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SynQor Headquarters UPS-1500 Series Operator's Manual

Uninterruptible power supply
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U
p
S
ninterrUptible
ower
Upply
Operator's Guide
UPS-1500 Series
UPS-1500-S-1U
N+M Redundancy
(optional)
UPS-1500-E-2U
Made in USA
www.synqor.com
1.888.567.9596 (USA only)
|
SynQor Headquarters 155 Swanson Road, Boxborough, MA 01719-1316 USA
|

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  • Page 1 Upply Operator’s Guide UPS-1500 Series UPS-1500-S-1U N+M Redundancy (optional) UPS-1500-E-2U Made in USA www.synqor.com 1.888.567.9596 (USA only) SynQor Headquarters 155 Swanson Road, Boxborough, MA 01719-1316 USA...

  • Page 2: Table Of Contents

    General Considerations ............................32 Standard Paralleling -F Option ......................... 32 Expanded Paralleling -R Option ........................33 Parallel Configurations of the AC OUTPUTS: Up to Three Units ............34 Multi-unit Configurations ..........................34 006-0006205 UPS-1500 Series Rev ZC 2 of 60 05/28/2019 www.synqor.com...
  • Page 3 Digital Input/Output Control Signals ....................... 49 RS232 Serial Interface ............................50 Ethernet Interface ..............................51 Section VII Maintenance Battery ..................................52 Fans ....................................52 Cleaning ..................................52 Section VIII Trouble-Shooting Guide Fault Conditions ............................... 53 006-0006205 UPS-1500 Series Rev ZC 3 of 60 05/28/2019 www.synqor.com...

  • Page 4: Hazardous Voltages

    ▪ However, never assume the terminals of the DC input connector or the wires of the DC input cable are safe to contact, even if the UPS or DC input source appears to be off. 006-0006205 UPS-1500 Series Rev ZC 4 of 60 05/28/2019 www.synqor.com...

  • Page 5: Hazardous Energies

    An electrical contact between any two of these power pins or between any power pin and ground should therefore not be damaging. However, care should take to avoid accidental electrical contacts of this sort. 006-0006205 UPS-1500 Series Rev ZC 5 of 60 05/28/2019...

  • Page 6: Battery Pack

    The SynQor UPS has no user serviceable parts inside of it. DO NOT REMOVE the cover of the UPS or any of its connectors. DO NOT OPEN the battery pack. Only factory trained personnel should perform repairs. 006-0006205 UPS-1500 Series Rev ZC 6 of 60 05/28/2019...

  • Page 7: General Product Information

    MIL-STD-810G. The UPS-1500 Series has two product formats: 1) a 1U high unit that has a standard battery pack that provides >10 minutes of full-power run-time, and 2) a 2U high unit that has an extended battery pack that provides >24 minutes of full-power run-time.

  • Page 8: Product Topology

    General Product Information Product Topology The SynQor UPS-1500 Series products use a true on-line double conversion topology that provides protection to the load from spikes, noise, surges, brownouts, blackouts, etc. in the input power sources. They also provide smoothing of load transients and nonlinear load profiles so that the input power sources are not subjected to these disturbances.
  • Page 9 The battery also contains protection circuitry to avoid damage due to improper charging or discharging, or to excessive temperatures. There is a communication/control port that provides a digital interface to a host computer system. 006-0006205 UPS-1500 Series Rev ZC 9 of 60 05/28/2019...

  • Page 10: Part Numbering Scheme And Options

    Options CE CE Marking The UPS-1500 Series of products provide up to 1500 VA and 1250 W of total output power (AC plus DC). They come in two different physical formats: • A 1U high, 32 lb. rackmount unit that uses the standard battery pack that provides >10 minutes of battery run- time at full power •...

  • Page 11: Product Specifications

    Port (1/4-20) Option Breaker Option UPS-1500-S-1U with DC1 Output/DC2 Output Option Exhaust Ethernet User Ground Exhaust Output Output Port Port Config Stud Output Input Circuit Port (1/4-20) Option Breaker Option 006-0006205 UPS-1500 Series Rev ZC 11 of 60 05/28/2019 www.synqor.com...
  • Page 12 (1/4-20) Option UPS Units with DC1 Output / DC2 Output Options Exhaust Ethernet User CONFIG Ground Exhaust AC Circuit Output Output Port Port Stud Output Input Breaker Option (1/4-20) Option 006-0006205 UPS-1500 Series Rev ZC 12 of 60 05/28/2019 www.synqor.com...

