Tripp Lite SU20KX, SU40KX, SU80KX, U60KX User Manual

Owner’s Manual

SmartOnline™ 3-Phase UPS Systems

Models: SU20KX, SU40KX, SU60KX, SU80KX

Input/Output: 220/380V, 230/400V or 240/415V AC, 3O, 4-wire + ground, wye

Not suitable for mobile applications.

1111 W. 35th Street, Chicago, IL 60609 USA

+1 773 869 1234 • www.tripplite.com

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Table of Contents

Русский 157

1 Introduction 3

2 Important Safety Instructions 4

3 Control Panel Features 6 4 Front and Rear Panel Features 7 5 Cabinet Installation 9

5-1 Preparation 9 5-2 Unpacking 9 5-3 Placement 10

6 Internal Battery Connection 11

(Models SU20KX and SU40KX Only)

6-1 Internal Battery Wiring Diagrams 11 6-2 Internal Battery Connection Procedure 13

7 Wiring 16

7-1 Wiring Warnings 16 7-2 Wiring Preparation 16 7-3 UPS System Terminal Block Diagram 17 7-4 External Battery Cabinet Wiring Diagrams 17

7-5 Electrical and Cable Data 18 7-6 External Battery Cabinet Wiring 19 7-7 AC Input/Output Wiring (Single UPS) 20 7-8 AC Input/Output Wiring (Parallel UPS – Single Input) 21

7-9 AC Input/Output Wiring (Parallel UPS – Dual Inputs) 21

8 Operating Modes 22

8-1 Online (Normal) Mode (Single UPS) 22

8-2 Battery Backup Mode (Single UPS) 22 8-3 Auto Bypass Mode (Single UPS) 22 8-4 Manual Bypass Mode (Single UPS) 22 8-5 Online Mode (Parallel UPS) 23

8-6 Battery Backup Mode (Parallel UPS) 23 8-7 Auto Bypass Mode (Parallel UPS) 23 8-8 Manual Bypass Mode (Parallel UPS) 24 8-9 Hot Standby Mode (Parallel UPS) 24

9 Start-Up, Shutdown and Bypass 25

9-1 Control Panel and Breaker Diagrams 25 9-2 Preliminary Checklist (Single UPS) 25 9-3 Normal Start-Up Procedure (Single UPS) 25

9-4 Battery Start-Up Procedure (Single UPS) 26 9-5 Manual Bypass Procedure (Single UPS) 27 9-6 Shutdown Procedure (Single UPS) 27 9-7 Preliminary Checklist (Parallel UPS) 28

9-8 Start-Up Procedure (Parallel UPS) 28 9-9 Shutdown Procedure (Parallel UPS) 29 9-10 Manual Bypass Procedure (Parallel UPS) 30 9-11 Switching from Manual Bypass to Normal (Parallel UPS) 31

10 Display and Conﬁ guration 32

10-1 Control Panel Diagram 32 10-2 Display Hierarchy 32 10-3 Default Display 33 10-4 Status Messages and Diagrams 33 10-5 Main Menu 35 10-6 UPS System “Measure” Menu 35 10-7 UPS System Setup Menu 36 10-8 Bypass Setup Menu 36 10-9 Output Setup Menu 37 10-10 Battery Setup Menu 38 10-11 Local Setup Menu 40 10-12 Maintenance Menu 41 10-13 Statistics Menu 42 10-14 Event Log Menu 43 10-15 Manual Setup & Test Menu 44 10-16 Firmware Upgrade Menu 45 10-17 Other Menu Choices 45

11 Communications 46

11-1 Communications Interfaces 46 11-2 SNMPWEBCARD Slot 46 11-3 Input Dry Contact Interface 46 11-4 Remote Emergency Power Off (EPO) Circuit Diagram 47 11-5 Auxiliary Dry Contact Input Circuit Diagram 47 11-6 External Battery Cabinet Temperature Inputs 47 11-7 External Battery Status Input 47 11-8 Output Dry Contact Interface Detail 48 11-9 Output Dry Contact Circuit Diagram 49 11-10 RS-232 Serial Port Circuit Diagram 50 11-11 Parallel Redundancy Port 50

12 Speciﬁ cations 51

12-1 UPS System Technical Speciﬁ cations 51 12-2 UPS System Floor Loading Table 51 12-3 Battery Pack Floor Loading Table 51

13 Storage and Service 52 14 Warranty 52

Español 53 Français 105

Русский 157

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1 – Introduction

Tripp Lite’s SmartOnline 3-Phase UPS Systems (Models SU20KX, SU40KX, SU60KX and SU80KX) are ideal for backing up and protecting data centers, telecommunications (VoIP), networks, industrial facilities, security/emergency systems and more.

Advanced Features:

True on-line double conversion with superior IGBT inverter technology• Low input current THD allows 1:1 generator sizing for maximum efficiency and cost savings• Internal N+1 power module redundancy (SU40KX, SU60KX and SU80KX)• Built-in parallel or hot standby redundancy (1+1) capability for increased capacity or fault-tolerance• Up to 80kVA capacity in a compact footprint; up to 160kVA in parallel redundancy (1+1) configuration• High input power factor and high efficiency with low thermal loss and low noise• Simplified, easy-to-repair, long-life, high-availability system design• Redundant auxiliary power and control circuits• Dual input design with separated rectifier and bypass input• All models support external battery cabinets for extended battery backup runtime• High-resolution LCD status screen simplifies operation and delivers detailed operational information, including system block diagrams•

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2 – Important Safety Instructions

SAVE THESE INSTRUCTIONS

All sections of this manual contains instructions and warnings that should be followed during the installation and operation of the UPS

systems described in this manual. Read all instructions thoroughly before attempting to move, install or operate the UPS systems described in this manual. Failure to comply may invalidate the warranty and cause property damage and/or personal injury.

Location Warnings

Install the UPS system in a controlled indoor environment, away from moisture, temperature extremes, flammable liquids and gasses, conductive • contaminants, dust and direct sunlight.

