Falcon XG2.2K-1T, XG3K-1T, XG1.5K-1T User Manual

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

OWNER'S

OPERATING

MANUAL

XG Series Mini-Tower or Rackmount UPS Plus®

Uninterruptible Power Supply Models

XG1.5K-1T,

XG2.2K-1T & XG3K-1T

Shown in mini-tower position with base brackets installed.

2005 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. 2005-10-14
Falcon®, Falcon® Electric and UPS Plus logos are registered trademar ks of Falcon Electric Inc
OM48030 Rev.

TABLE OF CONTENTS

SAFETY INFORMATION………………………….. 3

1.0 INTRODUCTION…………………………………….4

2.0 CIRCUIT DESCRIPTIONS…………………. 5
Input Filter
Current and Power Factor Regulator
DC/AC Inverter
Charger
DC/DC Converter
Battery
Bypass Switch
Output Filter

3.0 INSTALLATION…………………………………… 6
Unpacking
Inspecting the Equipment
Rack-Mount UPS Setup
Free-Standing UPS Installation
Battery Module Installation

4.0 DISPLAY AND CONTROLS……………………. 12
Indicators and LCD Display
Controls

5.0 OPERATION……………………………………… 15
Operating Modes
Turning UPS On
Turning UPS Off

6.0 CONFIGURATION………………………………. 17
Green Mode Setting
Voltage Setting

7.0 COMMUNICATION……………………………… 19
RS-232 Port
Dry Contact Option Boards

8.0 MAINTENANCE…………………………………. 22
UPS and Battery Care
Storing the UPS and Batteries
When to Replace Batteries
Battery Pack Replacement
Testing New Batteries
Recycling the Used Battery
Fuse Replacement

9.0 TROUBLESHOOTING…………………………..26
Audible Alarms and UPS Conditions
Troubleshooting Guide

SPECIFICATIONS………………………………. 28
BATTERY RUN TIMES…………………………... 30

WARRANTY…………………………………………31

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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 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 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, installation and operation of this UPS.

STORAGE AND TRANSPORTATION

This UPS must be handled with care and given special attention due to the high energy stored
within its internal sealed lead acid batteries. The shipping container should be retained in the
event the UPS needs to be returned for service.

INSTALLATION

Install this UPS in a clean environment, free from moisture, flammable gases or fumes and
corrective 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 scientific and data processing equipment. It is not intended for use
with life support and other designated “life-critical” applications.

The maximum UPS output load must not exceed that shown on the UPS rating label. DO NOT
CONNECT equipment that could overload the UPS or demand half-wave rectification from the
UPS, for example: electric drills, vacuum cleaners or hairdryers.

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

Warning

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

BATTERY

Once batteries have reached the end of their life, ensure they are disposed properly. REFER
TO YOUR LOCAL LAWS AND REGULATIONS FOR BATTERY RECYCLING REQUIREMENTS.

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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.

CAUTION

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.

1.0 INTRODUCTION

Manual Overview
This user manual has been written to provide basic information about the Falcon XG Series

UPS Plus. XG models are available in nominal power ratings of 1500, 2200 and 3000 VA . The
XG Series is a compact, double conversion, “on-line” UPS. It provides continuous power
conditioning, tight output voltage regulation and a true sinewave output. The XG Series UPS
protects your sensitive electronics equipment against the widest range of power problems,
including power failures, power sags, power surges, brownouts, line noise, high voltage
spikes, frequency variations, switching transients, and harmonic distortion.

This manual also describes unpacking, unit installation, the major features of XG series UPS,
as well as detailing operation, configuration and troubleshooting.

The specifications section states all of the detailed parameters of operation for the Series, and
provides general information on approvals and certifications.

Brief XG Overview
The Falcon XG Series UPS may be installed in either of two formats. Brackets are supplied to

facilitate installation into a standard 2U, 19 inch equipment rack slot, or free-standing on a
table top in a mini-tower tower format.

The XG Series front panel features includes a graphical LCD display to indicate the status of
the operation. The display enables the user or field service engineer to easily monitor and
troubleshoot localized power problems, in addition to UPS operation. UPS control is
accomplished through STANDBY, FUNCTION/TEST and SET/ALARM SILENCE buttons. Two
levels of audible alarms are also provided when the unit is operating on battery.