  • Page 13: Electrical Characteristics

    54 dB(A) 30 V at 0 A Air Flow 0.67(m /min) 23.7 CFM 26 V at 48.1 A =1250 W Two fans in system, above specs are for each fan separately. 006-0006205 UPS-1500 Series Rev ZC 13 of 60 05/28/2019 www.synqor.com...

  • Page 14: 1U Mechanical Diagram

    1.50" [38.1] [19.05] UNIT MOUNTING 17" HOLES [431.8] .55" 8-32 .250" [6.35] [13.97] .625" [15.875] POWER OUT LOAD BATT 1.73" [43.942] .313" BATT CHARGE MADE IN USA POWER IN [7.9502] 006-0006205 UPS-1500 Series Rev ZC 14 of 60 05/28/2019 www.synqor.com...

  • Page 15: Mechanical Diagram

    .250" [19.05] 17" [6.35] .55" [431.8] [13.97] 2.375" [60.325] 2.062" POWER OUT LOAD BATT [52.3748] 3.33" 1.749" CHARGE BATT MADE IN USA [84.582] POWER IN [44.4246] .625" .313" [15.875] [7.9502] 006-0006205 UPS-1500 Series Rev ZC 15 of 60 05/28/2019 www.synqor.com...

  • Page 16: Ups Efficiency

    Total Output Power that can be derived from the AC INPUT The total UPS output power (the AC OUTPUT power plus the optional DC OUTPUT power) for the UPS-1500 series is rated at 1250 W for an ambient temperature as high as 55 C (131 F).
  • Page 17 AC INPUT would be 1125 W at an AC INPUT voltage of 90 Vrms and an ambient temperature of 50 C (122 F). A higher output power than this would cause the UPS to switch over to its DC INPUT or the internal BATTERY PACK. 006-0006205 UPS-1500 Series Rev ZC 17 of 60 05/28/2019 www.synqor.com...
  • Page 18 15 seconds before the UPS will switch over to the DC INPUT or the BATTERY PACK. Also note that the UPS can drive it full rated power for a 2 second interval even if the AC Vrms INPUT voltage drops below 90 006-0006205 UPS-1500 Series Rev ZC 18 of 60 05/28/2019 www.synqor.com...

  • Page 19: Power Cable Wiring Diagram

    Function G, F, E B, C, D Return in A, H No Connect AC OUTPUT Function Line Neutral No Connect Ground DC1 OUTPUT Function C, D A, B Return OUT DC2 OUTPUT Function G, F, E B, C, D Return OUT A, H No Connect 006-0006205 UPS-1500 Series Rev ZC 19 of 60 05/28/2019 www.synqor.com...

  • Page 20: Power Cable Wire Size

    While this is an issue for all of the power cables, it is particularly important for the DC INPUT and DC2 Output cables because the current flowing through it is very high (as high as 65 A for the UPS-1500 Series) and the voltage across it is already relatively small (as low as 22 V). In fact, a common problem that arises (when the DC INPUT cable has too small a wire) is that the voltage seen at the DC INPUT of the UPS falls below the minimum specified value of 22 V even though the voltage at the source of the DC power is greater than 22 V.

  • Page 21: Operation

    • Move the AC BREAKER on the rear panel of the UPS to the ON position. Note: Be careful to not toggle the ON/OFF switch during the setup. Doing so could cause the UPS to turn on and present a hazardous voltage at its output. 006-0006205 UPS-1500 Series Rev ZC 21 of 60 05/28/2019...

  • Page 22: Start-Up

    (if no power sources are present). • It is not necessary to move the AC BREAKER on the rear panel of the UPS to the OFF position. 006-0006205 UPS-1500 Series Rev ZC 22 of 60 05/28/2019 www.synqor.com...

  • Page 23: Power Cable Connections/Disconnections While Operating

    UPS’s output voltage might cause one or more of the other loads to malfunction. Whether or not this will be a problem depends on the characteristics of the various loads. 006-0006205 UPS-1500 Series Rev ZC 23 of 60 05/28/2019...

