Staco Energy FirstLine User Manual

The FIRSTLINE UPS

Form No.003-2323 Rev B 09/04/2009

301 Gaddis Boulevard • Dayton, Ohio 45403
U.S. Toll Free 866-261-1191
[phone] • Fax: [phone]
Web site: www.stacoenergy.com

User’s Manual

25KVA, 30KVA, AND 37.5KVA

Before Installing the UPS:

-Read all safety and installation instructions.

-Make sure that the UPS is the correct model for your application.

-Verify that the available power source matches the input rating of the UPS. Unless the
UPS is in the tall cabinet and is equipped with a transformer option, the source should be
120 volts line to neutral, three phase, ABC sequence, with a grounded neutral.

Before starting the UPS:

-Read all safety and operating instructions.

-Verify that the UPS is installed in a clean, temperature controlled area.

-If the UPS is installed at an altitude above 1000 meters, the output load capability must be
derated by 1% for each 100 meters above 1000 meters.

-Verify that the installation includes an input breaker of the proper rating.

-Verify that the wiring is correct and that all connections are neat and tight.

-Verify that the internal batteries have been connected.

-If an optional Extended Run Time Battery Cabinet is present, verify that it is equipped with
the optional breaker or that an external breaker has been provided as part of the
installation. The battery breaker should be closed before the UPS is started.

-Make sure that single phase loads are fairly evenly distributed across the three output
phases. Balanced operation maximizes efficiency and reliability. (Check the individual
output phase currents when the UPS is operating)
.

FirstLine UPS

CONTENTS

Section 1 .............................................................................................................................. 1

Introduction ....................................................................................................................... 1

FirstLine UPS Part Number System ................................................................................. 2

Battery Option ................................................................................................................... 2

Accessories ...................................................................................................................... 3

Section 2 .............................................................................................................................. 4

Safety Warnings ............................................................................................................... 4

Section 3 .............................................................................................................................. 6

UPS Setup ........................................................................................................................ 6

Inspecting The Equipment ................................................................................................ 6

Floor Loading .................................................................................................................... 6

Clearances ....................................................................................................................... 6

Unloading the Cabinet(s) .................................................................................................. 7

Placing The Cabinet ....................................................................................................... 10

Section 4 ............................................................................................................................ 11

Electrical Installation ....................................................................................................... 11

Wiring Preparation .......................................................................................................... 11

Wiring Installation ........................................................................................................... 13

Wiring Specifications and Diagrams ............................................................................... 15

Removing and Replacing The Front Panel ..................................................................... 18

Connect The Internal Battery .......................................................................................... 18

Section 5 ............................................................................................................................ 20

Communication ............................................................................................................... 20

Customer Interface ......................................................................................................... 20

Section 6 ............................................................................................................................ 22

Operation ........................................................................................................................ 22

Display Functions ........................................................................................................... 24

Section 7 ............................................................................................................................ 25

Initial Start Up ................................................................................................................. 25

Normal Operation ........................................................................................................... 25

Manual Transfer to Bypass ............................................................................................. 26

Manual Transfer to Inverter ............................................................................................ 26

External Bypass Arrangement ........................................................................................ 26

Automatic Transfer To Bypass ....................................................................................... 27

Automatic Transfer To Inverter ....................................................................................... 27

OverLoad ........................................................................................................................ 28

Inverter ........................................................................................................................ 28

Bypass ........................................................................................................................ 28

Rectifier ....................................................................................................................... 28

Section 8 ............................................................................................................................ 29

Battery Removal, Installation, and Service ..................................................................... 29

Polarity Verification Procedure ....................................................................................... 32

Stopping the Rectifier in the UPS ................................................................................... 33

UPS Maintenance ........................................................................................................... 34

Battery Fuse Replacement ............................................................................................. 35

Section 9 ............................................................................................................................ 37

Optional FirstLine Extended Run Time Battery Cabinet ................................................. 37

Section 10 .......................................................................................................................... 38

FirstLine UPS Technical Specifications .......................................................................... 38

Form No. 003-2323 Rev B

FirstLine UPS

Table 1-Part Numbering System .......................................................................................... 2

Table 2-Symbols .................................................................................................................. 4

Table 3-Model Floor Loadings .............................................................................................. 6

Table 4-Input/Output Terminal ........................................................................................... 13

Table 5-Ground Lugs ......................................................................................................... 13

Table 6-FirstLine UPS 10-20kVA Current Requirements ................................................... 14

Table 7-Terminal Block Wiring ........................................................................................... 16

Table 8-Torque Values for TB1, 2, 3, 4 .............................................................................. 21

Table 9-Indicator Status and Description ........................................................................... 23

Table 10-Menu Map for Display Functions ......................................................................... 24

Figure 1-The FirstLine UPS 25-37.5kVA .............................................................................. 1

Figure 2-UPS on pallet ......................................................................................................... 7

Figure 3-Shipping Bracket .................................................................................................... 8

Figure 4-Lifting fork area ...................................................................................................... 9

Figure 5-Leveling foot being adjusted down to the floor ..................................................... 10

Figure 6-Bottom View ......................................................................................................... 12

Figure 7-Terminal Blocks ................................................................................................... 13

Figure 8-UPS Wiring-Single Line Diagram ......................................................................... 17

Figure 9-Removing the UPS Front Panel ........................................................................... 18

Figure 10-Internal Battery ................................................................................................... 19

Figure 11-Communication Options and Control Terminals ................................................. 20

Figure 12-TB3 .................................................................................................................... 21

Figure 13-TB4 .................................................................................................................... 21

Figure 14-FirstLine Front Panel Display and Control Module ............................................. 22

Figure 15-Battery Tray ....................................................................................................... 29

Figure 16-Battery Tray ....................................................................................................... 30

Figure 17-Battery Installation ............................................................................................. 31

Figure 18-The FirstLine Extended Run Time Battery Cabinet ............................................ 37

Form No. 003-2323 Rev B

FirstLine UPS

ESC

+

EPO

23.00 [584.2mm]

70.00 [1778.0mm]

FOR VENTILATION

WALL CLEARANCE

12.00 [304.8mm] MIN.31.94 [811.2mm]

23.00 [584.2mm]

52.00 [1320.8mm]

EPO

+

ESC

(2) RIGID CASTERS

(2) SWIVEL CASTERS

POWER CABLE ENTRY

7.25 [184.2mm] X 3.00 [76.2mm]

(4) LEVELING FEET

INTAKE VENTILATION HOLES

EXTERNAL BATTERY POWER CABLE ENTRY

2.25 [57.2mm] X 1.75 [44.5mm]

EXTERNAL BATTERY CONTROL

CABLE ENTRY

2.25 [57.2mm] X 1.75 [44.5mm]

32.38 [822.4mm]

SECTION 1

Introduction

The FirstLine uninterruptible power supply (UPS) is a true online, double-conversion, three­phase system that can be used to prevent loss of valuable electronic information and
minimize equipment downtime. It is ideal for protecting essential information technology
and electrical engineering infrastructure in corporate, telecom, health care, banking, and
industrial applications.

The FirstLine UPS continually monitors incoming electrical power and removes surges,
spikes, sags, and other irregularities that are inherent in commercial utility power. Working
with a building’s electrical systems, the UPS supplies clean, consistent power that sensitive
electronic equipment requires for reliable operation. During brownouts, blackouts, and other
power interruptions, batteries provide emergency power to safeguard operation.

Figure 1 shows two versions available: Short cabinet for compact 208/208 or 220/220
requirements and the tall cabinet for extended run time built in, or 480V I/O.

Form No. 003-2323 Rev B 1

Figure 1-The FirstLine UPS 25-37.5kVA

Full Part Number

kVA

Input Voltage

Output

Voltage

Run

Time

(min.)

Cabinet

Basic Part

No.