Install the UPS system in a • level, structurally sound location.

The UPS system is extremely heavy; be extremely careful when moving or lifting the unit.• Operate the UPS system at indoor temperatures between 32° F and 104° F (0° C and 40° C) only. For best results, maintain indoor temperatures •

between 62° F and 84° F (17° C and 29° C). Leave adequate space around all sides of the UPS system for proper ventilation. Do not block, cover or insert objects into the external ventilation •

openings of the cabinet. Do not place any object on the unit, especially containers of liquid.• Do not mount the unit with its front or rear panel facing down (at any angle). Mounting in this manner will seriously inhibit the unit’s internal •

cooling, eventually causing product damage not covered under warranty.

Do not install the UPS system near magnetic storage media, as this may result in data corruption. Keep all recorded magnetic media a minimum • of 60 cm (24 inches) away from the UPS system.

Do not attempt to stack the UPS system. Attempting to stack the UPS system may cause permanent damage and create a potential for serious • personal injury.

The casters are designed for minor position adjustments within the final installation area only. The casters are not designed for moving the UPS • system over longer distances.

The casters are not designed to provide long-term support for the UPS system after final installation. Use the levelers to provide long-term • support.

When moving the UPS system, push from the front or rear, not from the sides.• Do not attempt to unpack or move the UPS system without assistance.•

Connection Warnings

The UPS system must be installed in accordance with the requirements of IEC 60364-4-48. Compliance with the following standards • is required: EN 50091-1-1, EN 50091-2 Class A, IEC 61000-4-2 Level 4, IEC 61000-4-3 Level 3, IEC 61000-4-4 Level 4, IEC 61000-4-5 Level 4, IEC 61000-4-6.

The UPS system contains hazardous high voltages that have the potential to cause personal injury or death from electric shock.•

The UPS system has its own energy source (battery – internal and/or external). The output terminals may be live even when the UPS system is • not connected to an AC supply.

The power supply for the UPS system must be 3-phase rated in accordance with the equipment nameplate.• The power supply for the UPS system must be suitably grounded according to all applicable electrical wiring regulations.• If the UPS system receives power from a motor-powered AC generator, the generator must provide clean, filtered, computer-grade output.• Use of this equipment in life support applications where failure of this equipment can reasonably be expected to cause the failure of the life •

support equipment or to significantly affect its safety or effectiveness is not recommended. Do not use this equipment in the presence of a flammable anesthetic mixture with air, oxygen or nitrous oxide.

The UPS system is designed to power modern computer loads and associated peripheral devices. Do not use the UPS system to power pure • inductive or capacitive loads.

Input and output wiring should be performed by trained, qualified electricians only.• Due to high leakage current, a proper earth ground connection is essential before connecting the AC supply.• Isolate the UPS system before working on the circuit. An easily accessible disconnect device should be incorporated in the fixed wiring. The •

disconnect device must be a 4-pole device and must disconnect all line conductors and the neutral conductor.

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2 – Important Safety Instructions

Battery Warnings

The UPS system does not require routine maintenance. There are no user-serviceable parts inside. Only qualified service personnel should open • the access panels for any reason.

Batteries present a risk of electrical shock and burns from high short-circuit current. Battery connection or replacement should be performed • only by qualified service personnel, observing proper precautions. Turn off the UPS system before connecting or disconnecting internal batteries. Use tools with insulated handles. Do not open the batteries. Do not short or bridge the battery terminals with any object.

Replace batteries with equivalent batteries available from Tripp Lite. Do not operate the UPS system without batteries.• The batteries are recyclable. Refer to local codes for disposal requirements.• Do not dispose of the batteries in a fire, mutilate the batteries or open the battery coverings.• Battery fuses should be replaced by qualified service personnel only. Blown fuses must be replaced with the same number and type of fuses. • Potentially lethal voltages exist within the UPS system as long as the battery supply is connected. Service and repair should be performed •

by trained personnel only, while the UPS system is turned off or placed into bypass mode. Disconnect internal batteries (if present) before performing any service work by switching off the internal battery circuit breaker and removing the battery fuse(s). Disconnect external batteries (if present) by switching off the external battery cabinet breaker and disconnecting the external battery cabling from the UPS system.

Do not connect or disconnect batteries when the UPS system is operating from the battery supply or when the unit is not in bypass mode.• Do not remove the plastic sleeves covering internal batteries.• Internal and external batteries must be replaced by equivalent batteries available from Tripp Lite.• Before connecting an external battery cabinet to the UPS system, read the external battery cabinet’s documentation. Use only external battery •

cabinets that have been approved by Tripp Lite. If the UPS system remains off for an extended period of time, it should be turned on periodically to allow the batteries to recharge. The UPS •

system should be turned on and the batteries should be recharged at least one uninterrupted 24-hour period every 3 months. Failure to recharge the batteries periodically may cause irreversible battery damage.

Wiring Warnings

See • Section 7-1 for wiring warnings

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3 – Control Panel Features

A E F G H I J KBCD

“NORMAL” LED:• This green light illuminates to indicate that the UPS system is in online (normal) mode. The primary AC input supply is

present and within standard operating parameters. “BATTERY” LED:• This amber light illuminates when the UPS system is in battery backup mode, discharging the batteries to provide power

to connected equipment. An audible alarm will also sound. “BYPASS” LED:• This amber light illuminates when the UPS system is in bypass mode (auto bypass or manual bypass). Battery backup

power will not be available to connected equipment while the UPS system is in bypass mode, but connected equipment loads will be supported by the bypass (reserve) power source.

“FAULT” LED:• This red light illuminates when any UPS system or input power fault occurs. Available diagnostic information will be

displayed on the LCD screen. LCD Status Screen:• This illuminated LCD status screen displays text and graphics to indicate a wide range of UPS system operating

conditions and diagnostic data. Note: The LCD backlight will turn off after 10 minutes of inactivity. Turn on the backlight by momentarily pressing the ON button or one of the scroll buttons.