  • Page 24: Cooling System

    Operation Cooling System The SynQor UPS-1500 Series products are cooled by fans that draw air into the intake below the battery pack on the front panel and exhaust it out the two fan ports on the rear panel. Care should be taken to ensure there is no obstruction to this airflow, either at the front intake or the rear exhaust ports.

  • Page 25: Front Panel Indicators

    Each battery pack has 16 LEDs, as shown below, that indicated the status of the battery pack and of the operation of the UPS: POWER OUT LOAD BATT BATT CHARGE POWER IN 006-0006205 UPS-1500 Series Rev ZC 25 of 60 05/28/2019 www.synqor.com...
  • Page 26 UPS is On but the Output Voltage is Amber Out of Range UPS is Off and the Output Voltage is Within Range UPS is Off (Or the DC OUTPUT Option is not Installed) 006-0006205 UPS-1500 Series Rev ZC 26 of 60 05/28/2019 www.synqor.com...
  • Page 27 LED Appearance Indication Standby Discharging Charging Battery Charge <10% Battery Charge <25% Battery Charge >25% Battery Charge >50% Battery Charge >75% Battery Charge =100% Battery Charge =100% (Cell Balancing is Occurring) 006-0006205 UPS-1500 Series Rev ZC 27 of 60 05/28/2019 www.synqor.com...
  • Page 28 Battery is too Cold to be Charged Battery Temperature is Within its Specified Green Operating Range Amber Battery is too Hot to be Charged Battery is too Hot to be Charged or Discharged 006-0006205 UPS-1500 Series Rev ZC 28 of 60 05/28/2019 www.synqor.com...
  • Page 29 Green Battery Pack is OK Battery Pack’s Calculated Maximum Storage Capacity is Amber <75% of its Rated Value Battery Pack’s Calculated Maximum Storage Capacity is <50% of its Rated Value 006-0006205 UPS-1500 Series Rev ZC 29 of 60 05/28/2019 www.synqor.com...

  • Page 30: Audible Alarm

    Of course, if there is no source of input power available and the UPS is therefore drawing power from the battery, then the removal of the battery pack would cause the UPS’s outputs to shut down until a recharged battery pack is inserted. 006-0006205 UPS-1500 Series Rev ZC 30 of 60 05/28/2019...

  • Page 31: Operating Environment

    Operation Operating Environment The SynQor UPS-1500 Series is designed for the extreme environmental conditions of military and aerospace applications. All the electronic circuitry and the battery pack are contained in a sealed, weather-proof, shock-proof chamber constructed of die-cast aluminum. Only the redundant, water-proof cooling fans are exposed to the environment.

  • Page 32: Multiple Ups Configurations

    These CONFIGURATION cables are available from SynQor, and the proper part number for any configuration is given in the pages that follow. These CONFIGURATION cables are unique to –F option paralleling and cannot be used with –R option UPS units. 006-0006205 UPS-1500 Series Rev ZC 32 of 60 05/28/2019...

  • Page 33: Expanded Paralleling -R Option

    For expanded paralleling, all UPS units will be enabled if one UPS is enabled. Units can be enabled by actuating their front-panel “on” switches or by sending the appropriate signal over their USER I/O cables. 006-0006205 UPS-1500 Series Rev ZC 33 of 60 05/28/2019...

  • Page 34: Parallel Configurations Of The Ac Outputs: Up To Three Units

    Of course, there are multiple ways in which the INPUTS (both AC and DC) could be connected, as well. They could be connected to the same source, or they could be connected to separate sources. The possibilities will be discussed at the end of this section. 006-0006205 UPS-1500 Series Rev ZC 34 of 60 05/28/2019...

  • Page 35: Parallel Connection Of The Ac Outputs

    If the user is providing the AC OUTPUT cable, the cable sections shown above in either blue or in red should have the following minimum wire size, depending on whether the AC OUTPUT of the UPS units is 115 Vac or 230 Vac. 006-0006205 UPS-1500 Series Rev ZC 35 of 60 05/28/2019...