Battery

Option

Other

Options

25

208Y/120

208Y/120

11

Short

FLU-25S-20

-1

480

208Y/120

11

Tall

FLU-25T-42

-1

-I

480

480Y/277

11

Tall

FLU-25T-44

-1

-I

208Y/120

208Y/120

28

Tall

FLU-25T-20

-2

208Y/120

208Y/120

11

Tall

FLU-25T-20

-1

-I

220Y/127

220Y/127

11

Short

FLU-25S-22

-1

220Y/127

220Y/127

31

Tall

FLU-25T-22

-2 30

208Y/120

208Y/120

8

Short

FLU-130S-20

-1

480

208Y/120

8

Tall

FLU-30T-42

-1

-I

480

480Y/277

8

Tall

FLU-30T-44

-1

-I

208Y/120

208Y/120

22

Tall

FLU-30T-20

-2

208Y/120

208Y/120

8

Tall

FLU-30T-20

-1

-I

220Y/127

220Y/127

11

Short

FLU-30S-22

-1

220Y/127

220Y/127

24

Tall

FLU-30T-22

-2

37.5

208Y/120

208Y/120

5

Short

FLU-37S-20

-1

480

208Y/120

5

Tall

FLU-37T-42

-1

-I

480

480Y/277

5

Tall

FLU-37T-44

-1

-I

208Y/120

208Y/120

16

Tall

FLU-37T-20

-2

208Y/120

208Y/120

5

Tall

FLU-37T-20

-1

-I

220Y/127

220Y/127

5

Short

FLU-37S-22

-1

220Y/127

220Y/127

17

Tall

FLU-37T-22

-2

Other Options

Suffix

Notes

Isolation Transformer

-I

Isolation transformer required for use with delta (3­wire) input. Standard is K20 rated.

FirstLine UPS Part Number System

Table 1-Part Numbering System

FirstLine UPS

Battery Option

-1 = 1 string

-2 = 2 string

-0 = Without Batteries

220V Models are not listed to UL, CUL, or CSA.

Form No. 003-2323 Rev B 2

FirstLine UPS

Accessories

There are several external accessories that are designed to work with the FirstLine UPS:

The FirstLine Extended Run Time Battery Cabinet allows the addition of up to three

additional battery strings per cabinet to increase the available battery run time. Up to
three FirstLine Extended Run Time Battery Cabinets can be used with each UPS.
The cabinet is styled to match the FirstLine UPS. The battery cabinet can be ordered
with an optional disconnect switch or a user provided disconnect arrangement can
be used. The FirstLine Extended Run Time Battery Cabinet is listed to UL1778.

The FirstLine Options Cabinet is a steel enclosure designed to hold option devices

to be used in conjunction with the FirstLine UPS. The enclosure is styled to match
the UPS and includes provisions for terminating a number of conduits to facilitate
wiring. Available option devices include several transformers, a Maintenance Bypass
Switch (MBS), output panelboards, and output meters. The FirstLine Options
Cabinet is listed to UL1778.

The FirstLine Wall-Mounted Maintenance Bypass Switch is the same MBS switch

arrangement that is available in the Options Cabinet, but in a more compact
enclosure that mounts on a wall. The FirstLine Wall-Mounted Maintenance Bypass
Switch is listed to UL1778.

The FirstLine UPS is also available together with the FirstLine Extended Run Time

Battery Cabinet to form the FirstLine UPS Emergency Lighting System which is
listed to UL924.

Contact Staco Energy Company, your tailored power solutions provider, for

additional information.

Form No. 003-2323 Rev B 3

FirstLine UPS

Danger / Risk of Electric Shock

Caution

Risk of Explosion

Note

Ground Connection

Electrostatic Sensitive Device

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

SECTION 2

Safety Warnings

This manual contains important instructions that you should follow during installation and
maintenance of the UPS and batteries. Please read all instructions before operating the
equipment and save this manual for future reference.

READ AND FOLLOW ALL SAFETY INSTRUCTIONS
a. Do not use outdoors.
b. Do not route wiring across or near hot surfaces.
c. Do not install near gas or electric heaters.
d. Use caution when servicing batteries. Battery acid can cause burns to skin and

eyes. If acid is spilled on skin or in eyes, flush acid with fresh water and contact
a physician immediately.

e. Equipment should be installed where it will not readily be subjected to tampering

by unauthorized personnel.

f. The use of accessory equipment not recommended by the manufacturer may

cause an unsafe condition.

g. Do not use this equipment for other than intended use.

Table 2-Symbols

Form No. 003-2323 Rev B 4

FirstLine UPS

DANGER

WARNING

CAUTION

This UPS contains LETHAL VOLTAGES. All repairs and service should be
performed by AUTHORIZED SERVICE PERSONNEL ONLY. There are NO
USER SERVICEABLE PARTS inside the UPS.

This UPS contains its own energy source (batteries). The UPS output may

carry live voltage even when the UPS is not connected to an AC supply.

To reduce the risk of fire or electric shock, install this UPS in a temperature

and humidity controlled, indoor environment, free of conductive contaminants.
Do not operate near water or excessive humidity (95% maximum).

Input and output over-current protection and disconnect switches must be

provided by others.

Batteries can present a risk of electrical shock or burn from high short circuit
current. Observe proper precautions. Servicing should be performed by qualified
service personnel knowledgeable of batteries and required precautions. Keep
unauthorized personnel away from batteries.

Risk of explosion if batteries are replaced by an incorrect type. Replace with same
type and rating only.

Proper disposal of batteries is required. Refer to your local codes for disposal
requirements.

Never dispose of batteries in a fire. Batteries may explode when exposed to flame.

Form No. 003-2323 Rev B 5

FirstLine UPS

STANDARD MODEL FLOOR LOADING

25-30-37.5 KVA

Maximum Weight

Point Loading

Standard

1253 Lbs (568 kg)

399 lb/in2 (28 kg/cm2)

Extended Run

1765 Lbs (801 kg)

562 lb/in2 (39 kg/cm2)

480 I/O

1855 Lbs (841 kg)

590 lb/in2 (42 kg/cm2)

From Front of Cabinet

36” (91.4 cm) working space

From Back of Cabinet

12” (30.5 cm)

From Side of Cabinet

Minimum 24” (61 cm)

SECTION 3

UPS Setup

This section describes:

 Equipment inspection
 Floor loading and clearances
 Removing and replacing the cabinet panels
 Unloading the cabinet(s)

Inspecting The Equipment

If any equipment has been damaged during shipment, keep the shipping and packing
materials for the carrier or place of purchase and file a claim for shipping damage. If you
discover damage after acceptance, file a claim for concealed damage.

To file a claim for shipping damage or concealed damage: 1) File with the carrier within 15
days of receipt of the equipment, 2) Send a copy of the damage claim within 15 days to
your service representative.

Floor Loading

When planning the installation, consider the UPS weight for floor loading. The strength of
the installation surface must be adequate for point and distributed loading. The
approximate weights are shown in the following table.

Table 3-Model Floor Loadings

Clearances

The following clearances are recommended for the FirstLine UPS.

Form No. 003-2323 Rev B 6

FirstLine UPS

Pallet

Shipping bracket - (1) this
side and opposite side

Forklift access

from rear

CAUTION

Unloading the Cabinet(s)

The following tools are required for unloading the cabinet(s):

 Wrenches for 1/4” bolts and 1/2” nut
 Forklift

The UPS and optional cabinets are heavy (see Table 3). Unloading the cabinets
requires at least two people to safely remove the cabinets from the pallet.

To remove the UPS or optional cabinets from the ship pallet:

1. Remove all banding, wrapping, and foam protectors.

2. Loosen the six 1/2” nuts and washers securing the shipping brackets to the pallet
(see Figures 2 and 3).

3. Remove and discard the four 1/4” bolts and washers securing the shipping brackets
to the cabinet side panels. Also remove the four ¼” bolts and washers the bracket
surrounds but does not touch. Save these as they must be reinstalled later. Pull the
brackets away from the cabinet.

Form No. 003-2323 Rev B 7

Figure 2-UPS on pallet

FirstLine UPS

Remove and discard
1/4" bolt and washers
(4) places

Remove and discard
1/4" bolt and washers
(4) places

Pull (2) shipping brackets

away from cabinet.