“ESC” (Escape) Button:• Press this button to return to the previous page or menu.

F G

Scroll Buttons (• and ): Press these buttons to move the cursor up or down and navigate the control panel menus and screens. These buttons are also used for data entry in several screens.

Enter Button (• ): Press this button to select a menu item or confirm a setting change.

ON Button:• Press and hold this button for 3 seconds to turn the UPS system’s inverter ON.

OFF Button:• Press and hold this button for 3 seconds to turn the UPS system’s inverter OFF. If the UPS system is in online (normal) mode, it will switch to auto bypass mode. Note: If the UPS system remains off for an extended period of time, the batteries should be recharged

periodically. The UPS system should be turned on and the batteries should be recharged at least one uninterrupted 24-hour period every 3 months. Failure to recharge the batteries periodically may cause irreversible battery damage.

“EPO” (Emergency Power Off) Button:• Press this button to turn the UPS system’s output OFF and also disable bypass output.

If the UPS system is in battery backup mode when the EPO button is activated:

Main output and bypass output are turned off, the alarm sounds, fans shut down after approximately one minute, and control circuitry •

remains active.

Releasing the EPO button (by pressing it again) turns off the UPS system completely, including the alarm and control circuit. Press the •

ON button for 3 seconds to restart the UPS system.

If the UPS system is in online (normal) mode when the EPO button is activated:

Main output and bypass output are turned off, the alarm sounds, fans and control circuitry remain active.• Releasing the EPO button (by pressing it again) turns off the alarm and places the UPS system in auto bypass mode. Press the ON button •

for 3 seconds to return the UPS system to online (normal) mode.

See Section 10 – Display and Configuration for detailed information about the control panel’s menus and displays.

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4 – Front and Rear Panel Features

E F D

H H

I I

SU40KX shown (front)

Note: Individual models may vary from diagrams. Unit shown with front bezels removed.

Control Panel:• The control panel allows the operator to monitor and control the UPS system. See Section 3 – Control Panel Features for

more information.

Internal Power Modules:• 20kVA internal power modules can be replaced in the field without powering down connected equipment loads. The number of internal power modules varies by model. The internal power modules are capable of N+1 redundancy in SU40KX, SU60KX and SU80KX models.

Internal Battery Pack Compartment (SU20KX and SU40KX only; shown without batteries):• Internal batteries must be connected by a qualified electrician. See Section 6 – Internal Battery Connection for more information.

Output Circuit Breaker Switch (Q4):• Controls AC output power.

Manual Bypass Circuit Breaker Switch (Q3):• Controls AC input power to the UPS system during manual bypass operation.

Bypass Input Circuit Breaker Switch (Q2):• Controls AC input power to the UPS system during auto bypass operation.

Main Input Circuit Breaker Switch (Q1):• Controls AC input power to the UPS system during online (normal) operation. Levelers:• The levelers provide long-term support for the UPS system.

Casters:• The casters are designed for small position adjustments within the final installation location only; they are not designed for moving

the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation. Use the levelers to provide long-term support.

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4 – Front and Rear Panel Features (continued)

Note: Individual models may vary from diagrams. Unit shown with front bezels removed.

Levelers:• The levelers provide long-term support for the UPS system.

Casters:• The casters are designed for small position adjustments within the final installation location only; they are not designed for moving the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation.

Use the levelers to provide long-term support.

Accessory Slot:• Remove the cover panel to install a Tripp Lite SNMPWEBCARD accessory. The SNMPWEBCARD accessory provides an Ethernet interface for the UPS system and enables remote monitoring and control via SNMP, Web browser or telnet. Call +1 773 869 1234 for more information about the SNMPWEBCARD accessory.

RS-232 Serial Communications Port:• This DB9 port connects the UPS system to compatible workstations or servers, enabling automatic shutdown during extended blackouts and monitoring of operating and power conditions.

Parallel Redundancy Port:• This DB9 port connects the UPS system to another UPS system of identical type and capacity for use in a parallel redundancy (1+1) configuration. See Section 7 – Wiring and Section 8 – Operating Modes for more information.

Input Dry Contact Interface:• This interface receives dry contact signals that allow the UPS system to receive commands and monitor external battery conditions. See Section 11 - Communications for more information.

Output Dry Contact Interface:• This interface allows the UPS system to send information via dry contact communications. See Section 11 –

Communications for more information.

Internal Battery Circuit Breaker Switch (SU20KX and SU40KX only):• Controls the input/output power of the UPS system’s internal batteries.

Terminal Block Cover:• Remove the terminal block cover to access the UPS system’s input, bypass input, external battery cabinet, output and grounding connection terminals. Wiring conduits pass through the circular knockouts in the terminal block cover. See Section 7 – Wiring for more information, including a detailed diagram of the terminal block.

I I

SU40KX shown (rear)

M K N

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5 – Cabinet Installation

Read Section 2 – Important Safety Instructions Before Installation

5-1 Preparation

The UPS system must be installed in a structurally sound area with a level floor that is able to bear the weight of the UPS system, any external battery cabinet and other equipment that will be installed nearby. The installation site should also have a dedicated AC circuit available that is compatible with the UPS system’s input requirements. (See Section 12 – Specifications for details on input requirements and floor loading requirements.) Before unpacking the unit, you should transport the shipping container closer to the final installation site to minimize the distance you will need to move the unit after the protective shipping container has been removed. If you plan to store the UPS system for an extended period before installation, follow the instructions in Section 13 – Storage and Service. (Unpacking and storage instructions are also printed on the “Unpacking and Storage Instructions” sheet secured to the shipping container.) Warning: Do not attempt to unpack or move the UPS system

without assistance.

5-2 Unpacking

Inspect the shipping container(s) for visible damage. If you • determine that the unit has been damaged during shipping, contact Tripp Lite for assistance. Do not attempt to use the UPS system if it has been damaged or mishandled.