The XG Series rear panel has an RS-232 port to provide communications between the UPS and
a network server or other computer systems. This port when used along with the supplied
UPSILON software, gives the ability to remotely test the UPS, set UPS parameters, monitor
power status. The software will also automatically save open computer files and initiate an
unattended shutdown, in the event of a loss of utility.

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BLOCK DIAGRAM

2.0 CIRCUIT DESCRIPTIONS

INPUT FILTER
This internal UPS circuit provides surge protection, certified to meet IEC 61000-4-5 and IEC
801-5. It also filters both electro-magnetic interference (EMI) and radio frequency interference
(RFI). It minimizes surges or RFI interference present on the utility line.

CURRENT AND POWER FACTOR REGULATOR
In normal operation, this circuit converters utility AC power to regulated DC power for inverter
use. It ensures the input current maintains a sine waveform to minimize the amount of current
distortion that will be reflected to the utility. The XG Series UPS can tolerate a wide input
range and has an overload power factor regulator alarm to alert the user in the event the UPS
has an excessively heavy output load, while operation from a utility source with abnormally
low input voltage.

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

DC/AC INVERTER
In normal on-line operation, the Inverter utilizes the regulated DC output to invert DC 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 on-line and continuously generating clean, regulated AC output power to the load.
The XG Series has a pure sinewave output, which is produced with a Pulse Width Modulation
(PWM) Inverter. As a result, the UPS output is very stable, even with nonlinear loads.

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BATTERY
The XG Series UPS utilizes a flame retardant battery pack comprised of four 12V 7 AH, valve­regulated, and sealed lead acid batteries. All XG battery packs are interchangeable. They are
easy to install or change. To maintain battery design life, the user should operate the UPS in
an ambient temperature of 68oF to 77oF (20oC to 25oC). Extended Battery modules are available
to provide extend battery run times.

CHARGER
The battery charger uses the energy from the utility power 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. The charger will continue to operate as long as the
utility voltage is over 60 Vac.

BYPASS TRANSFER SWITCH
The XG Series UPS automatically switches to bypass to energize the connected load when
UPS encounters an overload, over temperature, over input current, over crest-factor load
(designed for 3:1 nonlinear load), or a UPS failure condition. Should any of these events
occur, the UPS will automatically transfer to bypass mode with an audible alarm, and provide
a “bypass” indication on the LCD display.

OUTPUT FILTER
This filter prevents electro-magnetic conductance (EMC) leakage and RFI noise to the UPS
output.

3. 0 INSTALLATION

UNPACKING
The XG Series UPS may be shipped in a number of boxes, depending on the model and

configuration ordered. The number of boxes you have received should be as indicated:
MODEL BATTERY MODULE NUMBER OF BOXES
XG1.5K-1T n/a (internal battery pack) 1 box shipped

XG2.2K-1T 1 battery module 2 boxes shipped
XG3K-1T 1 battery module 2 boxes shipped

If you have not received the proper number of boxes, please contact Falcon Electric Customer
Service at 1-800-842-6940

This UPS is shipped complete with all cables required for operation, along with UPSILON
software, and rackmount ears for 19” shelf mounting. A full list of the box contents is
provided as follows:

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XG1.5K-1T XG2.2K-1T / XG3K-1T
1 box contains: 2 boxes contain:

Box 1:
UPS module with fitted battery pack UPS module without battery
RS-232 cable RS-232 Cable
Software CD Software CD
Manual Manual
19” rack ears (+ screws) 19” rack ears (+ screws)
Tower Mounting feet Tower Mounting feet

Box 2:
Battery Module
Battery connection cable
Keyhole hardware
19” rack ears (+ screws)
1 set of mounting plates

INSPECTING THE EQUIPMENT

Visually inspect the UPS for freight damage. If any equipment has been damaged during
shipment, keep the shipping cartons and packing materials for 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:

1. YOU MUST file with the carrier within 15 days of receipt of the equipment;

2. YOU MUST send a copy of the damage claim within 15 days to Falcon Electric, Inc.

CAUTION

The UPS and Battery Module are heavy. Take proper precautions when lifting or moving them.
Install the UPS indoors in a controlled environment; place it in an area with unrestricted

airflow around the unit, away from water, flammable liquids, gases, corrosives, and
conductive contaminants. Maintain a minimum clearance of 4 inches in the front and rear of

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the UPS. Maintain an ambient temperature range of 32

F to 104oF (0oC to 40oC). To maximize
the life time of the batteries, an ambient temperature of 68oF to 77oF (20oC to 25oC) is
recommended. OPERATION IN TEMPERATURES ABOVE 77OF (25OC) WILL REDUCE
BATTERY LIFE.

The XG Series UPS can be installed in either a free-standing mini-tower or into a 19 inch
equipment rack. Follow the appropriate instructions in either RACK-MOUNT UPS SETUP or
FREE-STANDING UPS INSTALLATION.

RACK-MOUNT UPS SETUP

All XP Series UPSs are shipped with front panel mounting ears that allows the unit to be
installed in a 19” rack. Each UPS unit and external battery enclosure needs 2U of rack space.

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NOTE!

The rack-mounting ears WILL NOT support the weight of the UPS by themselves.

They are only to be used to secure the UPS to the front rails of the rack.

Mounting rails or an equipment shelf are required to support the weight of each

UPS or battery module.

Use the following procedure to install the UPS in a rack:

1. Place the UPS on a flat, stable surface with the front of the UPS facing you.

2. Align the mounting ears with screw holes on the side of the UPS and secure with the
supplied screws.

3. If installing the Battery Module, repeat above STEPS.

4. For slide rail installations, fasten the inner parts of the slide rails to the UPS on both
sides with the screws provided.

5. ** Securing hardware and slide rails are sold separately. Contact Falcon Electric for
these additional options and any assistance needed.**

6. Attach the two mounting brackets to the rack’s mounting rails. The brackets allow
adjustment of up to eight inches of the slide assembly mounting position, front-to­back, on the rack-mounting rails. Determine which adjustment holes to use on the
bracket, and attach it to the slide assembly on the stationary outer.

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7. Install the slide assemblies, with brackets into the rack enclosure.
The return flanges on the mounting brackets and outer parts fit to the inside of the
rack-mounting rails.

8. Make sure the slide assemblies are in the same alignment position on all four rack­mounting rails. After checking alignment, TIGHTEN ALL SCREWS.

9. Insert the UPS, with inner parts attached , into the slide assemblies. You may need to
depress the locking mechanisms on the inner and outer parts of the slide
assemblies to allow the slides to retract. The UPS should move smoothly forward
and backward on the slide assemblies. If not, recheck alignment.

10. Once the UPS is installed in the rack, the load may be connected.

Ensure the load equipment is turned off; plug all loads into the output receptacles on
the rear of the UPS. Plug the UPS into a dedicated wall receptacle properly protected
by a circuit breaker or fuse in accordance with national and local electrical codes.
Use a 15 amp rated device for 1000, or 1500 VA units, 20 amp for the 2200VA, and 30
amp for 3000VA. The wall receptacle must be grounded.

11. To turn on the UPS switch on the INPUT BREAKER; then turn on the connected
equipment.

FREE-STANDING UPS INSTALLATION

When using the XG Series UPS in a free-standing configuration, the XG1.5K-1T model is
provided with mounting feet (shown below, left) to stabilize the UPS. The XG2.2K-1T and
XG3K-1T models are provided with keyhole hardware to “lock” the units together in free
standing mode. This key lock is also required if additional battery packs are added.

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Mounting feet Mounting feet for additional Battery
Modules

XG1.5K-1T Free Standing XG2.2K-1T / XG3K-1T Free Stranding

The default LCD display mounting is for horizontal (Rackmount) viewing. To orient the LCD
display for vertical (Mini-Tower) viewing, remove the front plastic bezel by unscrewing the
screws. The unit has two front panel covers. Remove the left cover first. Next, pull the right
panel forward evenly. Refer to the following figure, unscrew the LCD board and rotate it 90
degrees, to the correct position for viewing. Mount the front covers back and reinstall the
screws.

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