Loosen (3) 1/2" nuts on each bracket

Remove (4) 1/4" bolts.
Reinstall after the unit is on the floor

Remove (4) 1/4" bolts.
Reinstall after the unit is on the floor

Figure 3-Shipping Bracket

4. Remove the front cover (see Figure 9) before inserting the lifting forks.

5. Ensure that the four (4) leveling feet are raised so that they will not touch the floor
when the cabinet is placed on the floor.

6. Lift the cabinet with a forklift from the rear of the unit, one to two inches (1”-2” [2.5­5cm]) above the pallet (see figure 5).

7. Slide the pallet completely away from the raised cabinet.

8. Slowly lower the cabinet to the floor or other appropriate flat service.

9. Reinstall the front cover and add (4) ¼” bolts and washers (see figure 3).

10. Roll the cabinet to the desired location

11. Do not move the cabinet to another location by forklift , as the cabinets are heavy

and may fall.

DO NOT ALLOW THE FORKLIFT TO MOVE WHILE THE CABINET IS
RAISED, ONLY MOVE THE CABINET VERTICALLY TO REMOVE THE
PALLET FROM UNDER THE CABINET.

Form No. 003-2323 Rev B 8

FirstLine UPS

Place forks in this area

so as not to damage the
leveling feet or casters.
Set forks to a maximum
13 inches at outside width.

Leveling foot

13.00" [330mm] Max.

Figure 4-Lifting fork area

Form No. 003-2323 Rev B 9

FirstLine UPS

Lower the leveling foot

to the floor to secure
the UPS in position

Placing The Cabinet

Once the cabinet has been rolled into position, remove the front panel to access the front
leveling feet by pulling the panel outward at the bottom of the unit until it unsnaps and then
lift up and off the cabinet (see figure 9). Adjust the leveling feet as shown in figure 5.

Figure 5-Leveling foot being adjusted down to the floor

Form No. 003-2323 Rev B 10

FirstLine UPS

WARNING

SECTION 4

Electrical Installation

The FirstLine has the following power connections:

 3-phase (L1, L2, andL3), neutral, and ground connection for rectifier/bypass input
 3-phase (L1, L2, and L3), neutral, and ground connection for load output

The input neutral connection is not used when the UPS is equipped with the optional
isolation transformer.

The nominal input/output voltages are:

 120/208 VAC is available in the short cabinet or tall cabinet.
 208 VAC, 60 Hz delta input is available when using the tall cabinet with an input

isolation transformer.

 127/220 VAC is available in the short or tall cabinet.
 480V, 60 Hz input is available when using the tall cabinet with an input transformer,

(isolation or auto.)

 480/480 Vac is available when using the tall cabinet with an input and output

transformer.

Input and output over current protection and disconnect switch must be provided by others.

Only qualified service personnel (such as a licensed electrician) should perform the
UPS installation and initial startup. Risk of electrical shock.

Wiring Preparation

To begin wiring the UPS:

1. Verify that the electrical connections to the installation site have been properly
installed.

2. A wall-mounted, user-supplied, readily-accessible disconnection device must be
incorporated in the input wiring.

Compare the circuit breaker ratings to the ones in Table 6 on page 14.

Form No. 003-2323 Rev B 11

FirstLine UPS

1.62 [41.3mm]

4.75 [120.7mm]

(4) LEVELING FEET

.81 [20.6mm]

4.75 [120.7mm]

(2) SWIVEL CASTERS

(2) RIGID CASTERS

FRONT

REAR

EXTERNAL BATTERY POWER

CABLE ENTRY

2.25 [57.2mm] X 1.75 [44.5mm]

EXTERNAL BATTERY CONTROL

CABLE ENTRY

2.25 [57.2mm] X 1.75 [44.5mm]

4.75 [120.7mm]

POWER CABLE ENTRY

7.25 [184.2mm] X 3.00 [76.2mm]

3. Switch off utility power to the distribution point where the UPS will be connected. Be
absolutely sure there is no power.

4. Determine your equipment’s grounding requirements according to your local
electrical code.

5. Remove the UPS rear panel.

6. Conduit landing plates are located at the rear bottom of the base to accommodate
bottom wire entry to the cabinet (see figure 6).

Remove plate and drill or punch hole to fit conduit bushing with Greenlee punch or similar
device. Make certain that the bushing will be clear in the opening in the base. Mount

bushing to plate and tighten to manufacturer’s recommendations. Replace the plate and

mount conduit.

Figure 6-Bottom View

Form No. 003-2323 Rev B 12

FirstLine UPS

NOTICE

FOR SUPPLY CONNECTIONS,

USE WIRES SUITABLE FOR AT

LEAST 75°C

A B C N

OUTPUT

INPUT

NCBA

INPUT/OUTPUT TERMINAL TIGHTENING TORQUE

#2/0 - #6 AWG

120 inch-pounds

#8 - #12 AWG

50 inch-pounds

GROUND LUGS TIGHTENING TORQUE

#10 AWG

35 inch-pounds

#8 AWG

40 inch-pounds

#4 - #6 AWG

45 inch-pounds

#1/0 - #2 AWG

50 inch-pounds

Wiring Installation

1. Unscrew and remove the rear panel.

2. Connect the input wires to the proper terminals shown in Figure 7. Insure proper
phase rotation. Input neutral is not required if the UPS is equipped with an optional
input isolation transformer.

3. Connect the output wires to the proper terminals shown in Figure 7.

4. Replace the rear panel.

Table 4-Input/Output Terminal

Table 5-Ground Lugs

Figure 7-Terminal Blocks

Form No. 003-2323 Rev B 13

UPS

Rating

Input

Voltage

Input

Transformer

Option

Max. Input

Current (A)

Allowed for

Specified

Branch

Protector

Maximum
Allowable Branch
Circuit Protection

(A)

25 kVA

208 V

None

80

100

25 kVA

208 V

Isolation

80

100

25 kVA

220 V

None

80

100

25 kVA

480 V

Standard auto

40

50

25 kVA

480 V

Isolation

40

50

30 kVA

208 V

None

100

125

30 kVA

208 V

Isolation

100

125

30 kVA

220 V

None

100

125

30 kVA

480 V

Standard auto

48

60

30 kVA

480 V

Isolation

48

60

37 kVA

208 V

None

120

150

37 kVA

208 V

Isolation

120

150

37 kVA

220 V

None

120

150

37 kVA

480 V

Standard auto

60

75

37 kVA

480 V

Isolation

60

75

UPS

Rating

Output

Voltage

Rated Max.

Output Current

(A)

(note 2)

Maximum
Allowable

Circuit

Protection (A)

PF=.8

PF=1

25 kVA

208 V

70

55

(note 1)

25 kVA

220 V

66

52

(note 1)

25 kVA

480 V

30

24

50

30 kVA

208 V

83

66

(note 1)

30 kVA

220 V

78

63

(note 1)

30 kVA

480 V

36

29

60

37 kVA

208 V

104

83

(note 1)

37 kVA

220 V

98

78

(note 1)

37 kVA

480 V

45

36

75

Table 6-FirstLine UPS 25-37.5 kVA Current Requirements

FirstLine UPS

Note 1: Output circuit protection requirement determined by distribution circuit.
Note 2: Do not apply continuous loads in excess of rated maximum output current. If the power factor of

Form No. 003-2323 Rev B 14

the load is not known, use PF=1. The UPS controls will permit transient loads within the limits
described in the OVERLOAD section of this manual.

FirstLine UPS

Note: Input neutral must be wired for proper operation or the UPS will not start.

Note: Do not over-tighten the screws; be sure to use the specified tightening
torque values shown in Table 4, Table 5, and Table 6.

Wiring Specifications and Diagrams

25 KVA, 208V: CAUTION to reduce the risk of fire, connect only to a circuit provided with

100 amperes maximum branch circuit protection in accordance with the
National Electrical Code, ANSI/NFPA 70.