Confirm that the shipping container is upright and use a • screwdriver to remove its top panel, front panel and back panel. Also remove the plastic wrap and interior cushioning material. Confirm that the model name and rating at the rear of the cabinet match the unit you ordered. Examine the cabinet for any damaged or loosened parts. Confirm that the shipping container includes the accessories that ship with the unit. The UPS system should include an RS-232 serial cable, a parallel redundancy cable, a remote EPO wiring connector, a dry contact input connector (4 contacts), a dry contact output connector (12 contacts) and a software CD-ROM. If anything is missing or damaged, contact Tripp Lite for assistance.

Confirm that the unit is stable, then remove the side panels from •

the shipping container.

Remove the bolts from the shipping brackets securing the unit •

to the pallet, then remove the shipping brackets from the UPS system. Warning: Be extremely careful, as the unit could shift

unexpectedly.

Use several of the screws you removed in step 2 to attach the top • panel of the shipping container to the front edge of the shipping pallet. The smooth surface of the panel should face upward so that it can be used as a ramp for rolling the unit off the shipping pallet. Do not attempt to use the top panel as a ramp if it is cracked or otherwise structurally damaged. Make sure the casters at the bottom of the unit are unlocked. Using extreme caution, slowly roll the unit down the ramp with the aid of several assistants.

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5 – Cabinet Installation (continued)

5-3 Placement

Use the casters to move the UPS system for a short distance over •

a level, smooth, stable surface. Do not attempt to use the casters to move the UPS system over longer distances. The UPS system should be moved close to its final installation location inside its shipping container before it is unpacked from the shipping container. Use a mechanical device of sufficient capacity to move the shipping container. Warning: The UPS system could tip if it

is moved over an unstable surface. Be extremely careful when moving the UPS system. Push the UPS system from the front or rear, not from the sides.

Position the UPS system in a structurally sound area with a • level floor that is able to bear the weight of the UPS system, any external battery cabinets and other equipment that will be installed nearby. The installation site should also have a dedicated AC circuit available that is compatible with the UPS system’s input requirements. (See the Section 12 – Specifications for more information about input requirements and floor loading requirements.) The UPS system must be installed in a clean, secure environment with a relative humidity less than 90% (noncondensing). Operate the UPS system at indoor temperatures between 17° C and 29° C (62° F and 84° F). Prevent damage to cabling by using suitable protective conduits. In order to maintain proper airflow and service access, you must maintain the following clearances:

At least 100 cm clearance in front of the UPS system.• At least 50 cm clearance behind the UPS system.• At least 50 cm clearance above the UPS system.•

Warning: The cooling fans circulate air from front to back. Do not use any air conditioning or fan that blows air directly toward the rear of the UPS system.

After moving the UPS system to its final location, lock the casters •

and use the levelers B to stabilize the cabinet. Ensure that all

four levelers make firm contact with the floor.

50 cm

100 cm

For emergency use, install a fire extinguisher rated for energized •

electrical equipment fires (Class C rating or exact equivalent, with a non-conductive extinguishing agent) near the UPS system.

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6 – Internal Battery Connection (Models SU20KX and SU40KX Only)

DANGER! LETHAL HIGH VOLTAGE HAZARD!

Potentially lethal high voltage exists within the batteries, even when not connected to a UPS system. Battery connection should be performed by qualiﬁ ed service personnel only, following all the precautions listed in this manual and adhering to local electrical codes. Read Section 2 – Important Safety Instructions before proceeding.

Internal battery connection is for models SU20KX and SU40KX only. Each internal battery pack consists of two strings of batteries: one string with a black cable and one string with a red cable. The number of internal battery packs varies with model.

6-1 Internal Battery Wiring Diagrams

Review the internal battery wiring diagrams prior to connecting the internal batteries. The UPS system can accept up to four internal battery packs (each pack consists of two strings; each string consists of 10 batteries). The number of internal battery packs varies with model.

VBoard

B+

VBoard

B-

SU40KX shown

W1: RED, W2: BLUE, W3: WHITE, W4: BLACK

RED RED

BLACK BLACK

RED RED

BLACK BLACK

RED RED

BLACK BLACK

RED RED

BLACK BLACK

SU40KX shown

12V, 9AH, 10PCS

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6 – Internal Battery Connection (continued)

6-1 Internal Battery Wiring Diagrams (continued)

UPS System

Battery Back

Connector

Fuse Block Bracket

UPS System

Battery Back

Connector

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SU40KX shown

6 – Internal Battery Connection (continued)

6-2 Internal Battery Connection Procedure

Place the UPS system in bypass (or turn it completely off) and turn •

off the internal battery circuit breaker switch, located on the rear of the UPS system.

Remove the battery access bezels, located on the front of the UPS •

system.

Remove the battery cartridge fuses from each fuse block.•

Disconnect the blue and white jumper cables attached to each fuse •

block. Warning: When disconnecting the jumper cables, pull them straight away from the fuse block with even force. Do not wiggle them side-to-side, as this may damage the connector.

Remove the fuse block bracket. Note its orientation before •

removal.

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6 – Internal Battery Connection (continued)

6-2 Internal Battery Connection Procedure (contiinued)

Slide a battery string with a red cable into an empty slot within •

the battery compartment. Make sure the battery string is oriented as shown in the diagram. Note: Start with the empty slots at the

bottom of the battery compartment and work toward the empty slots at the top of the battery compartment.

TERMINALS

SIDE VIEW

Slide a battery string with a black cable into an empty slot within • the battery compartment, next to the battery string that you inserted

in step 6. Make sure the battery string is oriented as shown in the diagram. Repeat steps 6 and 7 as needed until all the battery strings have been inserted into the empty battery slots. Note: Depending

on the model of the UPS system, some battery compartment slots may remain empty.

TERMINALS

SIDE VIEW

Reconnect the fuse block bracket. (The letters on the fuse block •

bracket should be upright when it is in the correct orientation.)