  • Page 36: Three Ups Units With Ac Outputs Paralleled

    AC OUTPUT of the UPS units is 115 Vac or 230 Vac. Blue Cable Section Minimum Red Cable Section Minimum UPS AC Output Voltage Wire Size Wire Size 115 Vac #14 AWG (2.5 mm #10 AWG (6mm 230 Vac #16 AWG (1.5 mm #12 AWG (4mm 006-0006205 UPS-1500 Series Rev ZC 36 of 60 05/28/2019 www.synqor.com...

  • Page 37: Series Split Phase Connection Of Ac Outputs

    If the user is providing the AC OUTPUT cable, all the cable sections should have the following minimum wire size, depending on whether the AC OUTPUT of the individual UPS units is 115 Vac or 230 Vac. UPS AC Output Voltage Cable Minimum Wire Size 115 Vac #14 AWG (2.5 mm 230 Vac #16 AWG (1.5 mm 006-0006205 UPS-1500 Series Rev ZC 37 of 60 05/28/2019 www.synqor.com...

  • Page 38: 3-Phase Connection Of Ac Outputs

    UPS unit that receives the “Line 3” connector. Connecting the three AC OUTPUTS to the three line wires of the AC OUTPUT cable in the proper order may be important for some loads, such as motors. 006-0006205 UPS-1500 Series Rev ZC 38 of 60 05/28/2019...

  • Page 39: Parallel Configurations Of The Ac Outputs: Up To 32 Unit -R Option

    UPS Unit 2 (0°) (120°) (240°) Phase B Phase A Phase C UPS Unit 10 UPS Unit 10 UPS Unit 10 (120°) * Configuration Cable (0°) (240°) * AC Output 006-0006205 UPS-1500 Series Rev ZC 39 of 60 05/28/2019 www.synqor.com...

  • Page 40: Parallel Connection Of Dc Outputs

    AC source (assuming it is present), or • each UPS unit’s AC INPUT can be connected from one line of the AC source to another (i.e., L1 to L2, L2 to L3, or L3 to L1) 006-0006205 UPS-1500 Series Rev ZC 40 of 60 05/28/2019...

  • Page 41: Multi-Unit Ac Output On/Off Control - Standard Parallel (-F Option)

    (PEGND) in one spot. The size of the neutral-to-PEGND connecting conductor must be sized to match the largest combined AC output neutral conductor specified in the wiring diagrams above. 006-0006205 UPS-1500 Series Rev ZC 41 of 60 05/28/2019...

  • Page 42: Wiring Caution

    UNIT AC OUTPUT CONNECTIONS. ALL AC OUTPUT CABLE CONNECTORS MUST BE INSTALLED DURING OPERATION AS A DISCONNECTED CABLE CONNECTOR MAY HAVE EXPOSED VOLTAGE PRESENT FROM ANOTHER UNIT IN THE GROUP . 006-0006205 UPS-1500 Series Rev ZC 42 of 60 05/28/2019...

  • Page 43: Battery Pack

    Battery Pack Battery Technology The battery packs for the UPS-1500 Series contain Lithium Polymer rechargeable batteries. For a given amount of energy storage they are much smaller and lighter than a lead-acid battery. They are capable of very high discharge rates and fast recharging, and can do so over many cycles and over a long life.

  • Page 44: Battery Capacity

    21 lbs. Its run-time, as a function of UPS load power, is: Total UPS Output Power Extended Battery Run-Time 100% Rated Power > 24 Minutes 80% Rated Power > 31 Minutes 60% Rated Power > 50 Minutes 006-0006205 UPS-1500 Series Rev ZC 44 of 60 05/28/2019 www.synqor.com...

  • Page 45: Storage Of The Battery Pack

    (200 Watt Hours) BAT-0500-E-2U-000 Extended Battery Pack (500 Watt Hours) Other Options also available, check the website or contact power@synqor.com for further information. Always use the proper SynQor battery pack. 006-0006205 UPS-1500 Series Rev ZC 45 of 60 05/28/2019 www.synqor.com...

  • Page 46: Handling The Battery Pack

    CAUTION: Do not open or mutilate batteries. Released electrolyte is harmful to the skin and eyes. It may be toxic. Always use the proper SynQor battery pack. See the battery replacement chart on page 45. 006-0006205 UPS-1500 Series Rev ZC 46 of 60 05/28/2019...