25 KVA, 480V: CAUTION to reduce the risk of fire, connect only to a circuit provided with

50 amperes maximum branch circuit protection in accordance with the
National Electrical Code, ANSI/NFPA 70.

30 KVA, 208V: CAUTION to reduce the risk of fire, connect only to a circuit provided with

125 amperes maximum branch circuit protection in accordance with the
National Electrical Code, ANSI/NFPA 70.

30 KVA, 480V: CAUTION to reduce the risk of fire, connect only to a circuit provided with

60 amperes maximum branch circuit protection in accordance with the
National Electrical Code, ANSI/NFPA 70.

37.5 KVA, 208V: CAUTION to reduce the risk of fire, connect only to a circuit provided with
150 amperes maximum branch circuit protection in accordance with the
National Electrical Code, ANSI/NFPA 70.

37.5 KVA, 480V: CAUTION to reduce the risk of fire, connect only to a circuit provided with
75 amperes maximum branch circuit protection in accordance with the
National Electrical Code, ANSI/NFPA 70.

220V units should be equipped with the same maximum rated breaker as 208V units.

Form No. 003-2323 Rev B 15

UPS
Rating

Voltage

Input
Transformer
Type

Phase
Conductor
Min/Max

Neutral
Conductor
Min/Max

Neutral Conductor with
non-linear loads
Min/Max

Ground Wire
Min/Max
25kva

208/120

NA

#2/2-0

#2/2-0

#2/2-0

#8/1-0 208

isolation

#2/2-0

(none)

(none)

#8/1-0

220/127

NA

#2/2-0

#2/2-0

#2/2-0

#8/1-0

480/277

auto

#4/2-0

#4/2-0

#4/2-0

#10/1-0 480

isolation

#4/2-0

(none)

(none)

#10/1-0

30kva

208/120

NA

#1-0/2-0

#1-0/2-0

#1-0/2-0

#6/1-0 208

isolation

#1-0/2-0

(none)

(none)

#6/1-0

220/127

NA

#1-0/2-0

#1-0/2-0

#1-0/2-0

#6/1-0

480/277

auto

#4/2-0

#4/2-0

#4/2-0

#10/1-0 480

isolation

#4/2-0

(none)

(none)

#10/1-0

37.5kva

208/120

NA

#1-0/2-0

#1-0/2-0

#1-0/2-0

#6/1-0

208

isolation

#1-0/2-0

(none)

(none)

#6/1-0

220/127

NA

#1-0/2-0

#1-0/2-0

#1-0/2-0

#6/1-0

480/277

auto

#3/2-0

#3/2-0

#3/2-0

#8/1-0

480

isolation

#3/2-0

(none)

(none)

#8/1-0

OUTPUT-Minimum wire size required to support rated load. Smaller wire may be used if rated
load current is not needed and the appropriate circuit protection is applied.

UPS
Rating

Voltage

Output
Transformer
Type

Phase
Conductor

Neutral
Conductor

Neutral Conductor with
non-linear loads

Ground Wire

25 kVA

208/120

NA

#2

#2

#2

#8/1-0

220/127

NA

#2

#2

#2

#8/1-0

480/277

auto

#4

#4

#4

#10/1-0

30 kVA

208/120

NA

#1

#1

#1

#6/1-0

220/127

NA

#1

#1

#1

#6/1-0

480/277

auto

#4

#4

#4

#10/1-0

37.5kVA

208/120

NA

#1-0

#1-0

#1-0

#6/1-0

220/127

NA

#1-0

#1-0

#1-0

#6/1-0

480/277

auto

#4

#4

#4

#8/1-0

Table 7-Terminal Block Wiring

FirstLine UPS

Note: No output circuit protection is required if the output conductor sizes are at least as large as
the input conductors, unless the UPS is equipped with an input isolation transformer. If the UPS is
equipped with an input isolation transformer, the UPS is considered a separately derived source
and circuit protection for the output conductors must be provided.

Use at least 75°C-rated copper wire. Minimum wire size is based on 120/208 full load ratings
applied to NEC Code Table 310-16. Code may require a large AWG size than shown in this table
because of temperature, number of conductors in the conduit, or long service runs. Follow local
requirements.

Form No. 003-2323 Rev B 16

FirstLine UPS

INPUT

OUTPUT

+

-

(NONE)

NO BATTERY

(OPTION)

(OPTION)

BATTERY

EXTERNAL

EXTENDED

BATTERY

(OPTION)

(STANDARD)

BATTERY

(480Y)

(OPTION)

AUTOTRANFORMER

208Y

(STANDARD)

RECTIFIER

INVERTER

STATIC

SWITCH

(STANDARD)

208Y

TRANSFORMER OPTIONS OR
EXTENDED BATTERY REQUIRE
"TALL" CABINET.
(SAME FOOTPRINT AS "SHORT" CABINET)

220Y INPUT/ 220Y OUTPUT
MODELS ARE ALSO AVAILABLE.

(OPTION)

TRANSFORMER

(480Y)

-

+

-

+

ISOLATION

TRANSFORMER

(OPTION)

(208 )
(480 )

Per NEC article 300-20(2), all three-phase conductors must be run in the same conduit. Neutral and
ground must be run in the same conduit as the phase conductors.

Conduit to be sized to accommodate one neutral conductor the same size as the phase conductor
and one ground conductor. If two neutral conductors or an oversized neutral conductor are to be
installed, check the size of the conduit needed to accommodate the extra wire or size and use that
conduit size in place of the conduit size listed. Conduit sizes can be chosen from NEC Table C1,
type letters RHH, RHW, RHW-2, TW, THW, THHW, THW-2.

Figure 8-UPS Wiring-Single Line Diagram

Form No. 003-2323 Rev B 17

FirstLine UPS

BALL STUD CATCH

SHOULDER SCREW

KEYHOLE SLOT

Removing and Replacing The Front Panel

1. Pull the top of the panel outward until the ball studs unsnap.

2. Lift the panel up and off the cabinet.

To replace the panel:

1. Lower the shoulder screws at the top of the panel into the keyhole slots on the

cabinet.

2. Press the panel inward until the ball studs snap into place.

Figure 9-Removing the UPS Front Panel

Connect The Internal Battery

To be performed by authorized service personnel:

1. Remove front cover panel and interior panel.

2. Remove and discard shipping support panel mounted in front of the battery trays.

3. Inspect battery trays for signs of damage. Verify that all terminal connections are

sound.

4. Use a voltmeter to verify that the battery string is above 420 VDC at the battery plug

shown in figure 10.

5. Verify that the blue plug of the lower tray is connected to the blue plug of the upper

tray.

Form No. 003-2323 Rev B 18

FirstLine UPS

Black

DC input plug

Battery plug

Red

Blue plug

Blue plug

Black

Battery plug

Red

Never connect the two plugs from the same tray together. Severe damage and

injury could result.

6. If an Extended Battery Cabinet is to be connected, do so at this time. Refer to the

User’s manual for the FirstLine Extended Run Time Battery Cabinet. Also, refer to
the special notes in Section 8 of this manual.

7. Reference figure 10. Connect the battery plug to the DC input plug.

8. If the UPS is equipped with a second battery string, repeat steps 4, 5, and 7 for the

second battery string.

9. Replace front panels.

Form No. 003-2323 Rev B 19

Figure 10-Internal Battery

FirstLine UPS

4321 9 1087651 2 3 4 15141312114321 5 6 7 8 109

9 1087651 2 3 4

REAR VIEW

RS-232 Connector

TB1 REPO/Bypass
terminal block

TB2 Contact sensing inputs
terminal block

TB3 Form C contact outputs
terminal block

TB4 Opto-isolated outputs
terminal block

120V Output receptacle

fuse

120V Output duplex receptacle

F

U

S

E

SECTION 5

Communication

Figure 11 shows the location of the communication options and terminals on the UPS.

CAUTION: The 120V receptacle on the rear panel must only be used to power Staco
supplied communications accessories.

Note: TB1, TB2, TB3, TB4 plug-in terminal blocks, fuse, and fuse cap are
shipped in the zip-lock bag with this manual. Install them before powering
up the UPS.

