the
"bypass" LED, and after several seconds, the "inverter" LED.

12. Turn on the connected equipment and verify the UPS does not go into overload by
observing the front panel load indicator LEDs.

13. The UPS, optional external battery bank(s) and additional chargers should be plugged
in and turned on for 24 hours to charge the batteries. During this initial 24 hour
charging period, battery backup time may be substantially reduced.

TO TURN OFF THE UPS, SWITCH OFF THE INPUT CIRCUIT BREAKER
LOCATED ON THE UPS REAR PANEL 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 SHUTDOWN. 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 SHUTDOWN PROPERLY.
SHOULD THIS OCCUR, TURN OFF THE INPUT CIRCUIT BREAKER AGAIN AND
WAIT UNTIL THE UPS SHUTS DOWN.

IMPORTANT

5

SWITCH SETTINGS FOR -1 MODELS

SWITCH SETTINGS FOR -2 MODELS

GREEN MODE SWITCH SETTINGS FOR ALL MODELS

VIEW OF DIP SWITCHES LOCATED ON THE UPS REAR PANEL

6

TYPICAL EXTENDED BATTERY BANK & UPS INTERCONNECTION

(Mini-tower models shown; same applies for floor standing banks)

INSTALLATION PROCEDURE FOR EXTENDED BATTERY BANKS

1. Remove the battery fuse located on the UPS rear panel. See illustration above.

2. Locate the battery interconnect cable(s).

3. Connect one end of the battery interconnect cable to the the UPS battery
connector. Connect the other end of the cable to the top battery connector on the first
battery bank. See illustration above.

4. If a second battery bank is to be connected, connect one end of the second battery
interconnect cable to the bottom battery connector on the first battery bank and
connect the other end of the cable to the top battery connector of the second battery
bank. (See illustration above.)

5. Follow the instructions in the proceeding step for additional battery banks.

6. Reinstall the battery fuse. A popping sound may be heard when inserting the fuse.

This is normal as the battery banks are pre-sharing the UPS.

7. For all battery banks that have the 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. Turn on the battery charger circuit breaker(s) (up).
f. 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 placed shutdown for more than

two weeks, turn off the battery charger circuit breaker, disconnect the
interconnecting cables and remove the battery fuse from the UPS battery or
damage may occur.

8. RETURN TO PAGE 5, Paragraph 8 FOR FURTHER INSTALLATION INSTRUCTIONS.

2ND BATTERY BANK

1ST BATTERY BANK

UPS

1ST CABLE

2ND CABLE

TO ADD MORE BANKS,
DAISY CHAIN TO NEXT

BANK FROM THIS

OPTIONAL BATTERY

CHARGER CIRCUIT

BREAKER

OPTIONAL BATTERY

CHARGER CIRCUIT

BREAKER

POWER INLET FOR

OPTIONAL CHARGER

POWER INLET FOR

OPTIONAL CHARGER

7

UPS

BATTERY

FUSE

TYPICAL

BATTERY

CONNECTOR