  • Page 47: Control Interface Details

    The designation/location of the pins for the User I/O female high-density DB15 connector is shown below: 006-0006205 UPS-1500 Series Rev ZC 47 of 60 05/28/2019 www.synqor.com...

  • Page 48: Internal User I/O Circuits

    Remote On/O Switch SHUTDOWN 1N4148 SPDT Momentary Input Pin (ON) OFF (ON) Note: A 2PDT or 3PDT switch may be substituted for single control of 2 or 3 UPS machines, respectively. 006-0006205 UPS-1500 Series Rev ZC 48 of 60 05/28/2019 www.synqor.com...

  • Page 49: Digital Input/Output Control Signals

    Drive this line “high” with ≥ 5mA to enable the UPS outputs SHUTDOWN Drive this line “high” with ≥ 5mA to disable the UPS outputs *with an internal 50 kΩ Pull-up Resistor to 5 V and ESD Protection Diodes. 006-0006205 UPS-1500 Series Rev ZC 49 of 60 05/28/2019 www.synqor.com...

  • Page 50: Rs232 Serial Interface

    Port (1/4-20) Option Breaker Option UPS-1500-S-1U with DC1 Output/DC2 Output Option Exhaust Ethernet User Ground Exhaust Output Output Port Port Config Stud Output Input Circuit Port (1/4-20) Option Breaker Option 006-0006205 UPS-1500 Series Rev ZC 50 of 60 05/28/2019 www.synqor.com...

  • Page 51: Ethernet Interface

    UPS and a host computer by including a DHCP server internal to the UPS. For a detailed description of the Ethernet port and SNMP implementation see the SynQor website http://www.synqor.com/ups/documents/UPS_Ethernet_SNMP_UG.pdf 006-0006205 UPS-1500 Series Rev ZC 51 of 60 05/28/2019 www.synqor.com...

  • Page 52: Maintenance

    Cleaning should be done either with soap and water or with an Isopropyl alcohol and water mixture. A soft cloth should be used. Do not immerse the unit in water to clean it. 006-0006205 UPS-1500 Series Rev ZC 52 of 60 05/28/2019...

  • Page 53: Trouble-Shooting Guide

    The front panel battery pack LED array is shown below. The designations of the 16 LEDs in this array are used in the following table. POWER OUT LOAD BATT BATT CHARGE POWER IN 006-0006205 UPS-1500 Series Rev ZC 53 of 60 05/28/2019 www.synqor.com...
  • Page 54 UPS it is still running and providing an DC OUTPUT voltage. LED is RED • Some other source of voltage is connected to the DC OUTPUT and is powering it when the UPS is not 006-0006205 UPS-1500 Series Rev ZC 54 of 60 05/28/2019 www.synqor.com...
  • Page 55 • The battery is too hot to be charged or discharged without damage. LED is STEADY RED • If the ambient temperature is within its specified range the battery will eventually cool down and this condition will go away. 006-0006205 UPS-1500 Series Rev ZC 55 of 60 05/28/2019 www.synqor.com...
  • Page 56 • The UPS is drawing power from the battery pack and its remaining charge is <10% of its rated charge. Four tones • Sources of input power should be restored or the loads should be shut down. 006-0006205 UPS-1500 Series Rev ZC 56 of 60 05/28/2019 www.synqor.com...
  • Page 57 006-0006205 UPS-1500 Series Rev ZC 57 of 60 05/28/2019 www.synqor.com...
  • Page 58 INPUT cable goes back to zero volts. ▪ After a while, the UPS decides the DC INPUT voltage is back within its proper range, and begins to draw a current from the DC INPUT. 006-0006205 UPS-1500 Series Rev ZC 58 of 60 05/28/2019...
  • Page 59 “gauge” for the length of the cable. The longer the cable, the bigger diameter the wire should have. See the section “Power Cable Wire Size” for recommended cable wire sizes. 006-0006205 UPS-1500 Series Rev ZC 59 of 60 05/28/2019...
  • Page 60 Upply Operator’s Guide UPS-1500 Series Made in USA 006-0006205 05/28/2019 Rev ZC www.synqor.com 1.888.567.9596 (USA only) SynQor Headquarters 155 Swanson Road, Boxborough, MA 01719-1316 USA...

This manual is also suitable for:

Ups-1500-s-1uUps-1500-e-2u

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