Customer Interface

The Customer Interface is located on the rear cover of the UPS. There are seven dry
contact inputs that function as follows:
 TB1 terminals 1 and 2-Remote Emergency Power Off (REPO) contact closure

causes immediate shutdown of the UPS. Contact the factory if a normally closed
REPO switch is required.

 TB1 terminals 3 and 4-Bypass Switch Sensing (To Staco MBS, if present).
 TB2 terminals 1 and 2-Battery Charge Inhibit. For future use.
 TB2 terminals 3 and 4-Reduced Current Operation. For future use.
 TB2 terminals 5 and 6-Automaitc Restart Inhibit. For future use.
 TB2 terminals 7 and 8-not defined.
 TB2 terminal 9 and 10-not defined

Figure 11-Communication Options and Control Terminals

Form No. 003-2323 Rev B 20

FirstLine UPS

TORQUE VALUES FOR TERMINAL BLOCKS

ON CUSTOMER INTERFACE BOARD

#22 - #12 AWG

4.4 inch-pounds

1

3

TB3

Example

2

2

1

Vcc = 5.0 VDC

R

L

Vo

TB4

Typical
application


There are five sets of form-C dry contact available as outputs. They are capable of
switching up to 30 volts (AC or DC) at up to 1 amp. Listed in order of NO, COM, NC.

 TB3 terminals 1, 2, 3 – running on inverter.
 TB3 terminals 4, 5, 6- battery discharging.
 TB3 terminals 7, 8, 9- low battery reserve.
 TB3 terminals 10, 11, 12- on bypass.
 TB3 terminals 13, 14, 15- alarm present.

Figure 12-TB3

There are five sets of optically isolated open collector outputs available. They are capable
of switching up to 30 volts DC and up to 3 milliamps. Listed in order of Emitter, Collector.

 TB4 terminals 1,2 – running on inverter
 TB4 terminals 3,4 – battery discharging
 TB4 terminals 5,6 – low battery reserve
 TB4 terminals 7,8 – on bypass
 TB4 terminals 9, 10 – alarm present

Figure 13-TB4

An RS-232 DCE three wire interface is available. The UPS shipped with an installation CD
containing monitor software and an RS-232 cable. The monitor software will allow a single
user to connect the UPS to a computer via the RS-232 port for local monitoring of UPS
operation.

For advanced monitoring Ethernet and SNMP are supported via the RS-232 interface with
an external adaptor. A 120 volt AC outlet has been provided on the back panel of the UPS
for powering the external adaptor. Consult the factory for more details.

The local RS-232 monitor function cannot be used at the same time as the external
monitoring adaptor.

If the UPS is connected to the Staco Maintenance Bypass Switch, there are required
connections between TB1-3, TB1-4, TB3-10, TB3-11 and the MBS. If an MBS is present,
TB3-10, 11, 12 (“On Bypass”) contacts are not available to the user.

Table 8-Torque Values for TB1, 2, 3, 4

Form No. 003-2323 Rev B 21

FirstLine UPS

ESC

+

EPO

Bypass Indicator

Input Indicator

Inverter Indicator

On Bypass Indicator

Battery Indicator

Alarm Indicator

Output Indicator

Rectifier Indicator

SECTION 6

Operation

This SECTION contains information on how to use the FirstLine UPS, including front panel
operation, UPS startup and shutdown.

Control Panel Functions
The UPS has LCD with backlight. It provides useful information about the UPS itself, load

status, events, measurements, and setting (see figure 14).

Figure 14-FirstLine Front Panel Display and Control Module

Form No. 003-2323 Rev B 22

Indicator

Status

Description

Bypass

Off

Bypass input voltage or frequency not qualified

Bypass

Green

Bypass input voltage or frequency qualified

Bypass

Yellow

Inverter output not synchronized to bypass input

Bypass

Red

Bypass input voltage has incorrect phase sequence

Input

Off

Rectifier input voltage or frequency not qualified

Input

Green

Rectifier input voltage and frequency qualified

Input

Red

Rectifier input voltage has incorrect phase sequence

Rectifier

Off

System OFF or Rectifier input not qualified

Rectifier

Green

Rectifier is running normally

Rectifier

Yellow

Rectifier is running at input power limit

Rectifier

Red

Rectifier failure or DC Bus Fault, call for Service

Battery

Off

System OFF

Battery

Green

Battery is being charged or is at full charge

Battery

Yellow

Battery is discharging

Battery

Red

Battery fault or no battery present

Inverter

Off

System OFF or on Bypass

Inverter

Green

Running ON INVERTER (normal mode)

Inverter

Yellow

Bus voltage out of range or tripped on overcurrent

Inverter

Red

Inverter failure, call for service

On Bypass

Off

System OFF or not on Bypass (normal mode)

On Bypass

Green

ON Bypass

On Bypass

Yellow

On Bypass, overload present, reduce load before system
shuts down

On Bypass

Red

Static Switch Failure, Do Not Operate UPS, call for Service

Output

Off

System off

Output

Green

Output is present (On Inverter or on Bypass)

Output

Yellow

Output is overloaded, reduce load before system shuts down

Output

Red

Output failed or EPO was activated or REPO was activated

Alarm

Off

No alarms are present

Alarm

Yellow

An alarm is present

The following table shows the indicator status and description:

FirstLine UPS

Table 9-Indicator Status and Description

Form No. 003-2323 Rev B 23

FirstLine UPS

>

>

Alarms

Logs

<

<

\/ /\ \/

/\ \/

Scroll

Scroll

Alarms

Logs

/\

\/

Staco Energy Products

Bypass Input

>

V Ph A ___ L-L

<

Rectifier Input

>

I Ph B ___ Amp

I Ph C ___ Amp

\/

\/

Frequency ___ Hz

V Ph B ___ L-L

V Ph C ___ L-L

\/

\/

<

Battery

>

V Ph A ___ L-L

<

UPS Output

>

V Ph A ___ L-L

V Ph B ___ L-L

V Ph C ___ L-L

\/

I Ph A ___ Amp

I Ph C ___ Amp

\/

\/

Frequency ___ Hz

____ Volts DC

____ Amps DC

V Ph B ___ L-L

V Ph C ___ L-L

\/

I Ph A ___ Amp

I Ph B ___ Amp

Escape

Key

ESC

Display Functions

As the default or after 15 minutes of inactivity, the LCD displays the selectable startup
screen. The default is the Staco Energy Products Co. logo and can be changed to the
Mimic screen in the User Settings menu.

The backlit LCD automatically dims after a long period of inactivity. Press any button to
restore the screen.

Use the two middle buttons (↑ and ↓) to scroll through the menu structure. Press the →
button to enter a submenu. Press the  button to select an option. Press the button to
cancel or return to the previous menu.
The following table shows the basic menu structure.

Table 10-Menu Map for Display Functions

Form No. 003-2323 Rev B 24

FirstLine UPS

SECTION 7

Initial Start Up

To be performed by authorized service personnel.

1. Inspect for damage. Remove front cover panel, inner front access panel, front

shipping support panel, top cover, and rear panel. Look for signs of damage due to
handling including bent supports, loose components, etc.

2. Connect input power source and load to terminal blocks at rear of unit as described

in Section 4. Before apply power to Ups, verify that the correct voltage is available
and that the phase sequence is correct (A-B-C).

3. If an external bypass switch is to be used, contact the factory for the correct method

to interface contact sensing to the UPS.

4. Double check that there is no visible damage to the battery. Insure the battery is

connected as described in Section 4.

5. Reinstall the rear cover, the top cover, and the front inner access panel. Reinstall the

decorative front panel.

6. If one or more Extended Battery Cabinets are connected to the UPS, close the

circuit breaker on each cabinet, if they are equipped with this option.

7. Apply power to the UPS.

8. Press the on/off button to start the UPS.

Normal Operation

To start the UPS, press the on/off power button . If the bypass input is qualified (voltage,
frequency, and phase sequence correct), the UPS will start on bypass. The rectifier and
inverter will automatically start and the static switch will transfer the load to the inverter.