Connect the blue and white jumper cables on each internal battery •

pack to the corresponding fuse block. The labeling next to the fuse block identifies the correct fuse block for each cable.

Insert the battery cartridge fuses into each fuse block. The fuses are • interchangeable. Make sure the fuses are firmly snapped into place.

Warning: Battery cartridge fuses must be inserted last due to potential arcing of connectors. Blown fuses must be replaced by a qualified electrician. Replace only with fuses of the same type and rating.

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6 – Internal Battery Connection (continued)

6-2 Internal Battery Connection Procedure (contiinued)

Use a voltmeter (user-supplied) to test the voltage of each internal • battery pack. Observing proper polarity, connect the voltmeter’s black probe to the battery pack’s black connector; connect the voltmeter’s red probe to the battery pack’s red connector. Make sure the voltmeter’s probes touch the metal contacts inside the battery pack’s connectors. The battery pack’s acceptable DC voltage range is between 220V and 280V DC (nominal 240V DC). If several voltmeter tests yield results outside the acceptable DC voltage range, contact Tripp Lite for assistance in determining the possible causes of the incorrect voltage reading before proceeding.

240

Connect the • black cable for each internal battery pack to the

nearest black connector located inside the UPS system’s battery compartment. Connect the red cable for each internal battery pack to the nearest red connector located inside the UPS system’s battery compartment. Warning: Observe proper polarity by

connecting negative to negative (black to black) and positive to positive (red to red). Failure to observe proper polarity will damage the UPS system and create a serious risk of personal injury and property damage.

Replace the battery access bezels.•

Turn on the internal battery circuit breaker switch. If you placed • the UPS system in bypass, return it to the previous operating mode. If you turned the UPS system off, turn it on. If you still need to wire the UPS system, proceed to Section 7 – Wiring.

Note: If you need to remove or replace internal battery packs, modify steps 6 and 7 by removing and/or replacing the existing internal battery packs, as required.

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7 – Wiring

DANGER! LETHAL HIGH VOLTAGE HAZARD!

7-1 Wiring Warnings

De-energize all input and output power sources of the UPS system before installing cables or making electrical connections.• Use flexible cable of sufficient length to permit UPS system servicing. The maximum cable length is 10 m (32.8 ft).• Use ferrule caps to cover termination cables and prevent frayed ends from shorting on the UPS system terminal block.•

Use cabling rated VW-1, FT-1 or better.• Use cable sleeves and connector clamps.• The neutral conductor must be the same size as the current conductors.• Tighten all connections with a torque of at least 3.95 N·m (35 in·lb)•

Confirm that all cables are marked correctly according to their purpose, polarity, phase and diameter.• If the UPS system’s input/output power source is wye-wye, then “Neutral” and “Ground” must not be connected.• If the input power source has VNG>0, install an isolation transformer before the UPS system and input power source, then connect the UPS •

system’s “Neutral” and “Ground” together. For equipment requiring a neutral connection to an IT power distribution system, the disconnect device must be a four-pole device and must •

disconnect all line conductors and the neutral conductor. If a disconnect device interrupts the neutral conductor, it must simultaneously interrupt all line conductors.

Allow the batteries to charge uninterrupted for 24 hours after the initial wiring connection.• Observe proper polarity by connecting negative to negative and positive to positive. Failure to observe proper polarity will damage the UPS •

system and create a serious risk of personal injury and property damage. Observe proper phase by connecting R to R, S to S, T to T and N to N. Failure to observe proper phase will damage the UPS system and create a •

risk of personal injury and property damage.

All wiring should be performed by a qualiﬁ ed electrician, in accordance with the warnings in this manual and all applicable electrical and safety codes. Incorrect wiring may damage the UPS system severely and cause serious personal injury and property damage. Read

Section 2 – Important Safety Instructions before proceeding.

7-2 Wiring Preparation

De-energize all input and output (AC and DC) of the UPS system and external battery cabinet (if present).•

Mark all cables according to their correct purpose, polarity, phase and diameter.• Review the diagrams in • Section 7-3 and Section 7-4 to familiarize yourself with the terminal blocks. Consult the table in • Section 7-5 to find the correct electrical input/output characteristics for the UPS system.

Note: If the UPS system’s input/output power source is wye-wye, then “Neutral” and “Ground” must not be connected. If the input power source has VNG>0, install an isolation transformer before the UPS system and input power source, then connect the UPS system’s “Neutral” and “Ground” together.

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7 – Wiring (continued)

7-3 UPS System Terminal Block Diagram

Input

Grounding Terminals

External Battery

Connection

7-4 External Battery Cabinet Wiring Diagrams

N+–

OutputBypass Input

External Battery Cabinet Breaker

Switch

+N–

–

SU80KX and BP480V26 shown for illustration only; consult the battery cabinet’s documentation for exact specifications

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7 – Wiring (continued)

7-4 External Battery Cabinet Wiring Diagrams (continued)

7-5 Electrical and Cable Data

Input, Reserve Input, Reserve,

and Output Battery Fuse Output and Battery Model Input Output Breaker Size Size Cable Size

SU20KX 220/380V, 230/400V 220/380V, 230/400V

or 240/415V AC, 3O, or 240/415V AC, 3O, 50A 60A 14 mm² 4-wire + ground, wye 4-wire + ground, wye

SU40KX 220/380V, 230/400V 220/380V, 230/400V

or 240/415V AC, 3O, or 240/415V AC, 3O, 75A 120A 14 mm² 4-wire + ground, wye 4-wire + ground, wye

SU60KX 220/380V, 230/400V 220/380V, 230/400V

or 240/415V AC, 3O, or 240/415V AC, 3O, 125A 160A 22 mm² 4-wire + ground, wye 4-wire + ground, wye

SU80KX 220/380V, 230/400V 220/380V, 230/400V or 240/415V AC, 3O, or 240/415V AC, 3O, 150A 220A 38 mm² 4-wire + ground, wye 4-wire + ground, wye

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7 – Wiring (continued)

7-6 External Battery Cabinet Wiring

Warning: External battery cabinets vary. Read the external battery cabinet’s documentation before attempting to connect it to the UPS system. Use only external battery cabinets that have been approved by Tripp Lite.

