Rockwell Automation 1609-BD UPS User Manual

User Manual

Bulletin 1609 Uninterruptible Power Supply

Catalog Numbers 1609-D and 1609-B

Important User Information

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication your local Rockwell Automation® sales office or online at

http://www.rockwellautomation.com/literature/) describes some

important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and Figures in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and Figures.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

SGI-1.1 available from

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

IMPORTANT

Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Identifies information that is critical for successful application and understanding of the product.

WARNING: This is a category C2 UPS product. In a residential environment, this product may cause radio interference, in which case the user may be required to take additional measures.

Preface

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation

Resource Description

Industrial Automation Wiring and Grounding Guidelines, publication

Product Certifications website,

Publication Number:

1609-UM007_-EN-P

Publication Number:

1609-UM008_-EN-P

Publication Number:

1609-IN012_-EN-P

Publication Number:

1609-IN013_-EN-P

Publication Number:

1609-IN014_-EN-P

Publication Number:

1609-IN015_-EN-P

1770-4.1

http://www.ab.com Provides declarations of conformity, certificates, and

Provides general guidelines for installing a Rockwell Automation industrial system.

other certification details.

Bulletin 1609 UPS Management Software User Manual

Network Management Card - Cat. No. 1609-ENET User Manual

Bulletin 1609-D Installation Instructions

Bulletin 1609-B Installation Instructions

Surge Protective Device (Cat. No. 1609-SPD) Installation Instructions

Network Management Card (Cat. No. 1609-ENET) Installation Instructions

You can view or download publications at

http:/www.rockwellautomation.com/literature/. To order paper copies of

technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

Rockwell Automation Publication 1609-UM009A-EN-P - January 2013 3

Preface

Notes:

4 Rockwell Automation Publication 1609-UM009A-EN-P - January 2013

Bul. 1609-D Installation Instructions

Bul. 1609-B Installation Instructions

Bul. 1609-EXBAT Installation Instructions

Battery Wiring and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mount the UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Hardwire UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Selection of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Connect Power and Equipment to the UPS . . . . . . . . . . . . . . . . . . . . . . . . . 10

Bul. 1609-D Block Figure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Battery Wiring and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Mount the UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Hardwire UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Selection of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Connect Power and Equipment to the UPS . . . . . . . . . . . . . . . . . . . . . . . . . 14

1609-B Block Figure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Battery Wiring and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Mount the 1609-EXBAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Selection of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Connect the 1609-EXBAT to the UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

General Information 1609-D and 1609-B

Troubleshooting

Recommended Battery for use with the UPS . . . . . . . . . . . . . . . . . . . . . . . .19

Dry I/O Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

USB Communication Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Manual or Remote Enable/Disable of UPS Output Selection . . . . . . . . . 20

Manual Enable/Disable/Self-test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Remote Enable/Disable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Display LED Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

UPS LED Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Output Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Output Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Over Temperature from the Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Over Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Over Voltage from The DC/DC Converter of Inverter . . . . . . . . . . 23

Over Voltage from The Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Under Voltage from The Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Over Voltage from the Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Under Voltage from the Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Charger Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

TMOV Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Missing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Replace Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Rockwell Automation Publication 1609-UM009A-EN-P - January 2013 5

Table of Contents

Troubleshooting (continued)

Specifications

Dimensions

Service Instructions

UPS Management Software Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . .25

UPS Network Managemenr Card Troubleshooting . . . . . . . . . . . . . . . . . .26

Bul. 1609-D Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Bul. 1609-B Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Bul. 1609-D Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Bul. 1609-B Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Bul. 1609-EXBAT Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Bul. 1609-BRK Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Service Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

6 Rockwell Automation Publication 1609-UM009A-EN-P - January 2013

-Bulletin 1609-D Installation Instructions

ATTENTION: Do not service the 1609-SPD without disconnecting the power

sources due to electric shock hazard for risk of severe injury or death.

Battery Wiring and Installation

1. To access the battery compartment remove the three screws and the battery door.

2. Remove the battery container, jumpers, and wire harness from the battery compartment. Place the battery container and batteries onto a flat surface. Use the provided jumper wires to connect the batteries in series. Connect the positive terminal (red) of the battery to the negative terminal (black) of another battery. See photo below for details.

3. Connect the red wire of the harness to the positive terminal (top red) and the black wire of the harness to the negative terminal (bottom black). See photo below for details.

Rockwell Automation Publication 1609-UM009A-EN-P - January 2013 7

Bulletin 1609 UPS

Battery Wiring and Installation (cont.)

4. Fold the battery container and seal it with tape.

5. To connect the batteries to the UPS, insert the batteries into the battery

compartment, open the white connector retainer and connect the two cables together as shown in the photo below.

Mount the UPS

6. To complete the battery installation, close the white connector retainer and reattach the battery door with the three screws (torque of 8.7+/-1.7 lb-in).

The UPS-D is designed to mount on the back of the panel or to the floor of the enclosure. The UPS mounts to a bracket assembly (1609-BRK) that allows it to mount to either the panel or floor (see Figure 1 below).

Figure 1 - Mounting the UPS

8 Rockwell Automation Publication 1609-UM009A-EN-P - January 2013

Bulletin 1609 UPS

Hardwire UPS

Selection of Cables

Wiring of the UPS should be performed by a qualified electrician using the appropriate wire gauges.

Table 1 - AC Main Input/Output Wiring for UPS:

Item Specification

Wire Size 14 AWG

Minimum temperature 75 °C

Wire conductor material Copper only

Tightening torque for terminals 4.4 lb-in.

Table 2 - DC Input / Output Wiring for External Battery Cabinet:

Item Specification

Wire Size 10 AWG

Minimum temperature 75 °C

Wire conductor material Copper only

Tightening torque for terminals 12 lb-in.

WARNING: To reduce the risk of fire, connect only to a circuit with 20 amperes maximum branch circuit overcurrent protection in accordance with the National Electric Code, ANSI/NFPA 70.

A disconnect switch shall be provided by others for AC output circuit. To reduce the risk of fire, connect only to a circuit with branch circuit overcurrent protection for 20 amperes rating in accordance with the National Electric Code, ANSI/NFPA 70.

Rockwell Automation Publication 1609-UM009A-EN-P - January 2013 9

Bulletin 1609 UPS

Connect Power and Equipment to the UPS

WARNING: This UPS features Surge Protection Device (SPD) is located

on the left front of the unit. Disconnect all power sources before servicing due to Electric Shock Hazard for risk of severe injury or death.

1. Connect the appropriate input power to the UPS's input (Line, Neutral and Ground) terminals (see Figure 2).

2. Connect the specified equipment to the UPS's output (Line, Neutral and Ground) terminals (see Figure 2).

Figure 2 - System Wiring

1609-D Block Figure

3. Connect any additional optional accessories (1609-ENET card).

Input

Breaker

Input

Filter

Backfeed

Relay

Backfeed

Relay

AC to DC DC to DC DC to AC

AVR

AC to AC

Inverter

Relay

Output

10 Rockwell Automation Publication 1609-UM009A-EN-P - January 2013

1609-B Installation Instructions

ATTENTION: Disconnect the 1609-SPD before servicing, due to electric shock

hazard for risk of severe injury or death.

Bulletin 1609 UPS

Battery Wiring and Installation

Note: Batteries are not included with the 1609-B UPS

1. To access the battery compartment remove the three screws and the battery door.

3. Fold the battery container and seal it with tape.

Rockwell Automation Publication 1609-UM009A-EN-P - January 2013 11

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