To stop the UPS, press the on/off button.

In an emergency, the UPS can be stopped by lifting the guard and pressing the “EPO”

button (Emergency Power Off). Activation of Emergency Power Off, either via the front
panel EPO button or via the Remote Emergency Power Off function (TB1 on the Customer
Interface), will also cause the system to reset, interrupting any display or communication
process that is underway.

The output circuits of the UPS; should not be considered safe unless the UPS is Off AND
the input power source to the UPS has been removed by opening the input disconnect
device which is external to the UPS.

If one or more Extended Battery Cabinets are connected to the UPS, do not open the
(optional) circuit breaker on any cabinet. If the circuit breaker is open, do not close the
circuit breaker while the UPS is operating. See Section 8 for the proper procedure to close
the circuit breaker.

Form No. 003-2323 Rev B 25

FirstLine UPS

Manual Transfer to Bypass

Verify that the bypass input is qualified by observing that the bypass indicator is green.
While holding down the ESC key, press the up-arrow key. When the conditions are met for
a transfer to bypass (bypass input is qualified and inverter is synchronized to bypass), the
static switch will transfer the load to bypass. After a few seconds, the mimic display will
update to show this.

Manual Transfer to Inverter

This procedure enables an automatic transfer to inverter. While holding down the ESC key,
press the down-arrow key. When the conditions are met for a transfer to inverter (inverter is
running and synchronized to bypass), the static switch will transfer the load to inverter.
After a few seconds, the mimic display will update to show this.

External Bypass Arrangement

If the UPS is connected to a Staco Maintenance Bypass Switch, refer to the manual for that
product for proper operation. The MBS is equipped with a label that describes common
transfer operations and a brief summary is provided below. Bypass switches provided by
others are not recommended as they are not equipped with the proper interlocks to prevent
backfeed, a hazardous condition that can be lethal to service personnel. Use of a non­Staco bypass switch may void the UPS product warranty.

The normal mode of operation (i.e. not bypass) requires that switches 1 and 3 in the MBS
are closed. The UPS should be operating in this state. To transfer operation of the load to
Maintenance Bypass mode, first perform a manual transfer to bypass per the procedure
above. Verify that the mimic display changes to show that the load is now connected to the
bypass line. Close Switch 2 in the MBS, then open Switch 3. Turn off the UPS, if desired,,
then open Switch 1.

To return from Maintenance Bypass to Normal mode, close Switch 1 and start the UPS,
Select manual Transfer to Bypass mode. Verify that the UPS is running and that the mimic
diagram shows that the output is being supplied from the bypass line. Close Switch 3, then
open Switch 2. Select Automatic Transfer to Inverter per the procedure below.

If the UPS fails to start and it is desired to get power to the load, open Switches 1 and 3 on
the MBS, then close Switch 2. The load is now powered from the bypass, Note that the
UPS logic is not involved in the decision to apply bypass power to the load, so there is no
assurance that the bypass source is suitable for powering the load. This procedure is

performed at the user’s risk. Also note that the UPS will not start when the bypass source is

out of specification.

Form No. 003-2323 Rev B 26

FirstLine UPS

Automatic Transfer To Bypass

The static switch will automatically transfer the load to bypass if the bypass input is
qualified and one of the following conditions applies:

1. Initial start-up of UPS.

2. The inverter is unable to support the load due to a) failure, b) overload, c) battery

reaches end of discharge voltage threshold.

3. Loss of output voltage is detected.

Automatic Transfer To Inverter

The static switch will automatically transfer the load to inverter if all of the following
conditions are true:

1. The inverter has been started and is running normally.

2. The inverter is phase-locked to the bypass input.

3. There was no manual transfer to bypass.

4. There is no overload present.

5. There have not been more than three overload-caused transfers to bypass in a one

hour period.

Form No. 003-2323 Rev B 27

FirstLine UPS

Load

Time Supported

100%

Continuous

110%

2 Minutes

125%

30 Seconds

Load

Time Supported

110%

Continuous

125%

2 Minutes

150%

10 Seconds

700%

5 Cycles

OverLoad
Inverter

When the overload limits are exceeded while running on inverter, an automatic transfer to
bypass occurs. When the overload clears, an automatic transfer to inverter occurs, unless
there have been three overloads within one hour. Inverter overload performance is not
guaranteed while running on battery.

Bypass

When the overload limits are exceeded while on bypass, the static switch will turn off. Note
that external circuit protection devices may operate during overload conditions.

Rectifier

The rectifier is microprocessor controlled using algorithms that limit the input current to
levels that protect the rectifier components. If the inverter requires more current than the
rectifier can provide, the battery will supply current as needed. Thus, the rectifier will supply
as much energy as is available from the rectifier input. At 80% input voltage, the rectifier
can support the rated inverter load, but does not have any extra capacity to charge the
battery. At higher line voltages, there is enough capacity to charge the battery while
supporting rated load.

The rectifier uses an advanced high frequency Pulse Width Modulated design that presents
low current distortion to the input power source. Its high power factor means that maximum
power is obtained for a given input current.

Form No. 003-2323 Rev B 28

FirstLine UPS

REMOVE THESE BUS BARS
BEFORE SERVICING THE
BATTERY TRAY

SECTION 8

Battery Removal, Installation, and Service

The batteries must only be serviced by authorized service personnel.
Before any battery service is attempted, the batteries must be disconnected by unplugging

the cables to the battery trays. Before unplugging the cables, the connections should be
marked in a way that no confusion will exist when it is time to reconnect the cables. The
batteries are mounted in slide out trays that permit access to the battery to battery
connections when the trays are withdrawn from the cabinet.

To service the battery trays, they must be removed from the cabinet by a
fork lift. The 3 bus bars at the back of the tray, as shown in figure 15,
must be removed before servicing or replacing the batteries.

If batteries are being replaced, only use the same manufacturer and battery type and rating
as the battery removed.

It is very important that only one tray at a time be extended from the cabinet. If more than
one tray is extended, the cabinet can become unstable and topple over.

After each tray is installed or serviced, it must be fully inserted and secured using the
supplied threaded fasteners before attempting to install or service another tray.

Form No. 003-2323 Rev B 29

Figure 15-Battery Tray

FirstLine UPS

Battery tray

Battery shelf

Notch

Extension limit tab

Cutaway side view of battery tray

batteries not shown for clarity

Tray mounting screw

WARNING

Never connect the two cables from a battery tray or from a battery string (two trays)
together as severe damage will occur, resulting in fire and/or injury. Battery connections
should only be made by a person wearing eye protection. It is advised that eye wash be
available. If there are any doubts about the proper connections, do not proceed.

If the trays are to be removed, always remove the highest tray first. The battery trays are
very heavy and it will be necessary to use a lifting device to support the trays as they are
removed. When the trays are to be reinstalled, use the procedure in the following
paragraph.

If the UPS was shipped with no batteries installed, batteries may be installed at a later time
using only those battery types shown in the REPLACEMENT BATTERY table under UPS
Maintenance. A Staco battery string consists of two (2) battery trays, Staco part

number 812-1355-S; consisting of 17 batteries each. 220/127V models use Staco part
number 812-1359-S trays; consisting of 18 batteries each. First, verify that the cabinet

is equipped with shelves to receive the battery trays. If this is not the case, contact the
factory for assistance. The battery trays are very heavy and it will be necessary to use a
lifting device to support the trays as they are installed. Do not take away the external
support until the extension limit tabs on the upper sides of the battery tray are inserted past
the notches on the upper edge of the battery shelf (see figure 16). Always install the lowest
battery tray first (see figure 17). After it is inserted fully into the support shelf, secure the
tray with the supplied threaded fasteners. After all of the trays are reinstalled and secured,
reconnect the cables using the markings as a guide. If this is a new battery installation,
connect the battery cables using the procedure in the following paragraphs.