Note: An external battery cabinet is required with models SU60KX and SU80KX. It is optional with models SU20KX and SU40KX. Contact Tripp Lite for external battery cabinet ordering information.

De-energize all input and output (AC and DC) of the UPS system •

and external battery cabinet, and confirm that the external battery

cabinet breaker switch been wired to an AC power source, see instructions.)

Remove the terminal block covers from the UPS system and • external battery cabinet.

is off. (If the UPS system has already

Section 9-6 for shutdown

+N–

Connect the positive (+), neutral (N) and negative (-) UPS • system connection terminals of the external battery cabinet to the corresponding positive (+), neutral (N) and negative (-) external battery connection terminals of the UPS system. See Section 7-3 and the external battery cabinet’s documentation for terminal block diagrams. See Section 7-4 for wiring diagrams. See Section

7-5 for cable size requirements. Cabling should be protected by

flexible conduit and routed through the appropriate knockouts in the terminal block cover. Warning: Observe proper polarity by

connecting negative to negative and positive to positive. Failure to observe proper polarity will damage the UPS system and create a risk of personal injury and property damage.

Connect the external battery cabinet’s grounding terminal• UPS system’s corresponding grounding terminal (5.189 mm) ground cable. Keep the ground cable connected at all times after installation.

Connect the UPS system’s grounding terminal• earth ground ground cable connected at all times after installation.

Replace the terminal block cover of the external battery cabinet. If •

you do not plan to wire the AC input/output of the UPS system at this time, replace the terminal block cover of the UPS system.

with a 4 AWG (5.189 mm) ground cable. Keep the

with a 4 AWG

to your facility’s

to the

+N–

–

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7 – Wiring (continued)

7-7 AC Input/Output Wiring (Single UPS)

After de-energizing all input and output (AC and DC) of the UPS •

system, remove the terminal block cover from the UPS system.

+N–

If you did not connect the ground cable in •

UPS system’s grounding terminal

with a 4 AWG (5.189 mm) ground cable. Keep the ground cable

connected at all times after installation.

Section 7-6, connect the

to your facility’s earth ground

Remove the UPS system’s front bezel to expose the circuit • breakers. First, confirm that the main input circuit breaker switch

and the bypass input circuit breaker switch

Second, confirm that the manual bypass circuit breaker switch is off. Third, confirm that the output circuit breaker switch off.

are both off.

C is

D B AC

Confirm the phase of each cable, then connect the cables according •

to the UPS system terminal block diagram in

Section 7-5 for cable size requirements. Cabling should be

protected by flexible conduit and routed through the appropriate knockouts in the terminal block cover. Warning: Observe proper

phase by connecting R to R, S to S, T to T and N to N. Failure to observe proper phase will damage the UPS system and create a risk of personal injury and property damage.

Section 7-3. See

R S T NR S T

R S T

Replace the UPS system’s terminal block cover.•

+N–

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7 – Wiring (continued)

7-8 AC Input/Output Wiring (Parallel UPS – Single Input)

Parallel Redundancy Warnings:

The total input cable length must be equal to the total • output cable length in order to prevent unbalanced load sharing between two UPS systems under reserve mode (i.e. Res1 + OP1 = Res2 + OP2; deviation must be <10%).

Parallel redundancy only supports 2 UPS systems (1+1 • redundancy ). Do not attempt to link more than two UPS systems via parallel redundancy.

The UPS systems must have the same rating and capacity • for parallel redundancy installation. Attempting to link dissimilar UPS systems will damage the UPS systems and create a serious risk of personal injury and property damage.

Follow the steps in •

in the diagram.

Connect the included parallel redundancy cable• redundancy port

Section 7-7, wiring the UPS systems as shown

to the parallel

of each UPS system.

7-9 AC Input/Output Wiring (Parallel UPS – Dual Inputs)

Parallel Redundancy Warnings:

Parallel redundancy only supports 2 UPS systems (1+1 • redundancy ). Do not attempt to link more than two UPS systems via parallel redundancy.

Follow the steps in • Section 7-7, wiring the UPS systems as shown

in the diagram.

Connect the included parallel redundancy cable • redundancy port B of each UPS system.

to the parallel

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8 – Operating Modes

This section provides a basic description of the UPS system’s operating modes. For more information about switching between operating modes, refer to Section 9 – Start-Up, Shutdown and Bypass.

8-1 Online (Normal) Mode (Single UPS)

In online (normal) mode, the UPS system’s rectifier converts incoming AC utility power to DC power that charges the batteries and supplies the inverter. The inverter transforms the DC power to precision-regulated,

pure sine wave AC power that supports the operation of connected equipment. This dual conversion technology isolates connected equipment from all power problems and ensures that connected equipment receives ideal power at all times.

8-2 Battery Backup Mode (Single UPS)

When a blackout or other extreme power event occurs, the UPS system automatically switches from normal mode to battery backup mode. The UPS system’s batteries (internal and/or external) provide emergency DC power to the inverter. The inverter transforms the DC power to precision-regulated, pure sine wave AC power that supports the

operation of connected equipment.

8-3 Auto Bypass Mode (Single UPS)

If the inverter malfunctions due to excessive temperature, overload, output short circuit, abnormal voltage or battery problems, the inverter

will shut down. If the UPS system detects a bypass (reserve) power source that conforms to normal parameters, then the UPS system automatically switches to auto bypass mode to continue supplying power to connected equipment. When all problems are eliminated, the UPS system switches back to online (normal) mode automatically.

8-4 Manual Bypass Mode (Single UPS)

If UPS system maintenance or repair is required, you can bypass the UPS system and enable bypass (reserve) power manually. After confirming that bypass (reserve) power is present, switch the UPS

system into manual bypass mode. This allows service technicians to perform maintenance or repair jobs without interrupting the flow of AC power to connected equipment. Warning: The UPS system must be

de-energized completely before performing maintenance or repair by shutting it down completely after switching it to manual bypass

mode.

