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