For a two tray (single string) battery, connect the blue plug from the upper tray to the blue
plug from the lower tray. Connect the black plug from the lower tray and the red plug from
the upper tray that are joined together, to the joined black plug from the electronics section
and the red plug from the battery fuse on the front of the electronics section (see figure 10).
For a four tray (double string) battery, connect the upper two trays as described above.
Then, take the joined black plug from the lowest tray and the red plug from the tray above
the lowest one and insert them into the second dc input connector, making sure that the red
plug from the battery tray goes to the red side of the dc input connector and that the black
plug from the battery tray goes to the black side of the dc input connector. Finally, connect
the blue plug from the tray above the lowest tray to the blue plug of the lowest tray.

Form No. 003-2323 Rev B 30

Figure 16-Battery Tray

FirstLine UPS

Tray mounting
screw

Battery tray
assemblies

1/4-20 Ground terminal

stud

EXTENDED RUN TIME BATTERY

TERMINAL TIGHTENING TORQUE

#2-#3 AWG

50 inch-pounds

#4-#6 AWG

45 inch-pounds

GROUND STUD TIGHTENING TORQUE

55 INCH-POUNDS

Figure 17-Battery Installation

Note: Size wire per local codes, #6 AWG 75°C copper wire minimum to #2 AWG

maximum.

A 7/16” wrench is needed to connect to the ground stud.

Form No. 003-2323 Rev B 31

FirstLine UPS

Special Considerations for Connection Batteries to the FirstLine UPS, including
Extended Run Time Battery Cabinets

It is never safe to work within either the UPS or the extended battery cabinet while the UPS
is powered. The battery produces a lethal voltage whether or not the UPS is powered or
running. Always work with extreme caution. No service work should be performed unless
the personnel are properly trained and appropriate tools and equipment are available.

All batteries must be connected to the UPS prior to starting the rectifier. The rectifier runs
whenever the UPS is on. If a battery is disconnected while the rectifier is running (for
example, if the optional breaker on an extended battery cabinet is opened while the UPS is
running), it must not be closed without first stopping the rectifier. This same precaution
applies to opening the external user supplied battery disconnect device. If one is present.
Connecting a battery while the rectifier is running will cause equipment damage that is not
covered by the equipment warranty. See the procedure, below, for stopping the rectifier.

It is essential that the Extended Battery Cabinet be connected with the proper polarity.
Reverse polarity will cause equipment damage that is not covered by the equipment
warranty. There is a polarity verification procedure, below, that will help to prevent mishaps.
Wires should be marked using colored tape to avoid confusion. Note that the terminal block
in the UPS and the terminal blocks in the Extended Battery Cabinet all use the left-hand
terminal for the positive connection and the right-hand terminal for the negative connection.

Before connecting the wires between the UPS and the Extended Battery Cabinet, the UPS
must be powered down, the front outer panel must be removed, the front inner safety panel
must be removed, and all internal batteries must be disconnected by unplugging the red
and black battery plug from the DC input plug for each battery string. Most units have one
battery string, but a second string is an option in the tall cabinet version. On the Extended
Battery Cabinet, the front outer panel must be removed, the front inner safety panel must
be removed, and all internal batteries must be disconnected by unplugging the red and
black battery plugs between each battery string and the plug pair between the lowest
battery string and the input/output panel. Connect the three wires (positive, negative, and
ground) to the external battery terminal block and the grounding stud at the UPS end.
Connect the Extended Battery Cabinet end of the three wires to the terminal block on the
left and to the ground stud. The positive wire goes to the left-hand terminal and the
negative wire goes to the right-hand terminal. If additional cabinets are to be added, run the
three wires from the first cabinet to the second using the right-hand terminal block in the
first cabinet and the left-hand terminal block in the second cabinet. If a third cabinet is
present, run the three wires from the second cabinet to the third using the right-hand
terminal block in the second cabinet and the left-hand terminal block in the third cabinet.

Polarity Verification Procedure

Check to make sure that all wiring is proper and secure and that all personnel are clear of
hazardous circuits.

For this procedure, the UPS should be off with no power applied.

Form No. 003-2323 Rev B 32

FirstLine UPS

If the UPS has an internal battery, connect it to the DC input connector. If there is an
external user supplied battery disconnect device, it should be closed. At the external
battery cabinet, measure the dc voltage from the left-hand fuse (positive lead of meter) to
the right-hand fuse (negative lead of meter). The voltage measured should be positive. If
not, the polarity of the connections is not correct. (The voltage measured during this
procedure should be in the range of 400 to 470 Vdc, depending on the state of charge of
the battery). Repeat this measurement for the other Extended Battery Cabinets, if present.
The battery plugs for all strings in the Extended Battery Cabinet(s) can be connected at this
time.

If the UPS does not have an internal battery, start by connecting the plug from the lowest
battery string in the Extended Battery Cabinet to the plug from the input/output panel. If
there is an external user supplied battery disconnect device, it should be closed. Measure
the voltage at the external battery terminal block in the UPS with the positive lead of the
meter on the left-hand terminal and the negative lead of the meter on the right-hand
terminal. The voltage measured should be positive. If not, the polarity of the connections is
not correct. If there is a second Extended Battery Cabinet, measure the dc voltage in that
cabinet from the left-hand fuse (positive lead of meter) to the right-hand fuse (negative lead
of meter). The voltage measured should be positive. If not, the polarity of the connections is
not correct. Repeat this measurement for the third Extended Battery Cabinet, if present.
The battery plugs for all strings in the Extended Battery Cabinet(s) can be connected at this
time.

Stopping the Rectifier in the UPS

Before connecting any batteries to the UPS, the rectifier must be stopped. The rectifier is
stopped whenever the UPS is OFF. The batteries are disconnected whenever the optional
disconnect breaker(s) in the Extended Battery Cabinet(s) is (are) open, or whenever the
external user supplied battery disconnect device is open. If the Extended Battery Cabinet(s)
is(are) equipped with the optional disconnect breaker, it is possible for a breaker to be
opened during operation, which requires that the rectifier be stopped before closing the
breaker. If the external user supplied battery disconnect device is opened during operation,
it is necessary to stop the rectifier before closing the device. All breakers should be closed
when the UPS is started. Generally, the only reason to open any of the battery disconnect
devices is to perform service, which requires that the UPS be turned off. It is best to close
the disconnect devices before starting the UPS and leave them closed during operation. In
the event of an emergency condition that requires opening a disconnect device, it will be
necessary to stop the rectifier in order to restore the system to normal configuration.

The simplest way to stop the rectifier is to turn off the UPS by pressing the power ("line­circle") button on the front panel. This will remove power from the load. Once the battery
breaker(s) has (have) been closed, the UPS can be restarted by pressing the power button.

If the UPS is connected to the load using a Maintenance Bypass Switch (MBS), the load
can be maintained when the UPS is turned OFF.

Form No. 003-2323 Rev B 33

FirstLine UPS

RECOMMENDED REPLACEMENT INTERVALS

Dc Filter Capacitors

5 years

AC Filter Capacitors

5 years

Fans

2 years

Rectifier Chokes

10 years

Batteries

2 to 5 years1

REPLACEMENT BATTERY

Manufacturer

Cat. Number

Quantity Required2

China Storage Battery

HR1290W

34 per string

To transfer to MBS:

1. Verify that the bypass source is available (Bypass lamp on UPS mimic display is

green).

2. Perform a manual transfer to bypass mode on the UPS by pressing and holding the

ESC key while simultaneously pressing the UP-ARROW key.

3. Verify that the UPS output is ON BYPASS by observing that the lamp associated

with the bypass line at the static switch block on the mimic display is green and that
the lamp associated with the inverter is not lit.

4. Operate the MBS to put it in bypass mode.

It is now safe to turn off the UPS and close the battery breaker(s). Restart the UPS. To
transfer back to normal mode:

1. Verify that the UPS is still ON BYPASS by observing the mimic display. If not,

perform a manual transfer to bypass as described, above.

2. Operate the MBS to put it in normal mode.

3. Enable automatic transfer by pressing and holding the ESC key while

simultaneously pressing the DOWN-ARROW key. After a few seconds, the mimic
display should show that the static switch has transferred the load to inverter.