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8 – Operating Modes (continued)

8-5 Online Mode (Parallel UPS)

Parallel redundancy (1+1) provides UPS system redundancy or increased total capacity. Under parallel redundancy, the total load is shared by two UPS systems. If one of the UPS systems malfunctions, the total connected equipment load is supported by the remaining UPS system. If the total load exceeds the capacity of the remaining UPS system, it will switch to auto bypass mode.

8-6 Battery Backup Mode (Parallel UPS)

Similar to on battery backup mode for a single UPS system (Section

8-2), except the total connected equipment load is shared by the parallel

(1+1) UPS systems.

8-7 Auto Bypass Mode (Parallel UPS)

Similar to auto bypass mode for a single UPS system (Section 8-3), except with parallel (1+1) UPS systems.

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8 – Operating Modes (continued)

8-8 Manual Bypass Mode (Parallel UPS)

Similar to manual bypass mode for a single UPS system (Section 8-4), except with parallel (1+1) UPS systems. Note: Both UPS systems must

be switched into manual bypass mode.

8-9 Hot Standby Mode (Parallel UPS)

For added fault-tolerance, the redundant UPS system acts as the bypass (reserve) power source for the main UPS system.

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9 – Start-Up, Shutdown and Bypass

Warning: The UPS system’s output voltage is set at 220/380V by default. If you require output voltage of 230/400V or 240/415V, you must change the UPS system’s output voltage by accessing the output setup menu described in Section 10-9. You must place the UPS system in bypass mode before changing the output voltage. Do not connect your equipment to the UPS system’s output until you have set the proper parameters.

9-1 Control Panel and Breaker Diagrams

“NORMAL” LED•

“BATTERY” LED•

“BYPASS” LED•

“FAULT” LED•

LCD Status Screen•

E F

“ESC” (Escape) Button• Scroll Buttons (• and )

Enter Button (• )

ON Button•

OFF Button•

J K

“EPO” (Emergency Power Off) Button• Output Circuit Breaker Switch•

Manual Bypass Circuit Breaker Switch•

Bypass Input Circuit Breaker Switch•

Main Input Circuit Breaker Switch•

Output

Circuit Breaker Switches (UPS System Front Panel)

Control Panel

Manual Bypass

Bypass

Input

Main Input

9-2 Preliminary Checklist (Single UPS)

All circuit breaker switches should be off, including the breaker of the external battery cabinet (if present).• Confirm that no voltage potential exists between Neutral and Ground.• Confirm that the input power source matches the rating (voltage, frequency and phase) of the UPS system.•

Note: After start-up, the UPS system will perform a brief self-test and display the results on the LCD screen. After a successful self-test, the UPS system will provide AC power to the connected equipment load.

9-3 Normal Start-Up Procedure (Single UPS)

If there is an external battery cabinet connected, switch on the •

circuit breaker A of the external battery cabinet.

Confirm that the manual bypass circuit breaker switch •

is off.

Output

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Manual Bypass

Bypass

Input

Main Input

9 – Start-Up, Shutdown and Bypass (continued)

9-3 Normal Start-Up Procedure (Single UPS) (continued)

Switch on the output circuit breaker switch •

circuit breaker switch

. After a brief initialization process, the LCD screen will show “ON AUTO BYPASS”, the “BYPASS” LED will illuminate and UPS system output will be supplied by the bypass (reserve) power source.

Switch on the main input circuit breaker switch •

power source is normal, the UPS system is ready for start-up.

Press the ON button •

release the button. The inverter will activate and synchronize with the bypass source, then automatically switch from auto bypass (reserve) mode to online (normal) mode. The “BYPASS” LED will darken and the “NORMAL” LED will illuminate.

for 3 seconds (until you hear a beep), then

and bypass input

. If the AC input

A B

Output Manual

Bypass

Input

Bypass

Input

Main Input

9-4 Battery Start-Up Procedure (Single UPS)

Note: The battery must be at least partially charged for this operation to succeed.

If there is an external battery cabinet connected, switch on the •

circuit breaker A of the external battery cabinet.

Confirm that the manual bypass circuit breaker switch •

is off.

Press the ON button • release the button. The inverter will activate and use stored DC battery power to supply AC power to connected equipment. The “BATTERY” LED will illuminate.

for 3 seconds (until you hear a beep), then

Output Manual

Bypass

Input

Main

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9 – Start-Up, Shutdown and Bypass (continued)

9-5 Manual Bypass Procedure (Single UPS)

Warning: Placing the UPS system in manual bypass will disable the inverter and power all loads from the manual bypass (reserve) source, but the UPS system will still be energized. Before performing maintenance or repair on the UPS system, shut down and de-energize the UPS system completely by following the steps in power source, they will not receive battery backup in the event of a utility power failure.

When the UPS system is in online (normal) mode, press the OFF •

button A for 3 seconds (until you hear a beep), then release the button. The inverter will automatically switch to bypass mode and the “BYPASS” LED will illuminate.

Switch on the manual bypass circuit breaker switch •

off the output circuit breaker switch B.

Section 9-6. Although connected equipment loads will be powered by the bypass (reserve)

, then switch

Output Manual

Bypass

Input

Main Input

9-6 Shutdown Procedure (Single UPS)

Warning: The UPS system shutdown procedure will eliminate the AC power output for all loads. Before shutdown, confirm that all loads are turned off or place the UPS system in manual bypass mode to keep loads powered by the reserve (bypass) power source.

Press the OFF button •

release the button. If the UPS system is in online (normal) mode, it will switch to bypass mode. If the UPS system is in battery backup mode, the inverter will shut down and AC output power will be interrupted.

Switch off the main input circuit breaker switch •

Switch off the bypass input circuit breaker switch •

for 3 seconds (until you hear a beep), then

Output

Manual Bypass

Bypass

Input

Main

Output

Manual Bypass

Bypass

Input

Main

Input

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9 – Start-Up, Shutdown and Bypass (continued)

9-6 Shutdown Procedure (Single UPS) (continued)

Confirm that the UPS system is off and that all main output circuits •

are off. If the UPS system is connected to an external battery cabinet, turn off the external battery cabinet circuit breaker switch

Switch off the output circuit breaker switch •

power source is normal, the UPS system is ready for start-up.

Note: If the UPS system remains off for an extended period of time, it should be turned on periodically to allow the batteries to recharge. The UPS system should be turned on and the batteries should be recharged at least one uninterrupted 24-hour period every 3 months. Failure to recharge the batteries periodically may cause irreversible battery damage.

. If the AC input

Output Manual

Bypass

Input

Main Input

9-7 Preliminary Checklist (Parallel UPS)

Warning: Parallel redundancy requires exactly two UPS systems (1+1 redundancy ). Do not attempt to link more than two UPS systems via parallel redundancy. The UPS systems must have the same rating and capacity for parallel redundancy installation. Attempting to link dissimilar UPS systems will damage the UPS systems and create a serious risk of personal injury and property damage.

All circuit breaker switches should be off, including the breakers of the external battery cabinets.• Confirm that no voltage potential exists between Neutral and Ground.• Confirm that the input power source matches the rating (voltage, frequency and phase) of the UPS systems.•

You must use the control panel to set the parallel ID numbers of the UPS systems to be 1 and 2. See • Section 10-11 for information

about setting the parallel ID numbers.

Note: After start-up, the UPS systems will perform a brief self-test and display the results on the LCD screen. After a successful self-test, the UPS systems will provide AC power to the connected equipment load.

9-8 Start-Up Procedure (Parallel UPS)

Connect the parallel redundancy cable •

redundancy port B of each UPS system.

If the UPS systems have external battery cabinets connected, •

switch on the external battery cabinet circuit breaker switch A of each battery pack.

to the DB9 parallel

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9 – Start-Up, Shutdown and Bypass (continued)

9-8 Start-Up Procedure (Parallel UPS) (continued)

Switch on the bypass input circuit breaker switch •

UPS system. After a brief initialization process, the LCD screen will show “ON AUTO BYPASS” and the “BYPASS” LED will illuminate.

Switch on the main input circuit breaker switch • system.

Press the ON button •

of one of the UPS systems for 3 seconds (until you hear a beep), then release the button. The inverter will activate and synchronize with the bypass source. Press the ON button for the other UPS system for 3 seconds (until you hear a beep), then release the button. When the inverter of each UPS system is operating normally, they will automatically switch from auto bypass (reserve) mode to online (normal) mode at the same time. The “BYPASS” LED will darken and the “NORMAL” LED will illuminate.

Check the output voltage of each UPS system. The phase deviation • between each UPS system should be less than 5V. If the phase deviation is within the acceptable range, switch on the output circuit breaker switch A of each UPS system. Note: For more

information on checking the output voltage of each UPS system, see Section 10-6.

of each

of each UPS

Output Manual

Bypass

Input

Bypass

Input

Main Input

Main

Input

Output Manual

Bypass

Input

Main Input

9-9 Shutdown Procedure (Parallel UPS)

Warning: The UPS system shutdown procedure will eliminate the AC power output for all loads. Before shutdown, confirm that all loads are turned off or place the UPS systems in manual bypass mode to keep loads powered by the bypass (reserve) power source.

For the UPS system you wish to shut down, press the OFF button •

for 3 seconds (until you hear a beep), then release the button. If the other UPS system can support the connected equipment loads alone, the UPS system that was turned off will shut down its inverter and its LCD screen will read “LOAD NOT POWERED”. The other UPS system’s LCD screen will read “ONLINE MODE”. If the total connected equipment load is too large to be handled by a single UPS system, both UPS systems will shut down their inverters and switch to bypass mode, and their LCD screens will read “ON AUTO BYPASS”.

For the UPS system you wish to shut down, switch off the main • input circuit breaker switch A, then switch off the output circuit breaker switch B.

Output Manual

Bypass

Input

Main

Input

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9 – Start-Up, Shutdown and Bypass (continued)

9-9 Shutdown Procedure (Parallel UPS) (continued)

For the UPS system you wish to shut down, switch off the bypass •

input circuit breaker switch

When the UPS system is completely shut down, the LCD screen •

will be completely off. If the UPS systems have external battery

cabinets connected, switch off the external battery cabinet circuit breaker switch A of each battery pack.

9-10 Manual Bypass Procedure (Parallel UPS)

Warning: When the UPS system is in manual bypass, the inverter shuts down. Connected equipment loads are powered by the bypass (reserve) power source and will not receive battery backup during a utility power failure.

For the first UPS system you wish to shut down, press the OFF •

button A for 3 seconds (until you hear a beep), then release the button. If the other UPS system can support the connected equipment loads alone, the UPS system that was turned off will shut down its inverter and its LCD screen will read “LOAD NOT POWERED”. The other UPS system’s LCD screen will read “ONLINE MODE”. If the total connected equipment load is too large to be handled by a single UPS system, both UPS systems will shut down their inverters and switch to bypass mode, and their LCD screens will read “ON AUTO BYPASS”. Repeat step 1 for the second UPS system you wish to shut down.

Switch off the main input circuit breaker switch • system.

of each UPS

Output Manual

Bypass

Input

Main Input

Output

Confirm that both UPS systems are shut down, then switch on the • manual bypass input circuit breaker switch A of each UPS system.

The bypass (reserve) power source will power the loads and the LCD screen will read “ON MANUAL BYPASS”.

Switch off the bypass input circuit breaker switch •

and the output

Output

circuit breaker switch B of each UPS system. The LCD screen

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will turn off completely.

Output

Manual Bypass

Bypass

Input

Bypass

Input

Bypass

Input

Main Input

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