UPS Maintenance

The FirstLine UPS is designed to be virtually user maintenance free, requiring only the
occasional wipe with a damp cloth or non-abrasive cleaner.

Spare kits are available for the FirstLine UPS series, please contact Staco Energy Products
Co. service center for details.

For maximum availability of the UPS, the components that are subject to wear should be
replaced as part of a comprehensive preventive maintenance program:

All servicing should be performed by qualified service personnel.

1

Battery life is highly dependent on the ambient temperature and the number and depth of discharge cycles.
A discharged battery should be recharged as soon as possible. If the battery is left in a discharged state,
irreversible sulfation occurs, reducing the capacity (run-time) of the battery.

2

Some model configurations will use 36 batteries per string. 36 battery models are not part of the UL listing.

Form No. 003-2323 Rev B 34

FirstLine UPS

Battery Fuse Replacement

If an input line voltage transient well in excess of the UPS rating occurs while the UPS is
running on battery, it is possible for the battery fuse to clear open. The symptom of an
open battery fuse is the same as a disconnected battery: after the UPS is started, the
battery lamp on the mimic display glows red. Prior to starting the UPS, the front panel
display can be used to read the battery voltage. If the voltage is less than 380 Vdc, the
UPS will determine that there is no useable battery present. Possible causes include a
blown fuse, a disconnected battery, and a defective battery.

There are two battery fuses. Either one could be open, so the safe action is to replace both
of them. The following procedure should only be performed by trained, authorized service
personnel. For continued safety, fuses must be replaced by parts of proper rating.

1. Turn off the UPS. If an MBS is present, the load can be maintained by transferring to
Maintenance Bypass mode prior to turning off the UPS.

2. Remove the utility ac power from the input of the UPS.

3. If any external battery cabinets are present, disconnect the batteries in all of them. If the
external battery cabinet is equipped with the optional circuit breaker, it is only necessary to
open (turn off) this breaker which is accessible by removing the front cover of the cabinet.
If not equipped with this breaker, it is necessary to remove the inner panel and unplug the
red and black connectors.

4. Remove the outer panel from the UPS by pulling the top away from the UPS and lifting
the panel.

5. Remove the inner panel by removing the screws around the periphery of the panel and
from the four holes next to the fans. The panel can be lifted off, but it is attached to the
UPS by a ground wire that will limit movement.

6. Unplug the battery by disconnecting the red and black plugs. If the UPS is in the tall
cabinet and has four trays of batteries, also disconnect the second battery connector.

7. For assured safety, measure the dc voltage across the terminal block for the external
battery. If the voltage is more than 10 Vdc, double check that all batteries are disconnected.

8. Also measure the dc voltage between the "-" (minus) terminal on the external battery
connector and the four connections on the two dc fuses. One dc fuse is just below the fans.
The other is on the shelf below and to the right of the fans. If the dc voltage is greater than
40 volts, there must be at least one battery still connected.

9. If voltage measurements are not possible, visually verify that all batteries are
disconnected and wait at least 5 minutes for capacitors to discharge.

10. The fuses can be replaced by loosening the nuts that hold the fuses in place using a 13
mm wrench, slipping out the old fuse, and slipping in the new one. Be sure that the
washers are above the tabs on the fuses. Re-tighten the nuts.

Form No. 003-2323 Rev B 35

FirstLine UPS

11. Reconnect the internal battery(s) in the UPS.

12. Replace the inner panel.

13. In there is an external battery, reconnect all of the batteries and replace the inner panel.
If there is the optional breaker, simply close the breaker to connect the battery.

14. Replace the outer panels on the UPS and the battery cabinet (if present).

15. Reapply utility ac power to the UPS.

16. Start the UPS.

17. Verify that the battery lamp glows green. Look at the battery parameter screen (Down,
Right, Right, Right) and verify that the battery current is positive (charging) or that it is near
zero and the voltage is 460 - 470 Vdc.

Form No. 003-2323 Rev B 36

FirstLine UPS

FOR VENTILATION

22.31 [566.7mm]

70.00 [1778.0mm]

WALL CLEARANCE

6.00 [152.4mm] MIN.31.94 [811.2mm]

(4) LEVELING FEET

CONTROL CABLE ENTRY

2.25 [57.2mm] X 1.75 [44.5mm]

POWER CABLE ENTRY

3.25 [82.6mm] X 1.75 [44.5mm]

(2) SWIVEL CASTERS

(4) RIGID CASTERS

CUSTOMER CONNECTION
TERMINAL ACCESS

SECTION 9

Optional FirstLine Extended Run Time Battery Cabinet

The FirstLine extended run time battery cabinet is used in conjunction with the FirstLine
uninterruptible power supply (UPS) to prevent loss of valuable electronic information and
minimize equipment downtime. During brownouts, blackouts, and other power interruptions,
batteries provide emergency power to safeguard operation.

Figure 18 shows the FirstLine extended run time battery cabinet, which can be outfitted
with one, two, or three strings of batteries and with or without a circuit breaker. Connections
in the UPS for the extended run time battery cabinet are shown in figure 16. For installation
and maintenance instructions see user’s manual no. 003-2324.

Figure 18-The FirstLine Extended Run Time Battery Cabinet

Form No. 003-2323 Rev B 37

UPS Rating kVA/Kw

25/20

30/24

37.5/30

Input

Voltage

208Y, 220Y or 480 Three Phase 4 wire plus ground - Optional 3 wire delta

ISO available

Range

+10% -20% From Nominal (-15% For Battery Recharge)

+10% -10% from nominal to start UPS

Frequency

57-63 Hz

Power Factor

> 0.98 At Full Load

Current Distortion (THD)

< 5% At Full Load

Input Current Nominal:

(208V rating, non-isolated) Maximum:

62
83

75

105

94

128

Input Current Inrush

Walk-In from 25% maximum to 100% full load rating in 5 seconds

Output

Voltage

208Y,220Y, 480 Three Phase 4 wire plus ground

Frequency (free running on
battery)

60 Hz +/- 0.01%

Voltage Regulation

+/- 1% balanced load, +/- 3% with 100% unbalanced load

Voltage Transient Response

< 5% voltage change for 100% load step with recovery to less than 2% in

less than 1 cycle

Voltage Distortion THD

< 2% with linear load, < 5% with 100% non-linear load

Inverter Overload

100% continuous, 125% for 2 minutes, 150% for 1 second

Bypass Overload

110% continuous, 125% for 2 minutes, 150% for 10 seconds, 700% for 5

cycles

Output Current (Amp’s at 208V)

70/55

83/66

104/83

Heat Rejection (BTU/Hr)

7583

9100

8900

Battery Run Time-Minutes3

One Internal Battery String

10 8 5

Extended Run Time - Two
Internal Battery Strings

27

22

16

Environmental

Altitude

Derate load capability above 1000 meters 1% per 100 meters,

Operating Temperature

40o C. Maximum.

Dimensions and Weights (mm) (Kg)

UPS-Standard

23.0 in (284.2) W x 32.38 in (822.45) D x 70.0 in (1778) H 1253 lbs (568)

Two Internal Battery Strings

23.0 in (284.2) W x 32.38 in (822.45) D x 70.0 in (1778) H 1765 lbs (801)

One Battery String
480/480 I/O

23.0 in (284.2) W x 32.38 in (822.45) D x 70.0 in (1778) H 1855 lbs (841)

Standards

208V and 480V Models

UL listed to 1778, CUL to CSA C22.2, NEMA PE-1, ASME, ASA-C-39.1-1984,
FCC Part 15 Subpart J Class B, NEC, OSHA, IEEE587, ANSI C 62.41-1980,
ISO9000

220V models are not listed to UL, CUL, or CSA Standards.

SECTION 10

FirstLine UPS Technical Specifications

FirstLine UPS

3

Run time is approximate and depends on the battery state of charge, age, operating temperature and other
conditions.

Form No. 003-2323 Rev B 38